Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 196 / 289

GENERAL INFORMATION
7.28
CONCENTRIC SWINGARM
MIDDLE HOUSING
INSTALLATION
1. Place brake caliper pivot bushing on stud with
flange inward as shown.
Fill the middle housing
with grease.
2. Install middle axle. (See Page 7.27)
3. Fill housing with grease until grease purges from
both seals.
REAR AXLE REMOVAL
REFER TO EXPLODED VIEW ON PAGE
7.28
1. Elevate and safely 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.
2. Remove wheels and hubs.
3. Hold inner axle nut and remove outer axle nut.
4. Remove axle nut and washer.
5. Place a block of wood on end of axle or use a soft
face hammer, and drive axle out from right to left.
6. Tap locating collar on left side of axle toward the
right enough to expose the circlip retainer.
Remove retainer and locating collar.
7. Inspect locating collar on left side of axle and
replace if worn or damaged. A worn collar will
allow dirt to enter axle bearing area.
1 3/4
″
Straight Wrench
(PN 2870772)
REAR AXLE INSTALLATION
1. Slide locating collar on left end of axle with recess
facing outward.
2. Install a new circlip.
3. Tap locating collar back towards left end of axle
until it captivates circlip.
4. Apply a light coat of grease to axle and install a
new O-Ring.
5. Insert axle from left to right.
6. Install O-Ring, sprocket hub, and washer.
7. Clean axle nut threads with a wire brush. Apply
Loctite
t
242 ( PN 2871949 )to threads and install
axle nut. Torque to 150 ft. lbs. (203 Nm). Rotate
axle and check for smooth operation.
8. Install lock nut and torque to 150 ft. lbs. (203 Nm).
9. Lightly grease splines of axle and install wheel
hubs, flat washers, and cone washers with
concave side facing flat washer.
10. Torque hub nuts to 80 ft. lbs. (110 Nm) and install
new cotter pin, bending one leg of cotter pin
inward and one outward against end of axle.
11. Install hub cap.
12. Place wheels on hubs and install wheel nuts with
tapered side facing in. Torque evenly to
specifications.
Rear Axle Retaining Nut:
150 ft. lbs. (203 Nm)
Rear Hub Retaining Nut:
80 ft. lbs. (110 Nm)
Rear Wheel Nuts:
50 ft. lbs. (69 Nm)