Front Strut Cartridge Replacement; Ball Joint Replacement - Polaris Ranger 500 2x4 2007 Service Manual

BODY / STEERING / SUSPENSION

Front Strut Cartridge Replacement

Refer to Illustration on Page 5.13.
1. Hold strut rod and remove top nut.
2. Compress spring using strut spring compressor tools.
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
nut.
Strut Rod Nut Torque
15 ft. lbs. (21 Nm)

Ball Joint Replacement

1. Loosen front wheel nuts slightly.
2. Elevate and safely support machine under footrest/frame
area.
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning
this service procedure.
3. Remove wheel nuts and wheels.
B
5.14
CAUTION
C
F
E
D
A
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 (E).
7. Using ball joint removal/installation tool kit (PN 2870871),
remove ball joint (F) from strut housing.
• Install puller guide (G) with extension cap (H).
• Apply grease to extension cap and threads of puller bolt
to ease removal.
• Thread bolt (K) with nut (J) onto ball joint stud as
shown.
• Apply heat to ease removal.
• Hold bolt (K) and turn nut (J) clockwise until ball joint
is removed from strut housing.
G
H
J
K
8. To install new ball joint:
• Remove extension cap and attach puller guide using
short bolts provided in the kit.
• Insert new ball joint (L) into driver (M).
M
• Slide ball joint / driver assembly into guide.
• Apply heat to ease installation.
• Drive new joint into strut housing until fully seated.
L