Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
7.16
3. Install snap ring to contain bearing cap just
installed. Repeat procedure for other side.
4. Install outer yoke, aligning marks made before
disassembly.
5. Repeat Steps 1-3 to install bearing caps on outer
yoke.
6. Seat all bearing caps against snap rings by
supporting cross shaft and tapping on each
corner as shown.
7. When installation is complete, yokes must pivot
freely in all directions without binding. If the joint is
stiff or binding, tap the yoke lightly to center the
joint until it pivots freely in all directions.
AWD FRONT HOUSING
REMOVAL
1. Stop engine, place machine in gear and set
parking brake.
2. Loosen right front wheel nuts slightly.
3. Elevate and support machine under
footrest/frame area.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when
removing and installing bearings and seals.
4. Remove right wheel nuts and wheel.
5. Remove cotter pin, lower ball joint nut and A-arm
from ball joint.
6. Punch spring pins out from both axle splines and
front prop shaft.
7. Remove bolts securing bottom of housing to
frame. Remove vent line. Remove housing from
right side of frame.
FRONT HOUSING
DISASSEMBLY
1. Drain and properly dispose of used oil.