Late 2004 Front Gearcase Information - Polaris SPORTSMAN 600 Service Manual

LATE 2004 - - FRONT
GEARCASE OPERATION - -
CENTRALIZED HILLIARD)
Normal Operation: With the AWD switch off the
vehicle drives only the rear wheels (2 wheel drive).
When the AWD switch is activated it engages the
Hilliard, locking both front axles into All Wheel Drive.
Armature
Plate
Coil
4x4 Engagement: When the AWD switch is
activated, a 12 VDC current charges the central coil
which creates a magnetic field. This magnetic field
attracts an armature plate keyed to a roller cage that
contains 14 rollers and roller cam. The difference in
rpm by input shaft and front axles the forces the rollers
up the external cam. The rollers engage themselves
to the output hubs that link both front axles, resulting
in True All Wheel Drive.
CAUTION: If the rear wheels are spinning, release
the throttle before turning the AWD switch on. If AWD
is engaged while the wheels are spinning, severe
drive shaft and clutch damage could result.
Roller Cage and Roller's Rotate Inward and
Grip the Output Hub for AWD Engagement
Roller Cage
Disengagement: As the front and rear wheels gain
Output
traction, rotating very close to the same speed, the
Hub
front wheels "overdrive" the output hubs and the
rollers are forced outward, disengaging the AWD.
The vehicle is now back to rear wheel drive until the
next loss of traction.
Cover
LATE 2004 - - FRONT
GEARCASE
DISASSEMBLY/INSPECTION
1. Drain and properly dispose of used oil. Remove
2. Remove bolts and output shaft cover.
Output
Hub
any metal particles from the drain plug magnet.
FINAL DRIVE
Rollers
Roller Cage
& Bearings
7.17