Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 207 / 432

5.22
BODY / STEERING / SUSPENSION
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Ball Joint Replacement
NOTE: Refer to the illustration on the previous page
for this procedure.
1. Loosen front wheel nuts slightly.
2. Elevate and safely support machine under footrest/
frame area.
3. Remove wheel nuts and wheels.
4. Remove cotter pin (A) from ball joint castle nut (B).
5. Remove castle nut (B) and separate A-arm (C) from
ball joint stud.
6. Remove screws (D) and ball joint retaining plate (E).
7. Use the Ball Joint Replacement Tool (PN 2870871),
remove ball joint (F) from strut housing. Refer to
photos.
8. Install puller guide (G) with extension cap (H).
9. Apply grease to extension cap and threads of puller
bolt to ease removal.
10. Thread bolt (J) with nut (I) onto ball joint stud as
shown.
11. Apply heat to ease removal.
12. Hold bolt (J) and turn nut (I) clockwise until ball joint
is removed from strut housing.
13. To install a new ball joint, Remove extension cap and
attach puller guide using short bolts provided in the kit.
14. Remove extension cap and attach puller guide using
short bolts provided in the kit.
15. Insert new ball joint (K) into driver (L).
16. Slide ball joint/driver assembly into guide.
17. Apply heat to ease installation.
18. Drive new joint into strut housing until fully seated.
19. Apply Loctite™ 242 (PN 2871949) to threads of
retaining plate screws or install new screws with pre-
applied locking agent. Torque screws to specification.
20. Install A-arm on ball joint and torque castle nut to
specification.
21. Reinstall cotter pin with open ends toward rear of
machine.
CAUTION
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this
service procedure.
F
E
D
A
B
G
H
I
J
= T
Retaining Screw Torque: 8 ft. lbs. (11 Nm)
= T
Castle Nut Torque: 30 ft. lbs. (41 Nm)
K
L