2010 RZR 800. Was high sided in the mud and AWD was not engaging. After several attempts of flipping the AWD switch, changing gears, restarting engine, the AWD engaged but went out again. Knowing most likely the sprague was broken, I began the repair process.
Removed the front diff, full of muck, cleaned everything, sprague broken, replaced with SuperATV one, replaced all bearings and seals, 23.6 ohms on coil. The new armature was slightly bent and would not hold very tight when 12 volt was applied to the diff cover. I tried the old armature and held very tight. Hard to turn by hand. Wear groves in plate worn evenly. Armature installed correctly with tabs in the slot of the cage AND in the indexing reliefs on the ring gear. I have removed and opened the diff twice to double check everything was installed correctly. Installed back on machine, RZR of the ground. I applied a separate 12 volts to the diff to eliminate any speedo or ECU signaling issues, more of that to come. Tried forward and reverse gears, front diff will not engage! Now, I did not install the axles and wheels. But I would think the output hubs should move after a 1/8 rotation of the rear wheels. Rechecked ohms on coil, 23.6. This is my first problem.
While checking the above, this is what I found out with the electronics. First, I checked the harness for power. When connecting both leads to the harness and placed the RZR in gear, switched the AWD on, the voltage would bounce from 4v to 12v. Speedo does indicate the gear position. I then removed the lead from the brw/wh wire, which leads back to the speedo for ground, and touched it to the frame. Viloa, 12 volts. So, I am assuming the speedo is NOT providing a constant ground for the coil, maybe it or the ECU is thinking the RPMs or above 3400. Now, same test, but I put the speedo in diagnostic mode, AND connect the ground lead back to the brw/wh wire on the harness….I get the constant 12v. Thinking I found the problem, I reconnected the harness to the diff, stayed in diagnostic mode knowing I have a complete circuit, and tried testing the engagement again. Nothing……so must be mechanical in the diff? Also, in diagnostic mode, the AWD setting displays “Off” when switching to AWD. I tested power at the switch, obviously working because I have power at the harness. So, bad speedo?
Recap.
– No AWD indicator on speedo in gear. Diagnostic mode shows “off” when the AWD switch is on.
– Coil ohms 23.6, 12volt from gray / brw/wh wires in harness in diagnostic mode but bounces when not.
– 12 volt from gray wire at harness when ground to frame.
– Diff completely rebuilt, except for armature plate which was hard to turn when energized.
– Rollers in cage smooth and move freely
– Pinion turns smoothly, resistance felt when diff energized on bench
Sorry for such a long post. I wanted to exhaust everything I could before asking for help. I am at wits end with this. I really don’t know what to do next. Any advice whatsoever would be appreciated. Thank You….
