Rear Axle Installation - Polaris Trail Boss 330 2003 Service Manual

FINAL DRIVE
4. Install foam seal and axle nut lock sleeve with
taper toward nut. Install snap ring to retain the
lock sleeve.
Foam Seal
Snap Ring
(Tapered side toward nut)
CONCENTRIC SWINGARM

REAR AXLE INSTALLATION

1. Install axle from left to right.
O--Ring on axle between
sprocket hub and bearing
2. Lubricate and install a new O-ring on right side of
axle. Slide new O-ring against RH axle bearing
seal. Apply grease to sealing area on inside of
sprocket hub and slide sprocket hub assembly
onto the axle. Seat the hub against O-ring and
bearing.
3. Apply Never Seize to threads of axle and install nut.
Tighten nut with wrench to approximately 8-10 ft.
lbs. (11-14 Nm). Align flat of nut with flat on hub.
Axle must rotate smoothly without binding. If axle
binds the nut is too tight. If axle movement (up and
down or side to side) is detected, axle is too loose.
Axle Nut (Sprocket Side) Torque:
8-10 ft. lbs.
7.8
Lock Sleeve
(11-14 Nm)
4. Install foam seal (C) and slide lock sleeve (B) onto
hub and install lock sleeve with taper inward.
Install snap ring (A).
C
5. Install brake caliper and drive chain. Adjust drive
chain (refer to Maintenance Chapter 2 for
procedure). Torque eccentric pinch bolts to 30 ft.
lbs. (41 Nm) on models without a trailer hitch, or
40 ft. lbs. (55 Nm) on models with a trailer hitch.
Verify proper chain adjustment after torquing
eccentric.
6. Torque brake caliper mounting bolts to 18 ft. lbs.
(25 Nm).
7. Apply Never Seize to axle splines and install rear
wheel hubs. Torque center hub nut to 80 ft. lbs.
(109 Nm) and install a new cotter pin. Torque
wheel nuts to 50 ft. lbs. (68 Nm).
8. Lubricate eccentric housing through grease fitting
with Polaris Premium All Season Grease until
grease is purged on each side of eccentric.
B
A