Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
7.23
3. Remove jam nut (D) and locking mid axle hub (E).
Remove swing arm housing and O-rings (F).
Discard O-rings. Inspect bearing and seals,
replace if worn or damaged.
Stop Ring
Disc Hub
Groove in spline
Threads
Splines
4. Remove brake disc assembly, and stop ring.
Inspect axle for straightness and damage.
Replace if necessary.
CONCENTRIC SWINGARM
MIDDLE AXLE ASSEMBLY
Stop Ring
Disc Hub
Groove in spline
1. Install stop ring in groove on left side of axle.
NOTE: Left side of axle is identified by the small
groove in the middle of the spline.
Stop ring
2. Install disc hub assembly on axle. Be sure hub
covers stop ring. Install disc in soft jawed vise.
Apply Never Seize to threads, install left axle nut
and tighten to 120 ft. lbs (166 Nm). Keep tightening
nut until flat aligns with flat on brake hub.
O-ring
Spacer
Axle Nut (Disc Side) Torque:
120 ft. lbs. (166 Nm)
3. Lubricate spacer and new O-ring. Install on axle.
Foam Seal
Nut Retainer
(Taper toward hub)
Retaining Ring
4. Lubricate and install swing arm assembly with
grease zerk facing away from brake disc.
Lubricate and install new O-ring and locking hub.
Foam Seal
Nut Retainer
(Taper toward hub)
Retaining Ring