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WARNING
The following bearing adjustments are very important. Incorrect adjustment will increase bearing wear, reduce
braking action, and may affect front drive hub engagement, which could result in serious personal injury or death.
AWD Front Hub Bearing Adjustment
1. Torque spindle nut to 160-170 inch lbs. while
rotating hub continuously.
2. Back off nut 1/2 turn.
3. Rotate axle several revolutions by raising rear of
machine and rotating rear wheels with the
machine in gear.
4. Re-torque hub nut to 108-144 inch lbs.
Front Spindle Nut Torque:
108-144 in. lbs.
Brake Caliper Retaining Bolt Torque:
18 ft. lbs. (2.5 kg-m)
5. Install cotter pin. Bend each leg of cotter pin
around castle nut in different directions.
NOTE: If cotter pin hole does not align, tighten slightly
to align and install pin. Do not exceed 144 in. lbs.
6. Reinstall hub cap.
7. Remove fill check plug and rotate hole to either
4:00 or 8:00 position.
8. Fill with Polaris Premium Demand Drive Hub Fluid
or Type F Automatic Transmission Fluid until fluid
trickles out. NOTE: Do not force the oil into the
hub under pressure. This can cause seal damage
and leaks.
Premium Demand Drive Hub Fluid
PN 2871654 (8 oz.)
PN 2872277 (2.5 gal.)
9. Reinstall plug.
10. Reinstall brake caliper assembly. Torque retaining
bolts to 18 ft. lbs. (2.5 kg-m).
11. Reinstall front wheels. Torque retaining nuts to 15
ft. lbs. (2.1 kg-m).
12. Carefully lower vehicle.
13. Field test vehicle for proper operation of brake
system and AWD operation.
Polaris Sales Inc.
AWD Front Hub Bearing Adjustment
7.11
FINAL DRIVE
4/99
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Troubleshooting
