Magnetic Coil Replacement - Polaris Magnum 2x4 Service Manual

FINAL DRIVE
Magnetic Coil Replacement
Magnetic Coil Replacement
Remove the seal sleeve from the strut casting
using a drift punch and hammer, tapping evenly on
each side until the sleeve slides off. Remove the
existing coil and clean the coil wire channel, coil
mount area and the seal sleeve mounting area of
all silicone and foreign matter.
1. Apply 1/4" (.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
1/4"
(.6 cm) bead of Loctite 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 the desired pole
gap is achieved. See page 7.7 for additional
information. Once the seal sleeve is properly
positioned, a 1/16" (.16 cm) bead of silicone
should remain around the inner edge. Clean
off all excess silicone. The seal sleeve area
must be free of silicone.
NOTE:
- Always install a new seal sleeve when
replacing the coil.
- It may be necessary to apply more silicone
to the wire channel area to properly secure
and protect the coil wires.
5. Apply 401 Loctite (super glue) to the inside of
the strut ribs and press the foam 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.
7/96 7.B
Strut Ribs
Coil Wire
Channel
Coil Mounting
Surface
(Inner Magnet Pole)
(Fixed)
Electromagnet Coil
Brake Line
Clip Location
Polaris Industries Inc.