Handlebar Removal - Polaris 1999 Sportsman 400 Service Manual

FRONT SUSPENSIO \,\ AI\D STEERI NG
HANDLEBARIXPLORERI
349
1. Top cover
2. Screw
3. Instrument pan el cover
4. Bolt
5. lock ring
6. Indictors
7. Enrichment (choke) knob
8. Wiring harness
9. Handlebar
10. Ignition key
11. Pod mounting bracket
12. Key or Ignition switch
13. Holders
14. Steering shaft
15. Selt-Iccklnq
nut
3. Alternating from side to side. slowly tighten the
bolts sec uring the control aml to the frame mount-
ing brack ets. Tighten the bolts to the torque specifi-
catio n listed in Ta ble 2.
4. After tightening the bolts. move the control ann
lip and down to ensure freedom of movement. The
ann must move
lip
and down with no binding. If
bindi ng occurs, rem ove the control arm and correct
the problem immediately.
5. lnstall the front drive axle as desc ribed in Chap-
ter Ten.
6. Install the front strut as descr ibed in this cha pter.
7. Install the fron t wheel as described in this chap-
ter.
8. Lower the vehicle and check the movement of
the frontsuspension prior to riding it. Push down on
the front bumper seve ral times to make sure the
control arms are moving up and down correct ly,
9. Test drive the ATV slowly
10
make sure all sus-
pension component s are operating correctly.
II ANDLEBAI{
Refer
10
Figu re 37 for Sportsman models and
Figure 38 for Xp lorer models.
CAUTION
Co ver
the front f ender and seat with a
heavy cloth or tarp to protect them
fnnn uny brake f luid that may he acct-
de ntatlv sp illed, Use soapy water
to
wash any spilled brake fluid from a
painted or plat ed surface immediately
to prevent damaging
to
the finish.
Rinse the area thorou ghly with clean