Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 193 / 289

GENERAL INFORMATION
7.25
6. Apply Never Seize to threads of and install nut (I).
Tighten nut with wrench to approximately 8-10 ft.
lbs. (11-14 Nm) . Align flat of nut with flat on hub.
Axle must rotate smoothly without binding. If axle
binds the nut is too tight. If axle movement (up and
down or side to side) is detected, axle is too loose.
I
7. Install foam seal and slide nut retainer with taper
inward onto locking hub. Install retaining ring.
Retaining Ring
Nut Retainer
Foam Seal
Axle Nut (Sprocket Side) Torque:
8-10 ft. lbs. (11-14 Nm)
8. Install brake caliper and middle drive chain.
Adjust drive chain-3/8” -- 1/2” (6.77 -- 12.70 mm)
deflection at the tightest point in the chain, refer to
Maintenance Chapter 2 for procedure). If housing
was removed, torque eccentric pinch bolts to 30
ft. lbs. (41 Nm) and torque brake caliper
mounting bracket 10-12 ft. lbs. (14-17 Nm). Verify
proper chain adjustment after torquing eccentric
by rolling ATV forward and checking chain tension
in several places on chain.
9. Torque brake caliper mounting bolts to 18 ft. lbs.
(25 Nm).
Grease Zerk Faces Upward
Brake Caliper Mounting Torque:
18 ft. lbs. (25 Nm)
Caliper Mounting Bracket Torque:
10-12 ft. lbs. (14-17 Nm)
10. Install rear swing arm. NOTE : The grease zerk
on the swing arm housing faces upward. Torque
bolts to 40 ft lbs. (55 Nm).
Rear Swing Arm Mounting Torque:
40 ft. lbs. (55 Nm)
11. Install rear drive chain. Adjust drive chain if
necessary (refer to Maintenance Chapter 2 for
procedure).
12. Apply Never Seize to axle splines and install
wheel hubs. Torque center hub nut to 80 ft. lbs.
and install a new cotter pin. Torque wheel nuts to
50 ft. lbs. (68 Nm).
13. Lubricate eccentric housing and swing arm
housings grease fittings with Polaris Premium All
Season Grease until grease is purged on each
side of eccentric and swing arm housing.