Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 174 / 289

GENERAL INFORMATION
7.6
AWD HUB SEAL
REPLACEMENT
1. Remove and disassemble front hub. Refer to
Page 7.3.
2. Remove brake disc attaching bolts and brake
disc.
NOTE: If the attaching bolts are difficult to
remove, it may be helpful to heat the outer
surfaces of the hub in the area of the disc
mounting bolts, to soften the locking agent.
3. Apply heat to the hub seal area. When the hub
becomes too hot to touch, pry out the old seal as
shown. Do not damage the surface of the seal
cavity. Clean the hub in the seal mating area.
4. With spring side of new seal facing toward hub
casting, press it in until flush with brake disc
mating surface. CAUTION: Do not use a
hammer as damage to the seal will result.
5. Thoroughly clean the brake disc with brake
cleaner. It is very important that the brake disc be
free of any oil or solvents.
6. Reinstall the brake disc using genuine Polaris
OEM bolts that have a pre-applied locking agent.
Do not substitute bolts or use old ones.
7. Install attaching bolts and torque to 18 ft. lbs.
(25 Nm).
MAGNETIC COIL SERVICE
1. Remove the front drive axle as described later in
this chapter.
2. Remove the seal sleeve from the strut casting
using a drift punch and hammer, tapping evenly
on each side until the sleeve slides off.
3. Remove the existing coil and clean the coil wire
channel, coil mount area, and the seal sleeve
mounting area of all silicone and foreign matter.
4. Disconnect the coil wires at the connector or
terminal board.