Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 170 / 289

GENERAL INFORMATION
7.2
WHEEL AND HUB TORQUE
TABLE
Item Specification
Front Wheel Nuts 20 Ft. Lbs. (27 Nm)
Middle & Rear Wheel Nuts 50 Ft. Lbs. (68 Nm)
Front Hub Nut Refer to text for procedure
(Pg 7.4)
Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm)
¡
Refer to exploded views and text for torque values
of other fasteners
CAUTION: Locking nuts, and bolts with preapplied
locking agent should be replaced if removed. The
self-locking properties of the nut or bolt are reduced
or destroyed during removal.
SPECIAL TOOLS
PART NUMBER TOOL
DESCRIPTION
2871199 Seal Sleeve
Installation Tool Kit
2870888 Hilliard Clutch
Garter Spring
Installation Tool
2872608 Roller Pin
Removal Tool
8700226 CV Boot Clamp
Pliers
2870772 1 3/4” Straight
Wrench
AWD OPERATION OVERVIEW
Ramps
Hub
Cage (2)
Roller (3)
Axle
Cam (5)
Ill. 1
With the Polaris All Wheel Drive System activated
(AWD selected), the machine operates as a 2 wheel
drive vehicle until the rear wheels lose traction. If the
rear wheels lose traction the front wheel rotational
speed will decrease, causing the front drive axle
speed to exceed front wheel speed. Restricting the
rotation of the drive clutch roller cage (2) (see Electric
Hub Operation) will cause the rollers (3) to climb the
ramps of the cam (5), and become squeezed between
the ramps and the ring in the hub. See Ill. 1.
When the hub clutch assembly, wheel hub, and drive
axle are engaged, the front wheels will drive and stay
engaged until rear wheel traction is regained. When
traction is regained, the front wheels will overdrive the
hub clutch, pushing the clutch rollers (3) toward the
lower part of the cam (5), disengaging the clutch. The
rollers are held in place by the spring (4). See Ill. 2.
The tension of this spring is critical to AWD hub
operation. Always use the correct spring (refer to
appropriate parts manual) and use installatiol
Hilliard
Clutch Garter Spring Installation Tool ( PN 2870888 ).
WARNING
It is important that the front and rear axle drive ratio
and tire size are not changed. Changing this ratio will
cause erratic engagement, which could result in a loss
of vehicle control and serious injury or death.
ELECTRIC HUB
ENGAGEMENT
1 2
3
5
4
A
Tabs must engage the slots
1. Armature Plate
2. Roller Cage
3. Roller
4. Garter Spring
5. Cam
Spacer
Ill. 2
When AWD is selected in a forward gear, current
flows through a coil of wire located in the strut housing,
creating a magnetic field. An armature plate (1)
coupled to the roller cage (2) is attracted to the
magnetic field, and resists rotation, creating drag on
the drive roller cage assembly. This causes the roller
to climb the ramps of the cam, engaging the hub.
NOTE: In reverse gear the override button must be
pushed to deliver power to the wheel coil. Electric hub
engagement offers an advantage over mechanical