Polaris 1999 Sportsman 400 Service Manual page 349

FRONT SUSPENSION AND STEERI NG
sion or burrs fro m the inner surface that wo u ld
make installation of the strut difficu lt.
In st all ati on
Refer to Fig u re 4.
NO TE
If
installing a new
S / 1111,
transf er the
scribe line made in Removal Step / 5
onto the new shock body. This will en-
343
sure the correct installed location of
the s trut within the strut support.
I.
Sl ide the strut dO\\11 into the strut suppo rt. Push
the strut into the correc t locat ion w ithin the strut
support (A . Figure (5). Refer to the scribe line
made in Removal Step 16.
2. Install the pinch bolt s (figure 16). washers and
Hen'
self-locking nuts. Note the location
of
the
clamp on the upp er bolt (8, Figure (5).
3. Verify thc loc ation of the strut in the strut sup-
port. readjust if necessary, and then tighten the nuts
to the torqu e specification listed in Table 2,
4. Slide the lower spring seat over the strut and into
position o n the strut support (Figure 13).
5. If the spring was repl aced , install the spring
compressor on the spring (f igu re (4). Slow ly and
care fully tight en the spring co mpresso r until the
spring is compressed sufficiently for installation.
6. Install the co mpressed spring over the strut and
set it on the lower spring sea t (Fig ure (2).
7. Insta ll the upper spr ing scat (8. Fig ure II) and
lower ba ll pivot on to the spring.
8. Install the
li e\\'
se lf-locki ng nut (A. Figure
II).
9. Tighten the se lf- locking nul onto the
stru t
dam per rod to the sa me location noted in Step 10 of
Remo val . Sec ure the upper end of the strut w ith a
socket (A, Figure 10). Securely tight en the new
se lf-locking nut w ith a 3/8 in. w rench (8. Figure
10) .
10. Slow ly and ca refu lly loo sen the spring com-
pressor. Make sure the spring (f ig ure 20 ) is sea ted
correctly in both the upper and lower spring seats,
then rem ove the tool (figure 8) fro m the spring.
I I. Install the upp er ball pivot and was her (F ig ure
7) ont o the frame .
12. Raise the strut ass embly up and insert the upper
end of the strut throu gh the frame opening and the
upper pivot ba ll and washer.
13. Install the nut (Fignre 6) and tighten it secure ly
to hold the assembly in place.
NO TE
Posi tion the
crOH'S
f oot wrench at a
90° ung le to the torque wrench so that
the torque specification does
110 1
hove
to be
recalculated.
14. Sec ure the upper end of the strut with a wrench
(A, figure 2 J) and tight en the nut wit h a crows foot
wrench (8, Figure 21 ) to the torqu e spec ifica tio n
listed in Table 2.