Polaris 1999 Sportsman 400 Service Manual page 360

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354
a. Loosen the se
lf-locking nut
(A,
Figure 48
)
securing
the tie
rod
to
th
e
steeri ng
shaft
plate.
NOTE
There (Ire two
plates
at
the
lov. . .
·er end
of the
steering
shaft
and a
spacer
(B.
Figure
48) is
located
between
them.
Thetie rod mounting bolt goes through
the
plates.
b. Hold onto the inboard
end
of the lie rod, then
remove
the
bolt
(C,
Figure
48)
and
nut from
the
tic
rod and the two
plates.
Remove
the
spacer (B,
Figure
48)
and
reinstall il on the
bolt along with
the
nut
to avo
id m
isplacing
them
.
c.
Disco
nnect the inner end
of
the
lie rod (0,
Fig-
u
re
48
)
from the
steering shaft plates and
re-
move the
tie rod
from the
vehicle.
6B.
To disconnect
the
right
side
inner
lie rod end
from
the
steering
shaft
plate, per
form
the following:
a.
Loosen
the self-
locking
nut
(A,
Figu re 49) se-
curing
the tie
rod
to
the
steering
shaft
plate.
b.
Hold
onto
the
inboard
end
of
the tie
rod,
then
remove the
bolt
(B, Fig
ure
49)
and nul
"om
the
tic rod and the
two
plates.
e.
Disconnect the
inner end of
the tie
rod
(C,
Fig-
ure 49
)
from
between the
steering
shaft
plates
and
remove the
tie
rod from the
vehiele .
Inspecti
on
NOTE
~rhe1J
cleaning the
tie
rods.
do not im-
merse the
outboard
end ball joint in
any type
ofso/rent that could
co
ntami-
nate the grease and/or
damage
the
rubber
boot
.
I.
C
lean
the
tie rod
and
dry
it
thoroughly,
2.
Inspect the lie rod
shaft
for
damage.
There
should
be
no creases or bends along the shaft. Check
with
a
straightedge
placedagainstthe tie rod shaft
(Figure
50).
3.
Inspect
the rubber boot
at
the tie rod
end.
If the
rubber
boot
is
damaged. dirt and
moisture
can enter
the
swive
l
joint
and
destroy
it. If
the boot is damaged
in
any
way.
disassemble the tie
rod and replace
the
boot and the tie rod
end.
4.
Pivot
the tic
rod end (A,
Figure
51)
back
and
forth
by
hand.
If the tie
rod end
moves
roughly
or
with
excessive play,
replace it.
CHA PT ER TW
ELV E
t
Disassemb ly/Assembl y
I.
Prior to disas
sembly, lay
the tie rod
assembly
on a
piece oflarge paper. Draw anaccurate outlinearound
the tic rod shaft, locknuts
and
the
fitting
at
each end.
This
will show the proper
relationship
of all
parts
and
the distance
between the
locknuts.
Carefully measure
the
distance between
the locknuts
lind record
this
on
the
drawing.
2.
The
outboa rd
end of the tie rod
has
left-hand
threads.
Mark
the
nut adjace nt
to
the outboa rd
tic rod
end
to
identify
it as
the outboard
end
.
Mark it with
a

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