Steering; Inspection; Handlebar Adjustment; Rod End Procedure - Polaris 2000 120 XCR Service Manual

STEERING

INSPECTION

Prior to performing steering alignment, inspect all steering and
suspension components for wear or damage and replace parts as
necessary. Refer to steering assembly exploded views in this
chapter for identification of components and torque values of
fasteners. While disassembling, make notes of what direction a
bolt goes through a part and what type of nut is used in an
application.
Some of the fasteners used in the IFS are special and cannot be
purchased at a hardware store. Always use genuine Polaris parts
and hardware when replacing front end components.
The following components must be inspected at this time:
• Tie rods and tie rod ends
• Radius rods and radius rod ends
• Handlebars and steering post assembly
• Spindles and bushings
• Trailing arms and bushings
• Skis and skags
• Steering arms
• Shock absorbers, shock mounts, springs
• All related fasteners - check torque. Refer to steering
exploded views at the beginning of this section.
• Grease all fittings.

HANDLEBAR ADJUSTMENT

Handlebars on the 2002 - current 120's can be adjusted to
accommodate rider preference.
1. Turn the fuel valve to the off position, then remove the
handlebar pad.
2. Loosen the lower handlebar bolt (Do not remove).
3. Remove the top handlebar bolt from the current position.
4. There are 3 positions to adjust the handlebar.
5. Insert upper carriage bolt and torque both upper and lower
carriage bolts to 15 ft. lb. (20.3Nm).
Handlebar Carriage Bolts 15 ft.lb (20Nm)
6. Replace the handlebar pad.

ROD END PROCEDURE

Rod ends must be parallel to their respective mounting surface
after tightening jam nut. Hold the rod end and tighten jam nut.
If possible, support the edge of the rod end to keep it from
rotating out of position until jam nut is tight. When rod ends are
properly tightened, the rod should rotate freely approximately 1/
8 turn.

ROD END ENGAGEMENT

Rod ends must engage the rod a minimum of 2x the thread
diameter when adjustment is complete.
Example: .4375" (11mm) rod end (1) X 2 = minimum thread
engagement (2) .875" (22mm).
1
BODY/STEERING
= T
2
5.3
5