Hi everyone, this is my first time post, but I have been reading these forums for quite some time now. I have a question about my 2004 Polaris Sportsman 700 and was hoping someone could help me out. So the problem began when my 4x4 quit working. I did some testing and found out that the magnetic coil in my front diff was reading open my my ohmmeter. I took the front diff out to inspect and when I opened it up I found that a small spot, about 1 inch looked like it had been melted on the magnetic coil. I got a used diff case and plugged the connector in to test the coil and before I could see if it was magnetized the wires just outside the case started smoking so I immediately unplugged. I have now ordered a brand new diff cover with new magnetic coil and before I plug it in to test it I wanted to see if anyone here could give me the amperage this thing is supposed to have going to that coil so I can keep from burning up a $400 part. I would like to test the amperage and make sure something wacky isn't going on with the electrical system where I am having too much power sent to the coil and burning them up. I have already put a call in from Polaris and a specialist told me that there is no such information. I already know that voltage and coil resistance for the new coil are within spec. Does anyone have the amperage spec for this circuit or could give me some tips on what to do next? Thanks

 

Just curios. Was atv running when you plugged in wires on used diff case if bike was off [key on power]ide think it would be some bad kinked shorted wires. If you had bike running when plugged wires in think overcharging electrical regulator Just my 2 cents

 

The atv was not running. I had the key on, engine off, AWD switch off when I plugged in the connector. Nothing happened until I flipped the AWD switch to the AWD on position it started smoking in around 10 seconds I would say. Thanks for the reply!

 

Almost sounds like the used diff wire was close to and shorted out when hooked up .Ide hook up a voltmeter to connector and see if getting 12 volts or more????? shouldn't then maybe check when running to be sure. I can see how ide be cautious to before hooking up new expensive piece too good luck

 

Yep, I tested the connector to have battery voltage of 12.45V when the key is on and the AWD switch is turned on. Looks like I might just have to plug it in and see. Thanks

 

Check the volts with a meter with it running just to make sure before plugging in just to be sure your not overcharging [BAD regulator]

 

Ok, I will do that. Thanks