Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 51 / 289

MAINTENANCE
2.31
CAUTION: During tie rod adjustment, it is very
important that the following precautions be taken
when tightening tie rod end jam nuts. If the rod end
is positioned incorrectly it will not pivot, and may
break.
Incorrectly
Tightened
Jam Nut
Correctly
Tightened
Jam Nut
Hold
Rod End
Ill.2
To adjust toe alignment:
G
-- Hold tie rod end to keep it from rotating.
G
-- Loosen jam nuts at both end of the tie rod.
G
-- Shorten or lengthen the tie rod until
alignment is as required to achieve the
proper toe setting as specified in
Method 1 or Method 2.
G
IMPORTANT: When tightening the tie rod
end jam nuts, the rod ends must be held
parallel to prevent rod end damage and
premature wear. Damage may not be
immediately apparent if done incorrectly.
See illustration 2.
G
-- After alignment is complete, torque jam
nuts to 12-14 ft. lbs. (16-19 Nm).
FRONT HUB FLUID LEVEL
INSPECTION
To check front hub fluid:
1. Place vehicle on a level surface.
2. Turn wheel until front hub fill/check plug is in either
the 4 o’clock or 8 o’clock position.
3. Remove fill/check plug.
4. Add Polaris Demand Drive Hub Fluid if necessary
until fluid trickles out. NOTE: Do not force the
fluid into the hub under pressure or seal damage
may occur.
5. Reinstall plug.
6. Repeat procedure for other hub.
FRONT HUB FLUID CHANGE
1. Place a drain pan beneath the hub.
2. Remove check/fill plug.
3. Turn the hub to the 6 o’clock position and drain the
fluid
into the drain pan.
4. Turn wheel until front hub fill/check plug is in either
the 4 or 8 o’clock position.
5. Add Polaris Demand Drive Hub Fluid ( PN
2871654 ) until fluid trickles out. NOTE: Do not
force the fluid into the hub under pressure or seal
damage may occur.
Polaris Demand Drive Hub Fluid:
(PN 2871654) - 8 oz.
(PN 2872277) - 2.5 gallon