Steering/Frame The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent or cracked and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
KM590
D. Ball joints not worn, cracked, or damaged.
5. Remove the cotter pin and slotted nut from the lower end of the steering post; then remove the upper steering shaft support block. Account for a cable guide, two steering support blocks, and the upper steering post bushing.
E. Tie rods not bent or cracked. F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing.
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The frame, welds, and racks should be checked periodically for damage, bends, cracks, deterioration, broken components, and missing components.
Steering Post/Tie Rods REMOVING 1. Remove the front rack and front center panel (see Body). 2. Remove the instrument pod; then remove the cap screws securing the handlebar to the steering post. Account for two handlebar holders.
KM588
KM589
6. Remove the steering post from the ATV. KM189A
3. Lift the handlebar out of the lower handlebar holders and lay the handlebar forward. 4. Remove the cotter pins and slotted nuts securing the tie rod ends to the steering post arm; then disconnect the tie rods from the arm.
CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends.
! WARNING Always wear safety glasses when using compressed air.
2. Inspect the tie rods for damaged threads or wear.
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