2004 Polaris Sportsman 600/700 Service Manual, Page 134Get this manual
FRONT STRUT CARTRIDGE REPLACEMENT
REFER TO ILLUSTRATION ON PAGE
1Compress spring using strut spring compressor
toolsStrut Spring Compressor Tools
(PN 2871573) and (PN 2871574)
Hold strut rod and remove top nutAemove upper strut pivot assembly4Remove co il spring and collapse strut cartridgeRemove two pinch botts from strut casting
Remove strut cartridgeInstaJl cartridge unlil bottomed in strut castingInstaJl pinch bolls with wire clamp(s)Torque pinch bolts to 15 ft Ibs(21 Nm)Reassemble spring and top pivot assemblyBe sure aJl parts are installed property and seated fully
Using the Ball Joint Replacement Tool (PN 2870871 ), remove ball joint (F) from strut housingRefe to photo Install puller guide (A) with extension cap (6) App ly grease to extension cap and threads of puller bolt to ease removalThread bolt (0) with nut (C) onto ball joint stud as shownApply ing heat will ease removalHold bolt (0) and turn nut (C) clockwise until ball joint is remc:l'-Ied from strut tlousng