21
NOTE: If the slots do not align with the holes in the
tie rod ends, tighten the nuts just enough to allow
installation of the cotter pins.
AF778D
4. Install the splash panels; then install the front wheels
and tighten to 45 ft-lb (steel wheels) or 80 ft-lb (alu-
minum wheels) using a crisscross pattern.
5. Lower the ATV and place the handlebar and caps
into position on the steering post; then position the
instrument pod mounts on top of the caps and secure
with the four cap screws. Tighten to 20 ft-lb.
6. Place the instrument pod into position; then secure
with reinstallable rivets and the ignition switch lock-
ing ring.
CD677
7. Install the steering post access cover and secure with
reinstallable rivets; then install and secure the radia-
tor access cover.
Handlebar Grip
REMOVING
1. Remove the plug and end-cap from the handlebar.
2. Using compressed air between the grip and the han-
dlebar, twist the grip back and forth until it slides
free of the handlebar.
INSPECTING
1. Inspect the grip for wear, cuts, or cracks.
2. Inspect the grip for deterioration.
INSTALLING
NOTE: Before installing a grip, use contact spray or
alcohol to clean the inside of the grip and the handle-
bar of glue residue, oil, or any other contaminant.
1. Apply a liberal amount of Handlebar Grip Adhesive
to the inside of the grip.
2. Slide the grip onto the handlebar until it is fully
seated with the smooth part of the grip facing up.
3. Wipe off any excess glue; then secure the grip with
the handlebar plug and end-cap.
Hand Brake Lever/Master
Cylinder Assembly
NOTE: The master cylinder is a non-serviceable
component; it must be replaced as an assembly.
REMOVING
1. Slide a piece of flexible tubing over one of the wheel
bleeder valves and direct the other end into a con-
tainer. Remove the reservoir cover; then open the
bleeder valve. Allow the brake fluid to drain com-
pletely.
NOTE: Compressing the brake lever several times
will quicken the draining process.
AF637D
2. Place an absorbent towel around the connection to
absorb brake fluid. Remove the banjo-fitting from
the master cylinder. Account for two crush washers
and a banjo-fitting bolt.
DE059A
