Middle Axle Assembly - Polaris 2004-2005 Sportsman 6x6 Service Manual

GENERAL INFORMATION
3. Remove jam nut (D) and locking mid axle hub (E).
Remove swing arm housing and O-rings (F).
Discard O-rings. Inspect bearing and seals,
replace if worn or damaged.
Disc Hub
Stop Ring
Splines
4. Remove brake disc assembly, and stop ring.
Inspect axle for straightness and damage.
Replace if necessary.
CONCENTRIC SWINGARM

MIDDLE AXLE ASSEMBLY

Disc Hub
Stop Ring
1. Install stop ring in groove on left side of axle.
NOTE: Left side of axle is identified by the small
groove in the middle of the spline.
Stop ring
Groove in spline
Threads
Groove in spline
2. Install disc hub assembly on axle. Be sure hub
covers stop ring. Install disc in soft jawed vise.
Apply Never Seize to threads, install left axle nut
and tighten to 120 ft. lbs (166 Nm). Keep tightening
nut until flat aligns with flat on brake hub.
Spacer
O-ring
Axle Nut (Disc Side) Torque:
120 ft. lbs. (166 Nm)
3. Lubricate spacer and new O-ring. Install on axle.
Foam Seal
Nut Retainer
(Taper toward hub)
Retaining Ring
4. Lubricate and install swing arm assembly with
grease zerk facing away from brake disc.
Lubricate and install new O-ring and locking hub.
Foam Seal
Nut Retainer
(Taper toward hub)
Retaining Ring
7.23