Steering Shaft Removal/Installation - Polaris 1999 Sportsman 400 Service Manual

356
install the nell' self-locking nut (A, Figure
49 ). Tig hten the nut finger-tight
at
this lime.
2. Install the outboa rd end of the tie rod end,
eq uipped with a thre aded stud. onto the steering arm
port ion of the strut support as follows :
a. Place the washer ( Figu re 47 ) on top of the
stee ring ann and align the bolt hole.
b. Ca refully insert the tic rod threaded stud
dow n through the upper washer and the steer-
ing arm portion of the strut support. Push it
down until
it
is seated.
c. Install the lower washer and the caste llated
nut
( Fi~ u re
46) onto the threaded stud .
d. Tighten the castellated nut to the torque
speci-
ficati on listed in Table 2.
c. Install a new cot ter pin and bend the end s over
co mpletely as shown in Figure 44. If the cot-
ter pin holes do not align , slightl y tighten the
nut-do not loosen
it
to achieve alignment.
3. Tighten the se lf- locking nut, installed in Step I
to the torque specification listed in Table 2.
4. Install the front fend er as described in Chap ter
Fifteen .
5. Install
the front whee ls as described in this chap'
ter,
6. Chec k the front wheel toe-o ut and adj ust as nec-
essary befo re tighten ing the locknuts against the tic
rod ends . Measure toe-out as described in Chap ter
Thre e.
STEERING SH A FT
The steering shaft pivot s on a split bushin g block
at the top and a bushin g block
at
the lower end. Ad-
j ustable tic rods co nnect the stee ring shaft to the
steering arm portion of the front strut.
Rernuval /I nsta lla tion
Refer to
F i~ure
42.
I.
Remove the front fender assembl y as described
in Cha pter Fifteen .
2. Remove the fuel tank as described in Chapter
Six.
3. Remo ve both front wheels as descri bed in this
chapter.
4. Remove the inboard ends of both tie rods from
the two pla tes on the base of the steerin g post. Sup-
port the inboard ends of the tic rod s to the cha ssis
with bungcc co rds or wire.
CHA I'TER TWELVE
SA. On Xplorer model s. perform the follow ing:
a . Remove the top cov er from the instru ment
panel cover.
b. Remove the two screws securing the instru -
menl panel cover and remove the cover.
58. On Sportsman models, remove
the headl ight
upper pod as described under High -Beam Headlight
(Sponsnum Models), Bulb Replacement in Chapter
Eleven .
6. Remove the hand lebar assemb ly as desc ribe d in
this chapter.
7.
Unscrew and remove the grease fittin g.
X.
Workin g at
the
lower end of the steering shaft,
perform the follow ing:
a, Remove thc co tte r pin and discard
it.
A new
cotter
pin
mus t
be
used during insta llation .
b. Loosen then remove the caste llated nut (Fig-
ure 54) and washer from the base of the shaft.
9. Workiug at the upper end of the steering shaft,
perform the followi ng:
a. Remove the bolt s and nuts securing the
mount ing bracket and upper bearing blocks to
the frame section.
b. Remo ve the mounting brac ket, the upp er
bea ring bloc ks and the strap at the back side
of the rear beari ng block.
10. Carefully lift the steering shaft from the frame.
Do not snag any electrica l wire s or hoses du ring re-
moval.
II. Install the steering sha n by reversing the re-
mova l procedure whi le not ing the following:
a, Tighten the cas tellated nut secure ly,
b. Install a
lW''''
cotter pin and bend the ends over
co mpletely as
shown in Figure 55 .
If the cot-
ter pin holes do not align, slightly tighten the
nut-do not
loosen it to
achieve align ment.