Steering Knuckle Removal/Installation; Ball Joint Removal/Installation - Polaris PREDATOR 2003 Service Manual

BODY / STEERING / SUSPENSION
STEERING KNUCKLE
REMOVAL / INSTALLATION
Removal
1. Follow the steps in the "Front Hub Removal"
section to remove the hub, if needed.
2. Remove the upper and lower ball joint cotter keys
and castle nuts.
3. Lift up on the upper A--arm and pull the top ball
joint from the steering knuckle. Push down on the
lower A--arm to move the lower ball joint from the
steering knuckle
Installation
4. Before installation check the condition of the ball
joints.
5.8
5. Place the upper and lower A--arms into the
steering knuckle.
6. Install the castle nuts onto the upper and lower
A--arms. Torque the nuts to 25 ft.lbs. (35 Nm).
7. Install new cotter pins into the castle nuts and ball
joints.
BALL JOINT REMOVAL /
INSTALLATION
Ball Joint Removal
1. The A--arm must be removed to perform this
procedure, Refer to "A--arm Replacement" on
Page 10.
2. Be sure to remove the retaining ring from the top
of the ball joint (See Ill. 1).
Retaining Ring
A--arm
Driver Dimensions
1.375 in.
(3.49 cm)
1.75 in.
(4.45 cm)
*Outside diameter of driver cannot be any larger
than 1.75 in. Inside diameter cannot be any small-
er than 1.375 in.. Driver must be 3 in. or taller.
3. A driver must be used for the removal of the ball
joints. Use the dimensions above to fabricate or
locate the correct size driver to use in the
following process.
4. Use a press and correct size driver to remove the
ball joint from the A--arm. NOTE: The driver must
fit the inside diameter of the A--arm (See Ill. 3
below). This will allow the ball joint to be properly
pressed out of the A--arm without damaging the
A--arm.
Ball Joint
Ill. 1
3 in.
(7.62 cm)