Polaris EV206PH-B Technical And Service Manual page 8

FIGUrE 2-5
3. loosen the handlebar stem clamp bolts (b, Figure 2-4)
4. lift the handlebar stem (C, Figure 2-4) from the head tube.
5. If necessary, remove the upper bearing by performing the following:
a. lower the fork within the head tube as needed, and remove headset spacer, seal and bearing cover
(Figure 2-5).
b. first remove the upper bearing with park rt-1 head cup remover, then the lower bearing (Figure 2-6).
Installation
1. If removed, install the upper bearing by performing the following:
a. press top and bottom bearing cup and bearing using park hhp-2 headset press (Figure 2-7).
b. press the front fork up into the head tube.
c. Install the bearing cover, then the seal and headset spacer
2. Set the handlebar stem onto the head tube, and turn in the handlebar stem bolt and washer (a, Figure 2-4).
WArNING!
The handlebar stem bolt and clamp bolt must be tightened as described below. Overtightening
the stem bolt can damage the headset bearings. If the handlebar stem clamp bolt is not properly
torqued, the fork may not turn when the handlebar is turned.
3. perform the following to set the headset bearings and to secure the handlebar stem in place and in
alignment with the front wheel.
a. tighten the handlebar stem bolt (b, Figure 2-4) until there is no play in the steer- ing.
b. tighten the stem bolt an additional 120 degrees (clockwise), and then loosen it 90 degrees
(counterclockwise).
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Servicemanual_101212.indd 10-11
FIGUrE 2-6
FIGUrE 2-7
c. With the front wheel off the ground, turn the handlebar from full stop to full stop. the fork should turn
smoothly.
d. torque the handlebar stem clamp bolts (a, Figure 2-4) to the specification in table 5.
e. tighten the handlebar stem bolts (b, Figure 2-4) an additional 30 degree (clockwise).
f. With the front wheel off the ground (a, Figure 2-4), again turn the handlebar from full stop to full stop.
the fork should turn smoothly.
FrONT FOrk rEmOVAL/INSTALLATION
removal
the front fork is not serviceable. If the fork is damaged, it must be replaced.
1. remove the handlebar (this chapter).
2. remove cable holder bolt with 3mm hex wrench (a, Figure 2-8) and release the front brake cable
(b, Figure 2-8) from the holder.
3. remove the caliper mounting bolts (a, Figure 2-10), and slide the front brake caliper (b, Figure 2-9) from
the brake disc. Suspend the caliper with a bungee cord (a, Figure 2-9).
4. remove the front wheel.
A
FIGUrE 2-8
B
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