Tie Rods Removal - Polaris 1999 Sportsman 400 Service Manual

FRONT SUSPENSI ON AND STEE RING
011
the lowe r ho lder and install the mo un ting
bo lts th rough all four co m po nents .
b. Install new self-locking nuts and tighten them
finger-tight.
2B . O n Spo rtsman models, perform the following:
a . Inst all the handl ebar and up per hol der (A ,
Fig ure 4 1) into place on the lo wer ho lder an d
install the mounting bolts through all four
co mpo ne nts.
b. Install new self-locking nuts and tighten them
fin ger-tight.
3. Raise the han d lebar into posit ion and t ig hten the
forw ard bolt s first an d then tigh ten the rea r bol ts.
T ighten all four bolts to th e to rq ue spec ifi catio n
listed in Ta b le 2.
4. If a new hand lebar is be ing inst all ed , a lso install
new grips. Fo llow the man ufact urer' s d irecti on s fo r
installi ng and sealing grips
L a
the hand leb ar.
5. Posi tion the left sw itch ho us ing (C, Figure 39)
o nto the hand lebar and seat
it
next to the grip as
show n. Tight en the sw itch sc rews sec urely .
6. Pos ition the brak e master cy linde r (B , Figure
39)
0 11
the ha nd leba r and inst all the clam p. Tig hten
the bo lts securely.
7. Pos ition the thrott le and right sw itch assemb lies
(F igu re 40 ) onto the handl ebar and sec ure them
with clamp sc rew s. Tighten the screws securely.
8.
C heck the brake lever. th rottle le ver and sw itch
positio ns o n both sides of thc han d leb ars w hile s it-
ting o n the seat. Tigh ten the cla m p screws se cure ly
whe n the co ntro ls ar c co mfo rta bly pos itioned.
9. A fter all assemb lies have been install ed. test
eac h one to make sure it operat es correc tly w ith no
binding. C orrect any prob lem at th is tim e.
I GA . On X plo rcr mod els, perform th e
followi ng:
a.
Install the instrument pa nel cover and two
screws. T ighten the scre ws securely.
351
b. Insta ll the to p cover o nto the instrument pane l
cove r.
lOB. On S portsma n m od els, remove the headli g ht
upper pod (A, Figure 39 ) as described under
High -Beam Headlight (Sportsman Models), Bulb
Replacem ent in C hapter Eleve n.
I I.
Sec ure
the
hou s ing
wiring
harne ss to th e han-
d lebar w ith wire a nd cab le tics. maki ng sure that
w ires
and
cables are properl y routed wit h no sharp
bends.
TIE RODS
Refer to Figure 4 2.
Rern oval
T he tie rod s connect the stee ring shaft to the
stee ring an n po rtion o f the stru l suppor ts. Eac h tie
rod includes an inner and ou ter end attac hed to a
threa de d rod. T he ind iv idual part s can be replace d
separately.
T he o uter tic rod end ( Figu r e 43 ) can be rep laced
with out deta chi ng the tic rod inner end fro m th e
stee ring
shaft.
W hen
replacing
the
inner
tie
rod end.
fir st rem o ve the co mplete tie rod from th e ve h icle so
that th e inne r end an d tic rod ca n be prop erly assem -
bled .
I. Su pport th e ve h ic le and re mo ve the front
w hee l(s) as de scribed in thi s cha pter.
2. Re mo ve the front fen der as described in C hapter
Fifteen.
3. Be fore detach ing eithe r end of th e tic rod , iden -
tify th e placement o f the ends. If impro perl y in-
sta lled. the tie rod ends may hit othe r co mpone nts
ca us ing da mage and po ss ible loss o f control.
4. To di sconn ect the tic rod ba ll joint from the front
strut, perform the foll owing:
a. Remo ve the cotter pin fro m th e caste llated nut
(F igu r e 44).
CAUTION
Do no t
1I .~·e
(J
f orked tool to separate
the tie rod from the fro nt strut ; this
will usually damage the rubber boot,
even when used carefully.
b. Loose n the caste llated nut until it is flush w ith
th e end o f the thr ead ed stud.
II