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2002 Polaris 500HO front hub rebuild???

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Old Apr 26, 2012 | 07:10 PM
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Default 2002 Polaris 500HO front hub rebuild???

I was replacing a front boot on the axcel eveything went well there.I started looking a bit closer and the bearings need to be replaced.I had the hub off and did not realized what order the bearings go .I no which bearing goes on the outside I just was wondering about the order ? Bearing #1 is correct I thought the book would show you but it does not. Here is a picture of the bearings.The first bearing is the one that you see first when the cap is removed from the hub.
 
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Old Apr 26, 2012 | 07:25 PM
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#3 and # four go into the strut front and back, #1 and #2 go in the inner and outer hub (one against the hilliard cage, then the hub is installed, the other on the hub outside. Doesn't matter if you mix up positions(inner or outer) between the two different size sets of bearings,I never really looked when I tore em apart! Just make sure they turn smooth and the races aren't rough and pitted that they fit into and torque to 15 to 20 pounds to preload the bearings,back off one turn,then torque to 12 foot pounds. OPT
 
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Old Apr 27, 2012 | 05:16 PM
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Thanks for the info I thought that was right.Much appreciated if the races are smooth I should be ok with just replacing the bearing part that runs on the races the races seem smooth.What is the bottom part of the A arm torqued to???
 
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Old Apr 28, 2012 | 01:28 AM
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Ball joint nut torque shows to be 25 foot pounds. OPT
 
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Old Apr 30, 2012 | 08:59 PM
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Hey thanks for the help much appreciated.After everything is torqued down the bike is on jack stands so I turned the rear wheels and all the wheels turn is this correct with the bike turned off.I have watched videos on you tube and that was one of the things to check for....I am also going to pick up some front dif oil from the dealer and change it.The book does not really give the specs on the exact amount of oil for the front dif.There is no dip stick just a fill hole and a drain hole.Thanks again....
 
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Old Apr 30, 2012 | 09:30 PM
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The Hiliard clutch that is in the hub should be greased is this correct.I was not sure if it just ran in the hub oil or not.I would say it should be greased?
 
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Old Apr 30, 2012 | 10:20 PM
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Hub fluid only!! NO grease! Just remove the 3/16" allen head drain screw,turn hub to 12 o'clock position,use a small funnel or anything that is small enough not to make a big mess,fill the hub full,let the fluid level go down,top off the hub again. Turn the hub to 4 o'clock position to drain the excess fluid out, a little extra wont hurt. you don't have to drain all the excess fluid. Turn hub back to 12 o' clock and put the drain screw back in. OPT
 
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Old May 1, 2012 | 01:49 PM
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Thanks for the help .I am going to use 80 /90 gear oil in the front diif because the hiliard clutches are in the hubs not the dif and the amount of 80/90 gear oil is 5 oz.
 
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Old May 1, 2012 | 02:03 PM
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Yes, 80/90 GL5 oil in the front diff,but you'll probably only get about 4 ounces in. Just fill to the bottom of the fill plug threads. OPT
 
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