95 Big Boss 6x6 rear axle - Polaris ATV Forum
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post #1 of 13 (permalink) Old 05-08-2019, 05:04 AM Thread Starter
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95 Big Boss 6x6 rear axle

HI there,

I have a quick question. I've changed my final drive rear axle bearing the other day on my 1995 Big Boss 6x6 (Same set-up as a Magnum 425 for example) with brand new bearings. the torque spec for the nut and lock nut are indicated at 150ft-pd in the manual. But after tightening the first nut not completely to torque spec. I can barely rotate the carrier around the axle. Is this normal ? I've removed the seals that came with the bearing kit and lubricated the balls as well as the inside of the carrier but still stiff to rotate. Is this going to get easier once driving on the ATV ?
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post #2 of 13 (permalink) Old 05-08-2019, 06:22 AM
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I don't know where you got your information, but according to my manual;

Concentric Swingarm Rear Axle Installation
1. Lubricate and install axle from left to right.
2. Lubricate and install a new 0-ring on right side of
axle. Slide new 0-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 0-ring and
bearing.
3. Apply Loctite TM 262 to threads of and install nut.
lighten nut with wrench to approximately 8-10 ft.
lbs. (11-14 Nm). 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.

I admit, I tighten the nut tighter than 10 ft lbs and it resists turning until it has run in for some miles

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

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post #3 of 13 (permalink) Old 05-08-2019, 09:12 AM Thread Starter
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95 Big Boss 6x6 rear axle

From the 1985 to 1995 ATV and Light Utility Hauler manual.
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Name:	rear axle re-assembly.jpg
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post #4 of 13 (permalink) Old 05-08-2019, 09:22 AM
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Nice to have you here with us Marty. Is this a work machine you have?? That' all ours does.
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post #5 of 13 (permalink) Old 05-08-2019, 09:32 AM
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This is the page from manual #9914752
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Name:	Polaris Magnum 425 2x4 4x4 6x61996 1997 1998 9913680 9914752 462.png
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ID:	117731  

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #6 of 13 (permalink) Old 05-08-2019, 10:32 AM Thread Starter
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Your Manual is for a 1996 and up.
Mine is a 1995.

Might be because they recommend using loctite 262 (RED - High strength) instead of the 242 (BLUE - Medium strengh). That might be why they are recommending a lower torque
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post #7 of 13 (permalink) Old 05-08-2019, 10:35 AM Thread Starter
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ArlyA - Pretty much the same.
Working around the cabin hauling wood and other stuff.
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post #8 of 13 (permalink) Old 05-08-2019, 11:14 AM
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We are the south shore of da BIG lake. Nearly straight south of Thunder Bay.

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Originally Posted by MartyP3030 View Post
ArlyA - Pretty much the same.
Working around the cabin hauling wood and other stuff.
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post #9 of 13 (permalink) Old 05-08-2019, 12:09 PM
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Quote:
Originally Posted by MartyP3030 View Post
Your Manual is for a 1996 and up.
Mine is a 1995.

Might be because they recommend using loctite 262 (RED - High strength) instead of the 242 (BLUE - Medium strengh). That might be why they are recommending a lower torque
Service manuals can be wrong - maybe they wanted it torqued to 120 ft lbs for 'seating' and failed to direct the mechanic to back off and re-torque to 10 ft lbs? At any rate the mechanic is instructed to back off the torque until it turns freely. Any other Polaris techs on here care to give your two cents?

I agree - the 85 to 95 manual # 9912004 does recommend 120 ft lbs, but all other manuals covering different and similar models using the same axle carrier recommends 10 ft lbs. The same axle and axle carrier was used in the following models:

1988 TRAIL BOSS 250 (X888528) - Rear Wheel Drive Assembly
1988 TRAIL BOSS 250 (X888528) - Swing Arm Weldment & Rear Shock Assembly
1988 TRAIL BOSS 250 R/ES (W888528) - Rear Wheel Drive Assembly
1988 TRAIL BOSS 250 R/ES (W888528) - Swing Arm Weldment & Rear Shock Assembly
1989 BIG BOSS (W899627) - Rear Wheel Drive Assembly
1989 BIG BOSS 4X6 (W898627) - Middle Drive Assembly
1989 BIG BOSS 4X6 (W898627) - Rear Wheel Drive Assembly
1989 BIG BOSS 4X6 (X898627) - Rear Wheel Drive Assembly
1989 TRAIL BOSS (W898527) - Real Wheel Drive Assembly
1989 TRAIL BOSS (W898527) - Swing Arm Weldment & Rear Shock Assembly
1989 TRAIL BOSS 2X4 (W897527) - Rear Wheel Drive Assembly
1989 TRAIL BOSS 4X4 (W898127) - Rear Wheel Drive Assembly
1989 TRAIL BOSS 4X4 (W898127) - Swing Arm Weldment & Rear Shock Assembly
1990 BIG BOSS 4X6 (W908627) - Middle Drive Assembly
1990 BIG BOSS 4X6 (W908627) - Rear Wheel Drive Assembly
1990 TRAIL BLAZER (W907221) - Swing Arm Weldment & Rear Shock Assembly
1990 TRAIL BLAZER (W907221) - Rear Wheel Drive Assembly
1990 TRAIL BOSS 250 (W908527) - Rear Wheel Drive Assembly
1990 TRAIL BOSS 2X4 (W907527) - Swing Arm Weldment & Rear Shock Assembly
1990 TRAIL BOSS 2X4 (W907527) - Rear Wheel Drive Assembly
1990 TRAIL BOSS 350L 2X4 (W907539) - Swing Arm Weldment 350 2X4
1990 TRAIL BOSS 350L 2X4 (W907539) - Rear Wheel Drive Assembly 350 2X4
1990 TRAIL BOSS 350L 4X4 (W908139) - Rear Wheel Drive Assembly
1990 TRAIL BOSS 350L 4X4 (W908139) - Swing Arm Weldment & Rear Shock Assembly
1990 TRAIL BOSS 4X4 (W908127) - Swing Arm Weldment & Rear Shock Assembly
1990 TRAIL BOSS 4X4 (W908127) - Rear Wheel Drive Assembly
1991 BIG BOSS 4X6 (W918627) - Middle Drive Assembly Big Boss 4X6
1991 BIG BOSS 4X6 (W918627) - Swing Arm Weldment Big Boss 4X6 Updated 2 91 (4919801980027A)
1991 TRAIL BLAZER (W917221) - Swing Arm Weldment/Rear Shock Assembly Trail Blazer
1991 TRAIL BOSS 250 (W918527) - Rear Wheel Drive Assembly Trail Boss Update
1991 TRAIL BOSS 2X4 (W917527) - Rear Wheel Drive Assembly 250 2X4 Update
1991 TRAIL BOSS 350L 2X4 (W917539) - Rear Wheel Drive Assembly 350 2X4 Update
1991 TRAIL BOSS 350L 4X4 (W918139) - Rear Wheel Drive Assembly 350 4X4 Update
1991 TRAIL BOSS 350L 4X4 (W918139) - Swing Arm Wld./Rear Shock Asm. 350 4X4 Update
1991 TRAIL BOSS 4X4 (W918127) - Rear Wheel Drive Assembly 250 4X4 Update
1992 BIG BOSS 4X6 (W928627) - Rear Wheel Drive Assembly 250 4X6
1992 BIG BOSS 6X6 (W928727) - Rear Wheel Drive Assembly 250 6X6
1992 EURO BIG BOSS 6X6 (S928727) - Rear Wheel Drive Assembly 250 6X6 / W928727
1992 TRAIL BLAZER (W927221) - Rear Wheel Drive Assembly Trail Blazer
1992 TRAIL BOSS 250 (W928527) - Rear Wheel Drive Assembly Trail Boss
1992 TRAIL BOSS 2X4 (W927527) - Rear Wheel Drive Assembly 250 2X4
1992 TRAIL BOSS 350L 2X4 (W927539) - Rear Wheel Drive Assembly 350 2X4
1992 TRAIL BOSS 350L 2X4 (W927539) - Swing Arm Weldment 350 2X4
1992 TRAIL BOSS 4X4 (W928127) - Rear Wheel Drive Assembly 250 4X4
1993 250 2X4 (W937527) - Rear Wheel Drive Assembly
1993 250 4X4 (W938127) - Rear Wheel Drive 4X4 250
1993 250 6X6 (W938727) - Swing Arm/Guard Mounting 6X6 250
1993 350L 2X4 (W937539) - Rear Wheel Drive Assembly 2X4 350L
1993 350L 4X4 (W938139) - Rear Wheel Drive Assembly 4X4 350L
1993 350L 6X6 (W938739) - Swing Arm/Guard Mounting 6X6 350L
1993 EURO 350L 4X4 (S938139) - Rear Wheel Drive Assembly 4X4 350L W938139
1993 EURO 350L 4X4 (S938139) - Rear Wheel Drive Assembly 4X4 350L
1993 EURO 350L 6X6 (S938739) - Swing Arm/Guard Mounting 6X6 350L W938739
1993 EURO 350L 6X6 (S938739) - Swing Arm/Guard Mounting 6X6 350L
1993 SPORTSMAN 4X4 (W938039) - Rear Wheel Drive Assembly Sportsman 4X4
1993 TRAIL BLAZER (W937221) - Rear Wheel Drive Assembly Trail Blazer
1993 TRAIL BOSS (W938527) - Rear Wheel Drive Assembly Trail Boss
1994 300 2X4 (W947530) - Rear Wheel Drive Assembly 2X4 300
1994 300 4X4 (W948130) - Rear Wheel Drive Assembly 4X4 300
1994 300 6X6 (W948730) - Swing Arm/Guard Mounting 6X6 300
1994 400L 2X4 (W947540) - Rear Wheel Drive Assembly 2X4 400L
1994 400L 4X4 (W948140) - Rear Wheel Drive Assembly 4X4 400L
1994 400L 6X6 (W948740) - Middle Drive Assembly 6X6 400L
1994 400L 6X6 (W948740) - Swing Arm/Guard Mounting 6X6 400L
1994 NORWEGIAN 400L 4X4 (N948140) - Rear Wheel Drive Assembly Swedish 4X4 400L S948140
1994 NORWEGIAN 400L 6X6 (N948740) - Swing Arm/Guard Mounting 6X6 400L, Swedish S948740 & Norwegian
1994 SPORT 400L (W948540) - Rear Wheel Drive Assembly Sport 400L
1994 SWEDISH 400L 4X4 (S948140) - Rear Wheel Drive Assembly Swedish 4X4 400L
1994 SWEDISH 400L 6X6 (S948740) - Swing Arm/Guard Mounting 6X6 400L, Swedish & Norwegian N948740
1994 TRAIL BLAZER (W947221) - Rear Wheel Drive Assembly Trail Blazer
1994 TRAIL BOSS (W948527) - Rear Wheel Drive Assembly
1995 BIG BOSS 6X6 400L (W958740) - Swing Arm/Guard Mounting 6X6 400L U.S. , Swedish S958740 & Nor
1995 MAGNUM 4X4 (W958144) - Rear Wheel Drive Assembly
1995 NORWEGIAN MAGNUM 4X4 (N958144) - Rear Wheel Drive Assembly W958144
1995 SWEDISH MAGNUM 4X4 (S958144) - Rear Wheel Drive Assembly W958144
1995 TRAIL BLAZER (W957221) - Rear Wheel Drive Assembly Trail Blazer
1996 400L 6X6 (W968740) - Rear Wheel Drive 6X6 400L & 6X6 400L Norwegian N968740
1996 400L 6X6 (W968740) - Middle Drive 6X6 400L & 6X6 400L Norwegian N968740
1996 NORWEGIAN 400L 6X6 (N968740) - Middle Drive 6X6 400L W968740 & 6X6 400L Norwegian
1997 MAGNUM 6X6 (W97AE42A) - Rear Wheel Drive Magnum 6X6 & Swedish Magnum 6X6 S97ae42e
1999 BIG BOSS 500 6X6 (A99AE50AA) - Rear Wheel Drive A99ae50da
1999 INTL BIG BOSS 500 6X6 (A99AE50DA) - Rear Wheel Drive

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience

Last edited by latebird; 05-08-2019 at 12:13 PM.
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post #10 of 13 (permalink) Old 05-09-2019, 04:51 AM Thread Starter
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I'm from the south shore too. But, Montréal in Québec
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