2008 Polaris ATV Sportsman 300 400 H.O. Service Manual, Page 117Get this manual
BODYSTEERINGSUSPENSION Handlebar Block Installation Procedure
1The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV
Tie RodTie Rod End Replacement
Use the following procedure to replace the tie rod assembly or tie rod ends1234Elevate and safely support the front of the vehicleRemove the front wheel(s)Remove the cotter pins (C) and tie rod end fasteners (D)Remove the tie rod assembly (E) If replacing just the tie rod ends (F), loosen the jam nuts (G) and remove the rod end and replace with new
Clean knurling when repositioning handlebars
Torque jam nuts to 12-14 ftlbs(16-19 Nm)5Install the new tie rod assembly (E) with new boot seals (H)Install the fasteners (D) in the proper orientation
NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper directionThe steering post arm bolt (J) points up; the rod end bolts (K) point downBe sure inner rod ends are placed below the steering post armReplace all cotter pins (C) if removed23The bottom handle bar block has side with holes, the side with holes faces up and to the front of the ATVAlign the pin (A) in the top block with the middle hole (B) in the bottom block for proper installationThe pin (A) and middle hole (B) should face the front of the ATVInstall the pin side bolts first and evenly tighten the bolts downTorque the front bolts to specificationK H