Front Hub Inspection; Front Drive Axle Removal - Polaris SPORTSMAN 600 2003 Service Manual

SPECIAL TOOLS
PART NUMBER
2872608
8700226
WHEEL AND HUB TORQUE
TABLE
Item
Front Wheel Nuts
Rear Wheel Nuts
Front Hub Nut
Rear Hub Retaining Nut
CAUTION: Locking nuts and bolts with preapplied
locking agent should be replaced if removed. The
self-locking properties of the nut or bolt are reduced
or destroyed during removal.

FRONT HUB INSPECTION

1. Support machine securely with front wheels
elevated.
2. Grasp wheel/hub and check for movement.
3. If movement is detected, inspect hub, hub nut
torque and bearing condition and correct as
necessary.
FRONT DRIVE AXLE
REMOVAL
1. Set the ATV in park. Remove hub dust cap.
2. Remove cotter pin.
3. Loosen the hub retaining nut.
4. Loosen - but do not remove - the wheel nuts.
5. Safely lift and support the front of the ATV.
CAUTION:
Serious injury could occur if machine tips or falls.
6. Remove wheel.
TOOL
DESCRIPTION
Roller Pin
Removal Tool
CV Boot Clamp
Pliers
Specification
30 Ft. Lbs. (41 Nm)
30 Ft. Lbs. (41 Nm)
70 Ft. lbs. (95 Nm)
80 Ft. Lbs. (109 Nm)
7. Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake
line. Use wire to hang the caliper to prevent
possible damage to the brake line.
8. Remove hub.
9. Remove cotter pin and nut from lower A-arm ball
joint. Remove lower A-arm from ball joint.
10. Pull strut assembly out while pivoting front drive
shaft downward until it clears strut assembly.
FINAL DRIVE FINAL DRIVE
7.3