Front Strut Cartridge Replacement; Ball Joint Replacement - Polaris 2004-2005 Sportsman 6x6 Service Manual

FRONT STRUT CARTRIDGE
REPLACEMENT
NOTE: Refer to the Illustration on the previous page
for this procedure.
1. Hold strut rod and remove top nut.
2. Compress spring using strut spring compressor
tools.
Strut Rod Wrench (PN 2871572)
Strut Spring Compressor Tools
(PN 2871573) and (PN 2871574)
3. Remove upper strut pivot assembly.
4. Remove coil spring and collapse strut cartridge.
5. Remove two pinch bolts from strut casting.
6. Remove strut cartridge.
7. Install cartridge until bottomed in strut casting.
8. Install pinch bolts with wire clamp(s). Torque
pinch bolts to 15 ft. lbs. (21 Nm).
9. Reassemble spring and top pivot assembly. Be
sure all parts are installed properly and seated
fully.
10. Torque strut rod nut to specification. Do not over
torque the nut.
Strut Rod Nut Torque
15 ft. lbs. (21 Nm)

BALL JOINT REPLACEMENT

NOTE: Refer to the illustration on the previous page
for this procedure.
1. Loosen front wheel nuts slightly.
2. Elevate and safely support machine under
footrest/frame area.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure.
5.14
GENERAL INFORMATION
3. Remove wheel nuts and wheels.
4. Remove cotter pin (A) from ball joint castlenut.
5. Remove castle nut (B) and separate A-arm (C)
from ball joint stud.
6. Remove screws (D) and ball joint retaining plate
plate (E).
7. Use the Ball Joint Replacement Tool (PN
2870871), remove ball joint (F) from strut
housing. Refer to photos at right.
H
I
J
.
Install puller guide (G) with extension cap
S
(H).
Apply grease to extension cap and
S
threads of puller bolt to ease removal.
Thread bolt (J) with nut (I) onto ball joint
S
stud as shown.
Apply heat to ease removal.
S
Hold bolt (J) and turn nut (I) clockwise
S
until ball joint is removed from strut
housing.
C
F
B
A
G
E
D