Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
5.10
CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION
Assembly / Installation
1. Install bushing (6) in left side of swingarm and two-piece bushings (3) in right side.
2. Clean threads of nut (1), and pivot bushings (4) with Loctite
t
Primer N ( PN 2870585 ). Apply Loctite
t
262
( PN 2871951 ) to threads of pivot bushing (4) and nut (1).
3. Install right pivot bushing (4) through the two-piece bushing (3).
4. Install washer (2) and nut (1). Hold pivot bushing (4) in vise and torque nut (1) to 120 ft. lbs. 163 Nm).
5. Install left pivot bushing (7).
Note: There are stop plates attached to the inside of the frame to prevent the pivot bushings from turning
when the pivot bolts are tightened. The flats of the pivot bushings must be oriented correctly to align with
the frame plate, or the pivot bolt holes will not be aligned. The top flat on the nut should be approximately
parallel with top surface of the swingarm.
6. Install swingarm assembly in frame.
7. Install and tighten pivot bolts slowly until the flats of the pivot bushings (4) and (7) engage the stop plate . . . . . .
on the frame.
8. Torque swing arm bolts (5) and (8) to 150 ft. lbs. (207 Nm).
9. Install pivot bolt retainer brackets in upper hole of bulkhead. Attach with self--tapping fasteners and torque
to 15--17 ft. lbs. (19--23 Nm).
9. Install lower rear shock bolt. Torque to 25 ft. lbs. (35 Nm). Assemble rear axle, brake caliper, caliper
mount, hubs, wheels and chain. (Refer to Chapter 7)
150 ft. lbs. (207 Nm)
150 ft. lbs. (207 Nm)
150 ft. lbs.
(207 Nm)
NOTE: Allow LocTite
t
to cure at least 24 hours before use.
(7) Left Pivot Bushing
(8) Swing Arm Bolt
(8) Pivot Bolt
Apply Loctite
t
262 to
the bolt threads.
262
262
Swing Arm Guard
Rock Guard
Mount Bracket
Swing Arm
Assembly
Chain Guard
Bushing
(1) Nut
Washer
(3) Bushing
Pivot Bushing
(6) Swing Arm
Bushing
Chain Guide
Pivot Bolt
Retainer
15--17ft. lbs. (19--23 Nm)