Polaris 2004-2005 Sportsman 6x6 Service Manual page 175

GENERAL INFORMATION
MAGNETIC COIL
INSTALLATION
Strut Ribs
Coil Wire
Channel
Seal
Sleeve
Mounting
Area
Coil Mounting
Surface
(Inner Magnet
Pole)
(Fixed)
Electromagnet Coil
Seal Sleeve (Outer Magnet Pole)
(Adjustable) Must use Seal Sleeve
Installation Tool Kit (PN 2871199)
1. Apply 1/4I (.6 cm) bead of silicone in the coil wire
channel.
2. Install the coil to the coil mount surface and press
the coil wires into the silicone in the coil wire
channel.
3. Apply 1/4I (.6 cm) bead of Loctitet Ultra Blue
silicone around the seal sleeve mounting area.
NOTE: This includes applying silicone over the
coil lead wires again. Always allow 12 hours' cure
time for silicone.
4. Press on the seal sleeve until even with the inner
pole. See Page 7.14 for additional information.
Once the seal sleeve is properly positioned, a
1/16I (.16 cm) bead of silicone should remain
around the inner edge.
silicone. The seal sleeve area must be free of
silicone or the hub seal may leak.
NOTE:
Always install a new seal sleeve
S
when replacing the coil. Use Seal
Sleeve Installation Tool Kit (PN
2871199).
It may be necessary to apply more
S
silicone (or an equivalent fast drying
glue) to the wire channel area to
properly secure and protect the coil
wires.
Apply 401 Loctitet to the inside of
S
the strut ribs and press the foam
Brake Line
Clip Location
Clean off all excess
block to contain the coil wires. Make
sure the foam block is bonded well to
protect the coil wires.
NOTE: Coil wires must be contained in the brake line
clip on the back side of the upper strut casting and the
wires must be snug against the casting.
5. Route the wires smoothly and away from any
moving parts and secure in place with tie straps.
6. Assemble front axle and connect hub wires.
HILLIARD CLUTCH
DISASSEMBLY/INSPECTION
1. Remove front hub. See Page 7.3.
2. Remove Hilliard clutch assembly.
3. Disassemble the roller clutch and thoroughly
clean all parts. CAUTION: Do not remove the
garter spring. If the spring is removed, it will
become over stressed
replacement.
4. Inspect roll cage sliding surface (A). This surface
must be clean and free of nicks, burrs or
scratches. Inspect roller cage (2) carefully for
cracks.
5. Inspect rollers (3). The rollers must slide up and
down freely within the roller cage sliding surfaces
A.
6. Without removing the garter spring, inspect the
coils for consistency. If coils are distorted or
uneven, cut the old spring with a side cutter to
remove it, and replace it.
1. Armature Plate NOTE: Armature plate is
positioned with tabs in round holes of cage.
2. Roller Cage
3. Roller
4. Garter Spring
5. Cam
Engage tabs in the slots
1 2
7. If garter spring replacement is necessary, it is
very important that the correct installation
procedure and special tool be used. Hold rollers
in place on roller cage with a light film of grease.
Gently and evenly roll the spring down the Hilliard
Clutch Garter Spring Installation Tool (PN
and will require
Inspect for cracks
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A
4
7.7