Handlebar Installation - Polaris 1999 Sportsman 400 Service Manual

350
water, making sure that both brake
fluid and soap are removed.
IA. On Xplorer mode ls, perform the follow ing:
a. Remove the top cover from the instrument
pane l cover.
b. Remove the
two screws
securing the instru-
men t panel cover and remove the cover.
l B, On Sportsman models, remove the headlight
upper pod (A, figure 39 ) as described under
High -Beam Headlight (Sportsma n Models). Bulb
Repla cement in Chapter Eleven.
2. Remove the master cylinder (B, figure 39 ) from
the handlebar as described in Chapter f ourteen.
Rest the master cy linder on the front fender. Keep
the hydraulic brake reservo ir upright to prevent
fluid from spilling and air from entering the brake
system. Do not detac h the brake line from the mas-
ter cy linder, unless
it
is going to be removed from
the vehicle.
CAUTION
Do
1101
allow the master cylinder to
hang by its hose.
3. Remo ve all tics or bands holding the wires and
cabl es to the handlebar.
4. Remove the screws securing the left switch as-
sembly (C, figure 39) , then remove the switch
housing from the handlebar. Lay the switch assem-
bly on the front fender.
5. Remove the screws and clamp securing the
throttle and right switch assembly (Figu re 40) to
the right side of the handlebar and remove the as-
sembly. Lay the assemb ly on the front fender. Do
not allow the cable to be kinked, crimped or dam-
aged.
6A. On Xplorer mode ls, perform the following:
a. Remove the four bolts and self-locking nuts
securing the handlebar upper holder,
ins
tnt -
ment panel cover mou nting bracket , handle-
bar and lower holder. Discard the self-locking
nuts.
b. Remove the handlebar upper holder and the
handlebar. Leave the instrument panel co ver
mounting bracket and lower ho lder in place
o n the s teering co lumn.
6B. On Sportsman models, perform the following:
a. Remove the four bolts and self-locking nuts
sec uring the handlebar up per holder (A, Fig-
C IIA I' TE R TWELVE
®
ure 41), handlebar and lower holder. Disca rd
the self-locking nuts.
b. Remove the hand lebar upper holder and the
handlebar (B, figure 41) . Leave the lower
holder and the pod-mounti ng bracket in place
on the steering co lumn.
7. To main tain a good grip on the handlebar and to
prevent it from s lipping . clean the knurled section
ofthe handlebar with a wire brush.
It should be
kept
rough so it will be held securely by the upper and
lower holders.
8. Also clean any metal from the upper and lower
holders that may have been go uge d loose
by
handle-
bar slippage.
ln st allatlon
I. Align the bolt ho les in the lower holde r and the
pod mounting bracket with the steering column
holes.
2A. On Xplorer mode ls, perfo rm the following:
a. Install the handlebar upper holder and instru -
ment panel cover mounting bracket into place