Ok first off thank you.
Second I recently lost awd.
So I tore the front gear box out. Had it checked by the polaris dealership. He said to replace the armature plate. So I did. Of course cleaned and reinstalled with new oil in it from Polaris. Got it all together. And didn't work. Could there be something else I am missing. Maby the override button. To be honest I don't know much about this button. Everything else works fine also. Don't have a meter at the moment to check anything. Any help would be appreciated and by no means am I an expert so any little thing you could think would be a big help. Thank you so much.

 

Should be 12 volts leading to the coil. Plus might be time to get a cheap meter. Resistance between the two gear case wires(gray,brown/white) should be between 22-25 ohms.Plus you can jump the brown wire to a better ground and see if the awd works. If not a coil or other electrical problem could be the roller cage. Most problems were because of the plastic roller cages cracking. Doesn't take much of a crack to disable the awd.It's already been updated once,but is still plastic.Item #9.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse If this is the problem forged aluminum roller cages are available to solve this. http://www.ebay.com/itm/POLARIS-SPORTSMAN-500-700-ALUMINUM-FRONT-4X4-SPRAGUE-CARRIER-Built-to-Last-/111276597237?pt=Motors_ATV_Parts_Accessories&hash=item19e89a1ff5&vxp=mtr

 

Ok thanks I checked the roller cage before I put everything together also the polaris guy did too. So don't think its that but I will get meater tomorrow and check what u said. Thanks so much.

 

Ok I checked for the 12 volts have 11. Think that should be ok. But when I checked the resistance I got 538. ? I m new to using meeters and read the book how to check resistance and think I had it right. So what do you think I should do now. Tried to jump the brown wire with no luck.

 

Have the meter on ohms. Place red lead on grey wire,black lead on brown/white wire at the connector on the front diff. If resistance is way off(+ or - 20% allowed) could be the coil is weak. If you have good voltage,cover plate assy with coil may need to be replaced. Item#2. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I checked the ohms and I have 24. Thanks for telling me that. So now does this mean it is good since I got 12 volts also. And if this is good do you think the awd switch could go haywire. Or the speedo would affect this. The awd light flashes when I put the machine in gear whether it's in awd or not. I appreciate all your help you have done for me. Can't wait till this is fixed.

 

With voltage ok,the coil resistance is ok,a new armature plate installed,about the only thing left is the roller cage to keep if from engaging properly. Cage doesn't have to be cracked either. They cage can have a bulge spot on it that can cause problems. We found a couple like this on close inspection of cages at the shop.

 

Well guess I'm tearing it out again. Gonna buy that cage u recommended. Looks pretty staught. Also would the awd switch go bad. And anything else you could tuink of that might cause this.