polaris 2003 sportsman front hub torque

fmongeau · #1 (**permalink**) 11-09-2009, 03:50 PM

Does any one know where to find the torque specs for a 2004 Polaris Sportsman? I am getting ready to rebuild the front end on the machine and would like to know if there is any specs on the torque for the hardware.

4play · #2 (**permalink**) 11-09-2009, 06:02 PM

110ftlbs for the centre axle nut, the rest tight with locktight.

fmongeau · #3 (**permalink**) 11-14-2009, 07:44 AM

Thank you again. I am getting ready to go out and start putting the machine back together.

overdbars · #4 (**permalink**) 04-05-2010, 08:09 PM

I'm questioning the 110 foot lbs for the axle nut. I don't think we are on the same page here. I just replaced front rotors & pads on a 2001 500 Sportsman. I used 16 foot lbs anything tighter the wheel will not rotate freely. I don't think this (16lbs) is correct & I'm still researching this spec. I saw the 110 lbs so I went to 30 foot lbs & was unable to turn the wheel at all. If anyone knows the spec on the front axle nut for a 2001 please post it. 110 is very questionable.

JD

cowslinger64 · #5 (**permalink**) 04-06-2010, 03:52 AM

below is out of the manual for the 02 Sportsman 500. I'd imagine its the same. If you're gonna do this sort of work, I'd recommend getting a manual for it.

1. Torque spindle nut to 160-170 inch lbs. (18--19
Nm) 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 in. lbs. (12--16.3
Nm).
5. Install cotter pin. Bend each leg of cotter pin
around castle nut in different directions. See
below.
NOTE: If cotter pin hole does not align, tighten slightly
to align and install pin. Do not exceed 144 in. lbs. (16.3
Nm).
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.
9. Reinstall plug.
10. Reinstall brake caliper assembly. Torque retaining
bolts to 18 ft. lbs. (25 Nm).
11. Reinstall front wheels. Torque retaining nuts to 15
ft. lbs. (21 Nm).
12. Carefully lower vehicle.
13. Field test vehicle for proper operation of brake
system and AWD operation.

overdbars · #6 (**permalink**) 04-12-2010, 08:16 AM

Thanks,
I did take the 110 ft lbs & then divided them by 12 to get the inch pounds.
(that put me in the ballpark). Thanks for the update & the added instructions.

JD