Front Hub Wheel Bearings; Rear Suspension; Nuts, Bolts And Other Fasteners; Wire Harness, Control Cables And Hose Lines - Polaris 1999 Sportsman 400 Service Manual

LUBRICATION, MAINTENAN CE AND T UNE-UP
81
4 . If the mea sured d istance is incorrect, adjus t as
fo llows:
a. Loose n the inner and o uter tie rod end lock
nuts (A, Fig ure 75) on bo th tie rod s. Bo th tie
rods must be adj usted.
b. Rotate the tie rods (B , Fi g ur e 75) the same
amount on both sides to establish the recom-
mended toe-o ut. The distan ce between the
ball end s of the two tie rod s sho uld be the
same to center the steer ing.
e. Tighten the lock nuts (A, Figure 75) sec urel y
wh en adju stment is correct. Recheck to mak e
sure toe-out is correct after tighten ing the lock
nuts. Make sure the tie rod has full movement
a fter tightening the lock nu ts. The tie rod ends
s hould be square with each ot her (not cocked)
aft er the lock nut s are tight ened .
CAUTION
The fast eners that atta ch the lie rod
ends must be installed in u certain di-
rection to pre vent s teer ing system in-
terference
and
binding. III addit ion.
tile tie rod ends must be correctly po-
sitioned or interference can
OCC IlI:
Re-
fer to Chapter Twelve fo r correct
installation ofthe inner tie rod to tire
plates
a l l
the base
oI
tire steering
shoji. The threaded stud
Oil
the out er
tie 'rod end must fa ce do wn with the
nut
0 11
the
bottom.
Frou t lI uh Wheel Bea ri ngs
Inspect the front hub bearings for excessi ve wea r
or damage at the intervals specifi ed in Table I . Re-
fer to
Front Hub
in the Periodic Lubrication sec tio n
of this ch apter for lubrication requirements. Refer
to C hapter Twel ve for removi ng and ins ta llin g the
bearings and sea ls.
I. S uppo rt the vehicle w ith both front whee ls otT
the g ro und. Block the rear wheels so the vehicle
ca nnot ro ll in either d irection.
2. Tum bo th w hee ls by hand. T he w heel s shou ld
III
rotate smoothly w ithout exce ssive noise or exces-
sive play.
3. lf necessa ry, se rv ice the front hub bearings as de-
scribed in C hapter Twe lve .
Rear Suspeusion
I.
Place the ve hicle on level ground and set the
parking brake .
2. Push down on the rear of the vehicle and obse rve
the
movement o f a ll rear sus pe nsion com ponents.
3. C heck the rubber bushings on the stabilizer link-
age rod s for wear o r deteriorat ion.
4.
Ins pect the rear drive axle rubber boots for hard-
ness or tea rs.
5. If nece ssary, service the rear suspensi on compo-
nents as descr ibed in Chapter Thirt een,
N uts, Bolts,
and
Other Fasteners
Check the tightness of
fastene rs.
Co nsta nt vibra-
tio n can loosen man y o f the fasteners and all shou ld
be checked for tightn es s, es pec ially:
1. Eng ine moun ting ha rdware.
2. Engine cov ers.
3.
I land lcbar mo unting.
4. Exhaust sys tem.
\Vire Harness, Control Cables an d Hose Lines
Inspect a ll wiring , cables and hoses for proper
root ing. The spar k plug wire mu st be root ed di rectly
to the front.
Sec ure hoses. cables and w ires to the frame with
cab le tics. Tight en cable ties o nly enough to hol d the
co mpo nents, but not tight enough to co llaps e the
hoses.
Replace dama ged w ires, hoses and cab les as re-
qu ired, fo llowing the origi nal ro uting . Attach a
string to the o ld w ire. cable or hose before w ith-
d rawing
it to
make follow ing the origina l rou ting
ea sier.
If ca
refu lly removed, the st ring ca ll then be
used to pu ll the new co mponent through the same
path as the old one.