Front Strut Weldment Replacement; Front Strut Cartridge Replacement; Strut Assembly - 2X4 Models - Polaris Magnum 2x4 Service Manual

BODY AND STEERING
Front Strut Weldment Replacement
Front Strut Cartridge Replacement
1 . Hold strut rod with holder wrench and remove top
nut.
2.
Compress spring using strut spring compressor
tools.
3.
Remove upper strut pivot assembly.
4.
Remove coil spring and collapse strut cartridge.
5.
Scribe a line on the strut cartridge level with the top
of the aluminum strut casting. This line can be used
as a reference for installed height of the new
cartridge upon reassembly.
6.
Remove two pinch bolts and tap upper and lower
pinch bolt boss with a
3/8"-16
tap.
7.
Install a large, thick flat washer as shown in photo at
right.
8.
Use a
3/8"-16
bolt to spread the strut casting just
enough to allow the old cartridge to be removed and
the new one to be installed. Install cartridge until
bottomed in strut casting or to the same level as the
one removed.
9.
Torque pinch bolts to
15
ft. Ibs.
(2
kg-m).
10.
Reassemble spring and top pivot assembly. Be
sure all parts are installed properly and seated fully.
11.
Torque strut rod nut to specification. Do not over
torque nut.
Strut Assembly - 2x4 Models
Self locking nuts (1 and 2) should not be reused as the
locking properties will be destroyed. If these nuts are
removed, make sure to replace with new nuts.
Grease fitting location (3). Check lubrication guide for
recommended service intervals.
7/96 5.24
15
ft. Ibs.
(2.07
kg-m)
15
ft. Ibs.
(2.07
kg-m)
.~
2
Polaris Industries Inc.