Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 182 / 289

GENERAL INFORMATION
7.14
Hub Seal Sleeve Replacement
3. New front drive axle CV joint assemblies and
drive axle assemblies have the seal sleeve
installed from the factory.
Inner Magnet Pole
(Fixed)
Coil
Seal Sleeve
(Outer Magnet
Pole) (Adjustable)
Not Unusual To See
Two Wear Rings
Max. .001
″
(.025mm)
Measure at 3
places 120
_
apart
Pole Gap:
.000”--.001” (.00--.025 mm)
Seal Sleeve Installation Tool Kit:
(PN 2871199)
4. The hub seal sleeve must be driven onto the strut
casting until flush with the inner magnet pole. Use
the flat side (no step) of the Seal Sleeve
Installation Tool Kit ( PN 2871199 ).
5. To check the gap between the inner and outer
poles place a straight edge on the outer pole so
that it just intersects with the inner pole. The gap
between the straight edge and inner pole should
be 0 to .001
I
(0-.025mm). This measurement
should be checked in three different positions
around the pole assemblies. The three
measurements must be within .0005
I
(.013 mm)
of each other. If the gap is excessive, the hub may
notengage.
Seal Sleeve Tool
Step
Use flat side to install seal sleeve
Inner Pole Shoe
Seal
Sleeve
(Outer
Magnet
Pole)
AWD FRONT PROP SHAFT
REMOVAL
1. Using Roller Pin Removal Tool (PN 2872608) ,
remove the roll pin from the prop shaft at rear of
housing. Slide prop shaft back and away from
front housing. Pull sharply forward to remove
from transmission shaft.
NOTE: If removing front housing, use roll pin
remover to remove the roll pins from both front drive
axles.
Roller Pin Remover Tool (PN 2872608)