143
KX039
9. Remove two cap screws securing the lower steering
post bearing flange to the frame; then remove the
steering post.
AL600D
CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
1. Wash the tie rod ends in parts-cleaning solvent. Dry
with compressed air. Inspect the pivot area for wear.
Apply a low-temperature grease to the ends.
2. Inspect the tie rods for damaged threads or wear.
3. Inspect the tie rods for cracks or unusual bends.
4. Inspect all welded areas for cracks or deterioration.
5. Inspect the steering post and steering-post brackets
for cracks, bends, or wear.
6. Inspect the bearing halves, bearing caps, and bearing
housings for cracks or wear.
7. Inspect the handlebar tube for cracks, wear, or
unusual bends.
8. Inspect the handlebar grips for damage or wear.
INSTALLING
1. Place the steering post into position; then secure the
lower bearing flange to the frame with two cap
screws. Tighten to 20 ft-lb.
AL600D
2. Place the upper steering post bearings into the hous-
ings; then position on the steering post and secure the
housings to the frame with two cap screws. Tighten
to 20 ft-lb.
CD760
3. Install the tie rods and secure with the slotted nuts.
Tighten to 35 ft-lb; then install new cotter pins.
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.
! WARNING
Always wear safety glasses when using compressed
air.
Manual
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