Front Gearcase Operation - Polaris SPORTSMAN 600 2003 Service Manual

CAUTION: Do not hang the caliper by the brake line.
Use wire to hang the caliper to prevent possible
damage to the brake line.
6. Remove the front hub from the drive shaft.
7. Remove cotter pin, lower ball joint nut and A-arm
from ball joint.
8. Pull the hub and strut assembly out and pull the
drive--shaft out of the hub.
9. Pull both driveshafts from the front gearcase.
Replace the circlip on the driveshaft end for
reassembly.
10. Remove bolts securing bottom of housing to
frame. Remove vent line. Remove the front
gearcase from right side of frame.
Frame
Front Gearcase
FRONT GEARCASE
OPERATION - - CENTRALIZED
HILLIARD)
Normal Operation: With the AWD switch off the
vehicle is only driving the rear wheels (2 wheel
drive).When the AWD switch is activated it engages
the Hilliard and locks both front wheels and we then
have, True All Wheel Drive.
Armature
Plate
Engagement: When the AWD switch is activated it
charges the coil. It then charges an armature plate
that is keyed to a roller cage that contains 14 rollers
which are forced in by an external cam. The 14 rollers
engage themselves to the output hubs that link both
front axles. The vehicle now has True All Wheel Drive.
FINAL DRIVE FINAL DRIVE
Coil
Cover
Output
Hub
7.9