2003_TrailBoss parte III.pdf

FINAL DRIVE

WHEEL, HUB, AND SPINDLE

TORQUE TABLE

4. Remove the two brake caliper bolts and the brake

caliper.

Item

Specification

Front Wheel Nuts

20 Ft. Lbs. (27 Nm)

Rear Wheel Nuts

50 Ft. Lbs. (68 Nm)

Front Spindle Nut

40 Ft. Lbs. (54 Nm)

Rear Hub Retaining Nut

80 Ft. Lbs. (109 Nm)

NOTE: Refer to exploded views and text for torque

values of other fasteners

CAUTION: Locking nuts and bolts with preapplied

locking agent must be replaced if removed. The

self-locking properties of the nut or bolt are reduced

or destroyed during removal.

FRONT HUB

DISASSEMBLY/INSPECTION

1. Elevate front end and safely support machine

under footrest / frame area.

CAUTION: Serious injury may result if machine tips

or falls. Be sure machine is secure before beginning

this service procedure. Wear eye protection when

removing bearings and seals.

2. Check bearings for side play by grasping tire /

wheel firmly (top and bottom) and checking for

movement. It should rotate smoothly without

binding or rough spots.

5. Remove hub cap, cotter pin, front spindle nut, and

washer.

6. Rotate each bearing by hand and check for

smooth rotation. Visually inspect bearing for

moisture, dirt, or corrosion. Replace bearing if

moisture, dirt, corrosion, or roughness is evident.

7. Place a shop towel on hub to protect surface.

Carefully pry seal out of hub.

3. Remove wheel nuts and wheel.

7.2

FINAL DRIVE

8. Using a brass drift, tap bearing spacer to one side

to expose inner bearing race. Drive bearing out

using a drift through opposite side of hub and

discard.

FRONT HUB ASSEMBLY

Hub assembly view

Tap spacer to side

Seal

1. Drive or press one new bearing into hub using a

1.180 (46 mm) bearing driver.

9. Remove spacer and drive other bearing out and

discard.

10. Clean hub and spacer thoroughly.

11. Inspect spacer for wear or damage. Measure

length of spacer and replace if worn beyond

service limit or if ends are rounded.

CAUTION: Do not drive on the inner race of the

bearing.

Premium All-Season Grease

(PN 2871322) (3 oz. Tube)

(PN 2871423) (14 oz. Tube)

2. Coat bearing spacer with grease and install into

hub. Drive or press the other bearing into hubuntil

seated against spacer.

Bearing Spacer Length:

Service Limit: 2.1850 (5.55 cm)

7.3

FINAL DRIVE

3. Install seal into hub (with numbers facing out) until

flush with end of seal bore.

5. Install spindle nut and tighten to specification.

Seal

FRONT HUB INSTALLATION

2x4SpindleNutTorque:

40 ft. lbs. (55.0 Nm)

1. Inspect spindle seal and bearing surface for wear

or damage.

6. Install a new cotter pin. Tighten nut slightly if

necessary to align cotter pin holes.

7. Rotate wheel and check for smooth operation.

Bend both ends of cotter pin around end of

spindle in different directions.

8. Lightly grease a new O-ring and install on hub

cap. Install hub cap.

9. Rotate hub. It should rotate smoothly without

binding or rough spots or side play.

10. Install brake caliper using new bolts. Tighten

bolts to specified torque.

Inspect and Grease

Caliper Mounting Bolt Torque

18 ft. lbs. (25 Nm)

2. Apply grease to spindle.

3. Install hub on spindle.

4. Apply grease to washer and install with domed

side facing out.

11. Install wheel and wheel nuts and tighten evenly in

a cross pattern to specified torque.

Flange Nuts:

Flat side against

wheel

Out

Cone

Washer

Front Wheel Nut Torque

20 ft. lbs. (27 Nm)

7.4

FINAL DRIVE

FRONT HUB EXPLODED VIEW

Strut Housing

Spindle

Bearing

Brake Disc

Hub

Seal

18 ft. lbs. (24.9 Nm)

Use new bolts with pre-applied

locking agent.

Washer

(domed side out)

Spacer

Bearing

Cotter Pin

Wheel Nut

O-Ring

Hub Cap

Nut

40 ft. lbs.

(55.3 Nm)

7.5

FINAL DRIVE

CONCENTRIC SWINGARM

REAR AXLE REMOVAL

1. Securely support rear of machine with rear wheels

off the floor. Remove rear wheels and hubs.

2. Remove drive chain.

3. Remove snap ring (A), lock sleeve (B) and foam

seal (C) from axle.

Remove Rear Caliper

6. Support rear caliper withwire or a tie strap. Donot

hang caliper by brake line.

Support Caliper from Frame

4. Remove sprocket hub nut (D).

7. Slide axle assembly out left side.

5. Remove the two rear brake caliper bolts. Remove

the rear brake caliper.

7.6

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