Polaris 2009 Ranger RZR 800 EFI Manual page 160

BODY / STEERING / SUSPENSION
Steering Wheel Removal
1. Remove the steering wheel cap.
2. Loosen the nut and back it half way off the steering shaft.
3. With a glove on your hand, place it under the steering
wheel. Lift upward on the inner portion of the steering
wheel while using a hammer to strike the steering shaft nut.
IMPORTANT: If the steering wheel will not pop loose,
proceed to "Steering Shaft Removal".
4. Once the steering wheel pops loose, completely remove the
nut and lift the steering wheel off the shaft.
Steering Shaft Removal
1. Remove the pinch bolt retaining the lower portion of the
steering shaft to the steering gear box assembly.
Pinch Bolt
Gear Box
Asm.
2. Remove the fastener retaining the upper portion of the
steering wheel tilt shock to the pivot tube.
3. Remove the (2) fasteners that retain the pivot tube.
4. Remove the steering shaft and steering wheel from the
vehicle as an assembly.
5. Refer to steps 11-13 of the "Steering Shaft Bearing
Replacement" procedure for installation.
5.16
Steering Shaft
Figure 5-16
Figure 5-17
Pivot Tube
Tilt Shock
Steering Shaft Bearing Replacement
1. Perform the "Steering Shaft Removal" procedure.
2. Remove the steering wheel cap and retaining nut.
3. Press steering shaft out of the steering wheel and pivot tube.
4. Note the order and location of the washers and spacers
between the steering wheel and pivot tube.
5. Drive the bearings out of the pivot tube using a drift punch.
6. Inspect the pivot tube bearing surfaces for signs of
excessive wear or damage.
7. Slide a new lower bearing onto the steering shaft and install
the steering shaft through the pivot tube.
NOTE: Be sure the lower washers and spacers are
still on the steering shaft.
Cap
Nut
Bearing
Thin
Washer
8. Slide a new upper bearing onto the steering shaft and press
it into the pivot tube by hand.
NOTE: Bearings will be seated in the pivot housing
upon tightening the steering wheel nut in step 14.
9. Reinstall the upper washers and spacers in the order in
which they were removed.
10. Install the steering wheel and hand tighten the nut.
11. Reinstall the steering shaft assembly in the vehicle. Install
the lower portion of the steering shaft onto the steering gear
box assembly (see Figure 5-16). Torque the lower pinch
bolt to 27-33 ft. lbs. (37-45 Nm).
12. Install the (2) fasteners that retain the pivot tube (see Figure
5-17). Torque fasteners to 23 ft. lbs. (31 Nm).
13. Install the fastener retaining the upper portion of the
steering wheel tilt shock to the pivot tube (see Figure 5-17).
Torque fastener to 7 ft. lbs. (10 Nm).
14. Be sure the front wheels are facing straight forward.
Remove the steering wheel and align as needed. Torque the
steering wheel nut to 25-31 ft. lbs. (34-42 Nm).
15. Install steering wheel cap and field test steering operation.
Thick
Washer
Spacer
Pivot Tube
Spacer
Thick
Washers
Thin
Bearing
Washers