Polaris 1999 Sportsman 400 Service Manual page 348

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342
17.
Loosen
then
remo ve the pin
ch
bolt
s (Figure
(6
), se
lf-locking
nuts
and
was
her
s from the front
strut.
Note
the
location of the cla
mp
on
the
upper
bolt
(B,
Fig
ure
15).
ISA
.
Slide
the strut (Figure
17)
up to wit
hdraw
it
from
the
strut
support.
NOTE
One of the fo
llowing
steps
may be
neces sary
to
release the
strut/rom the
strut suppo rt ifit will not slide out
af-
ter
the
clamping bolts
and nu
ts
have
been
removed.
I
SB.
App
ly a
liberal
amount of
penetrating
oi
l
be-
tween
the
strut
cartridge and the strut support.
Let
the oi
l work about
15-20
m
inutes.
Using a
soft-faced
mallet,
carefully tap
aro
und
the
strut
sup-
port
whe
re the
cartridge
is located .
Withdraw
the
strut from
the
strut support.
CA
UTION
Do not spread
the s
trut s
upport
joint
in the
areas
of
the
bolt
hole
bosses.
AIso
do not spread
tile
j
oint anyfar-
ther than
necessary, as the aluminum
casting will
crack
and
must be re-
p
lace d.
When using this method,
sp read
the j
oint
ve
l }'
slowly
to avo
id
damaging
(he strut support.
ISe. Carefully
spread
the
front
strut
j
oint
with
an
aluminum
or
brass
tool
sufficiently
to release the
strut. Withdraw
the
strut
from
the
strut
support.
18D.
If the
previo
us
methods were unsuccessful,
perform
the
follow
ing:
a.
Tap both
uppe
r
bolt
mounting
bosses
with
a
3/S
in.
tap.
b. Screw
a
3/8
in.
bolt part way
into
each
upper
mounting
boss.
c.
Place a thick stee
l washer
into
the
joint below
the
bolts.
Do
not
align the washer
bolt
hole.
the
bolt
is
to contact
the
washer.
not
go
through
it.
d
. Slow
ly tighten
the
bolt
s
onto
the washers to
spread
the
jo
int
sufficiently
to
release the
strut.
Withdraw
the
strut
from
the
strut
sup-
port.
e. Remove
the
bolts and
washers.
CHAPTER T
WELVE
®
Ins
pection
I.
Inspect the spring
for distort
ion, cracks,
or ot
her
damage.
If one
spring
is
damage
d,
replace
both
springs.
2. Inspec t the strut
for oil leaks (A
,
Figu
re
(8).
3.
Check
the rub
ber
bumper (B, Figu
re 18)
for de-
terioration
or
hardness.
Replace
if
necessary.
4. Check
the LIpper spring
seat
for wear
ordamage.
5.
Clean the strut recep
tac
le
in
the
strut
support
(Figure 19) wit
h solvent
and
dry.
Clean
any co
rro-

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