Double check to make sure that the play you feel isn't coming from the balljoints.That's strange that you'd still have play from a new wheel bearing,even if the hub was worn that much you would've seen that when you were putting it back together.
when i crank mine down tight, there is drag on the wheel. i back it off to allow it to spin freely.The shop manual also says not to back off on the nut once you reach the 58 Ft Lbs of torque. If the slots in the Castle nut dont line up with the hole in the spindle, then tighten it just a little more to line up the holes to install the cotter pin.
Hi first post here! I have a 01 Foreman ES, one of the front wheel bearings was really loose, replaced the bearing, still loose. The new bearing fit tight in the knuckle, and the hub had a tiny bit of play but when you put it together you can move the wheel quite a bit at 12 and 6 o'clock. I'm guessing I'm looking at a hub (flange)?