2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 182Get this manual
BODYSTEERINGSUSPENSION
BALL JOINT REPLACEMENT
REFER TO ILLUSTRATION ON PAGE 5.91Loosen front wheel nuts slightly2Elevate and safely support machine under footrestframe areaCAUTION: Serious injury may result if machine tips or fallsBe sure machine is secure before beginning this service procedure3Remove wheel nuts and wheels4Remove cotter pin (A) from ball joint castlenutB 5Remove castle nut (B) and separate A-arm (C) from ball joint stud6Remove screws (D) and ball joint retaining plate plate (E)7Using ball joint removalinstallation tool kit (PN 2870871), remove ball joint (F) from strut housingRefer to photos at right& Install puller guide (A) with extension cap (B)& Apply grease to extension cap and threads of puller bolt to ease removal& Thread bolt (D) with nut (C) onto ball joint stud as shown& Apply heat to ease removal& Hold bolt (D) and turn nut (C) clockwise until ball joint is removed from strut housing8To install new ball joint:Remove extension cap and attach puller guide using short bolts provided in the kit& Insert new ball joint (E) into driver (F)& Slide ball jointdriver assembly into guide& Apply heat to ease installation& Drive new joint into strut housing until fully seated9Apply Loctite 242 (blue) to threads of retaining plate screws or install new screws with pre-applied locking agentTorque screws to ftlbs(11 Nm)10Install A-arm on ball joint and torque castle nut to 25 ftlbs(35 Nm)11Reinstall cotter pin with open ends toward rear of machineF A