Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 54 / 289

MAINTENANCE
2.34
First, check foot brake effectiveness by applying 50 lb.
(approx.) downward force on the pedal. The top of the
pedal should be at least 1 inch, (25.4mm) above the
surface of the footrest.
50 lbs
1
″
or greater
1/8, to 1/4,
Free Play
Floorboard
If less than one inch, two things must be examined:
Free Play:
Free play of the brake pedal should be 1/8 - 1/4
inch (3.2 - 6.35 mm).
If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any
parts as needed.
Bleeding:
If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in
a conventional manner, following the procedure
outlined in Brake Chapter 9.
DRIVE CHAIN
INSPECTION/ADJUSTMENT
CAUTION:
Never adjust or operate the vehicle with the rear drive
chain slack out of the specified range, as severe
damage to the transmission and drive components can
result.
CHAIN INSPECTION
Check the amount of chain slack by moving the
vehicle slightly forward to gain slack at the top side of
the chain. Then pull up and down on the chain. Total
slack should be as specified below. If slack is not
within specification, adjust the chains. If the chains
appear dry (no sign of lubrication), apply Chain Lube
( PN 2872073 ), coating the plates and rollers as often
as needed.
MIDDLE AXLE CHAIN
ADJUSTMENT
A
B
Drive Chain Adjustment
1. Loosen chain guard.
2. Loosen two eccentric locking bolts (A).
3. Insert a pin punch (B) through the sprocket hub
and into the eccentric axle housing.
4. Roll the vehicle ahead or back to adjust chain
slack to the proper dimension. Correct chain
slack adjustment is 3/8”
″
to 1/2
″
(6.77--12.70
mm) at the tightest point in the chain.
5. Roll the vehicle ahead and check tension in
several places around the chain.
6. Tighten the eccentric locking bolts to 40 ft. lbs. (54
Nm).
7. Reinstall chain guard.
NOTE: Reposition chain guide to allow 1/8
″
(.3 cm)
clearance between sprocket and guide.
REAR AXLE DRIVE CHAIN
ADJUSTMENT
To adjust the rear axle drive chain on 6x6 models,
loosen the rear most eccentric and rotate using the
same method as outlined for the middle axle chain.
Total slack, however, should be adjusted to 3/8
″
to
1/2” (6.77--12.70 mm) at the tightest point on the
chain.