Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
7.4
AWD FRONT HUB BEARING
ADJUSTMENT
WARNING
The following bearing adjustments are very important.
Incorrect adjustment will increase bearing wear,
reduce braking action, and may affect front drive hub
engagement, which could result in serious personal
injury or death.
1. Torque spindle nut to 160-170 inch lbs. (13
Nm--14Nm) while rotating hub continuously.
2. Back off nut 1/2 turn.
3. Rotate axle several revolutions by raising rear of
machine and rotating rear wheels with the
machine in gear.
4. Re-torque hub nut to 108-144 inch lbs. (12 --16
Nm).
Front Spindle Nut Torque:
108-144 in. lbs.
Brake Caliper Retaining Bolt Torque:
18 ft. lbs. (25 Nm)
5. Install cotter pin. Bend each leg of cotter pin
around castle nut in different directions.
NOTE: If cotter pin hole does not align, tighten slightly
to align and install pin. Do not exceed 144 in. lbs. (16
Nm).
6. Reinstall hub cap.
7. Remove fill check plug and rotate hole to either
4:00 or 8:00 position.
8. Fill with Polaris Premium Demand Drive Hub
Fluid or Type F Automatic Transmission Fluid
until fluid trickles out. NOTE: Do not force the oil
into the hub under pressure. This can cause seal
damage and leaks.
Premium Demand Drive Hub Fluid
(PN 2871654) (8 oz.)
(PN 2872277) (2.5 gal.)
9. Reinstall plug.
10. Reinstall brake caliper assembly.
Torque
retaining bolts to 18 ft. lbs. (25 Nm).
11. Reinstall front wheels. Torque retaining nuts to 20
ft. lbs. (27 Nm).
12. Carefully lower vehicle.
13. Field test vehicle for proper operation of brake
system and AWD operation.