Polaris 4×4 models usage a Hilliard clutch to communicate power to the former wheels. The more recent models home the Hilliard system in a central front gearcase that from the exterior looks comparable to most 4x4s. The at an early stage 2004 and older models have actually an individual Hilliard clutch in each front wheel hub. This hubs space a an important part the the drive system and must it is in maintained.

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The hub liquid must be readjusted on a constant basis follow to the periodic maintenance chart in the company manual. It must be drained and replaced at any time the hub is removed. Also, the hub requirements to be drained and flushed with oil to eliminate moisture if the hub has been submerged in water or otherwise contaminated. Carry out not allow the hubs operation dry together the hub fluid provides lubrication for the former wheel bearings.

Support the vehicle with a perfect stand or jack and also remove the front wheels for much better access to the hubs. Picture the hub together a clock face and also position the hub fluid plug right up in ~ the 12 o’clock position. Eliminate the liquid plug from the hub. Revolve hub forward or ago until the liquid plug hole reaches the 4 or 8 o’clock position. If the fluid level is correct the fluid should dribble out of the hole. Turn the hole to the 6 o’clock position or eliminate the cap to drain the fluid. Position the hole at the 4 or 8 o’clock position once filling to set the level correctly.

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Look over the seals if the liquid level is low. The hub liquid can leak indigenous a faulty cap O-ring top top the outside of the hub, hub seal on the earlier side of the hub, or the strut hub seal on the strut real estate where the CV axle enters the strut housing. Change the seals together necessary. Execute not hesitation to replace them all. Apply a light coat that grease come the new seals, however do no grease wheel bearings or permit the grease to contaminate the Hilliard clutch components.

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Clean and inspect the Hilliard clutch materials if the hub is removed. Replace the retaining spring v a brand-new item if that is in negative condition or longer than the mentioned length. Usage the Polaris unique spring installer tool to download the spring v minimal stretching. Make sure to replace the spring with the appropriate component as the springs differ over the years, and while they might look the same the spring stress and anxiety is not. A dangerous situation can be created if the spring is faulty or the incorrect ingredient is installed, as the Hilliard clutch might inadvertently engage at high speed.

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Check the action of the Hilliard clutch by hand prior to installing it. Hold the roller cage and rotate the inside cam. The rollers need to be required out through the cam, and when the roller cage is exit the rollers should return to their relaxing position.

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Inspect the seal sleeve (outer pole) to inner pole clearance in multiple locations with a straight edge and also feeler gauge. The seal sleeve must sit 0 ~ 0.025 mm above the inner pole. This is specifically important if the coil and seal sleeve are being changed with new items. Adjust the seal sleeve position so the pole clearance is correct.

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Lubricate the wheel bearings and Hilliard clutch assembly with Polaris need Drive Hub liquid or various other specified fluid. Assemble the hub and also tighten the fasteners to specification. Place the fluid plug feet at the 4 or 8 o’clock position and also fill the hub fluid until the reaches the plug hole. Install the hub fluid plug and tighten that securely. Check ride the vehicle and also check because that hub liquid leaks.

If you require a organization manual for her Polaris check out the aramuseum.org virtual manuals: https://www.aramuseum.org/online-manuals/polaris-atv-online-repair-manuals/ or acquire a print hand-operated here: https://www.repairmanual.com/