Steering Post Removal; Steering Post Assembly; Suspension; Front Strut Cartridge Replacement - Polaris 2007 Sportsman 500 EF Service Manual

BODY / STEERING / SUSPENSION

Steering Post Removal

1. Remove the front cab.
2. Remove the handle bar pod.
3. Remove the handle bar.
4. Remove the fuel tank bracket assembly.
5. Remove the steering tie rod ends from the steering bracket.
Note the orientation of the fasteners and bracket on the
steering assembly.
6. Remove the steering post nut (A) at the mount plate.
7. Remove the top steering bracket .
8. Remove the steering post.

Steering Post Assembly

12 ft.lbs. (16 Nm)
1. Hand tighten steering post slotted nut (A).
2. Align the cotter pin hole on the steering post slotted nut (A).
3. Install the cotter pin (B). Bend both ends of the cotter pin
around the slotted nut (A) in opposite directions.
4. Check the steering, the handle bars must move freely and
easily from full left to full right without binding.
5.20

SUSPENSION

Front Strut Cartridge Replacement

NOTE: Refer to illustration on following page.
1. Hold strut rod and remove top nut.
2. Remove upper strut pivot assembly.
Strut Rod Wrench:
(PN 2871572)
Strut Spring Compressor Tools:
(PN 2871573) and (PN 2871574)
3. Compress spring using any commercially available spring
compressor tool and remove the spacer nut.
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 specification.
Pinch Bolt Torque:
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
the nut.
Strut Rod Nut Torque:
15 ft. lbs. (21 Nm)
= T
= T