Polaris 2012 Sportsman Forest 500 International, Service Manual

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5.23
BODY / STEERING / SUSPENSION
5
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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 nuts at the mount plate.
7. Remove the top steering bracket.
8. Remove the steering post.
Steering Post Assembly
1. Install the steering post.
2. Install the steering post nuts at the mount plate.
3. Install the top steering bracket.
4. Torque all fasteners to specification.
5. Install the steering tie rod ends from the steering
bracket, noting the orientation of the fasteners and
bracket on the steering assembly.
6. Install the fuel tank bracket, handle bar and pod.
Torque fasteners to specification.
7. Check the steering, the handle bars must move freely
and easily from full left to full right without binding.
8. Install front cab.
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.
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.
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.
17 ft.lbs. (23 Nm)
NOTE: Steering post bearing is shown in exploded
view form. This bearing is attached to the post using
a radial riveting method and is a non-serviceable item.
Steering post replacement is required in the event of a
bearing failure.
Strut Rod Wrench:
(PN 2871572)
Strut Spring Compressor Tools:
(PN 2871573) and (PN 2871574)
= T
Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
= T
Strut Rod Nut Torque:
15 ft. lbs. (21 Nm)