2005 Polaris Sportsman 400/500 Service Manual, Page 150Get this manual
BODYSTEERINGSUSPENSION
FRONT STRUT CARTRIDGE REPLACEMENT
REFER TO ILLUSTRATION ON PAGE 5.12
1Hold strut rod and remove top nut2Remove upper strut pivot assemblyStrut Rod Wrench (PN 2871572) Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 3Compress spring using strut spring compressor tools and remove the spacer nut4Remove coil spring and collapse strut cartridge5Remove two pinch bolts from strut casting6Remove strut cartridge7Install cartridge until bottomed in strut casting8Install pinch bolts with wire clamp(s)Torque pinch bolts to 15 ftlbs(21 Nm)9Reassemble spring and top pivot assemblyBe sure all parts are installed properly and seated fully10Torque strut rod nut to specificationDo not over torque the nutStrut Rod Nut Torque 15 ftlbs(21 Nm)
3Remove wheel nuts and wheels