9916575 1998-1999 Big Boss 6x6 Service Manual Chapter
Contents
1. CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools 5 1 Body Assembly Exploded View 5 2 Dump Box Exploded View 02 0005 5 3 Cover Panel Removal eee ee ee eens 5 4 Steering Assembly Exploded View 5 5 A Arm Replacement cece eee ees 5 6 Standard Swing Arm Rear Suspension 5 7 Rear Strut Stabilizer Exploded View 5 8 Rear Swing Arm Weldment 000000 5 9 Front Swing Arm Weldment aaa 5 10 Strut Assembly Exploded View 05 5 11 Front Strut Weldment Replacement 5 12 Front Strut Ball Joint Replacement 5 13 Steering Post Assembly 2 002 cece 5 14 Decal Replacement eee eens 5 14 BODY STEERING SUSPENSION TORQUE SPECIFICATIONS Front A Arm Attaching Bolt 30 ft Ibs 41 Nm Front A Arm Ball Joint Stud Nut 25 ft Ibs 85 Nm Handlebar Adjuster Block 10 12 ft Ibs 14 17 Nm Master Cylinder 000e eee eee 45 55 in lbs 5 2 6 3 Nm Rear Axle Nut and Lock Nut 150 ft Ibs 207 Nm Rear Shock Bolt upper 25 ft Ibs 85 Nm Rear Shock Bolt lower aa 25 ft Ibs 85 Nm Rear Wheel Hub Nut 0 05 80 ft Ibs 110 Nm Rear Wheel Nuts 0 eee eee 50 ft Ibs 69 Nm S2. G SUSPENSION STANDARD SWING ARM AND FRONT SUSPENSION 25 ft Ibs 55 ft Ibs 76 Nm 55 ft Ibs a 76 Nm a 25 ft Ibs 35 Nm 5 7 BODY STEERING SUSPENSION REAR STRUT STABILIZER ong 30 ft a Grease Fittings ko S 30 ft ko a NA m Pa O A oN PA CE Se TAA DEC tg aa z J IVY F NN Oe mn P BO 30 ft Ibs DY 41 Nm 60 ft Ibs 83 Nm 5 8 BODY STEERING SUSPENSION REAR SWING ARM WELDMENT 16 ft Ibs oe 22 Nm 18 ft Ibs 25 Nm 60 ft Ibs 83 Nm e Rear strut 1 and weldment 2 can only be replaced as an assembly They are pressed and welded together at the factory and cannot be disassembled e Grease fittings 8 and 4 Check lubrication guide for service intervals 5 9 BODY STEERING SUSPENSION FRONT SWING ARM WELDMENT 55 ft Ibs 76 Nm ye 55 ft Ibs 76 Nm po 9 5 10 STRUT ASSEMBLY 21 Nm Washer Spacer Rubber Upper Pivot Ball Spacer eek Lower Pivot oe Spring ee BODY STEERING SUSPENSION Strut Bumper Spring Retainer Clamp 18 ft Ibs 25 Nm ni Wire retainer Seal Sleeve Install Using tool PN 2871199 NOTE Be sure steel insert notch 1 and strut casting notch are lined up and provide a channel for the magnetic coil wires to lie in If insert and strut do not match strut replacement will be necessary Grease fitting 2 location Check lubrication gui
3. Lower Grease Fitting DECAL REPLACEMENT Plastic polyethylene material must be flame treated prior to installing a decal to ensure good adhesion The flame treating procedure can often be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged The following procedure involves the use of an open flame Perform this procedure in a well ventilated area away from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold the torch too close to the surface Keep the torch moving to prevent damage 2 Apply the decal
4. de for recommended service intervals Specified pole gap is 0 001 0 0254mm Gp POLARIS 5 11 BODY STEERING SUSPENSION FRONT STRUT CARTRIDGE REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5 11 1 Hold strut rod and remove top nut 2 Compress spring using strut spring compressor tools Strut Spring Compressor Tools PN 2871573 and PN 2871574 Remove upper strut pivot assembly Remove coil spring and collapse strut cartridge Remove two pinch bolts from strut casting Remove strut cartridge Install cartridge until bottomed in strut casting On ONE OO ee O Install pinch bolts with wire clamp s Torque pinch bolts to 15 ft Ibs 21 Nm 9 Reassemble spring and top pivot assembly Be sure all parts are installed properly and seated fully 10 Torque strut rod nut to specification Do not over torque nut Strut Rod Nut Torque 15 ft Ibs 21 Nm 5 12 Gp POLARIS BODY STEERING SUSPENSION BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5 11 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin A from ball joint castlenut 5 Remove castle nut B and separate A arm C from ball joint stud 6 Remove screws D and ball joint retaining
5. els must be in place when body parts are assembled 5 3 BODY STEERING SUSPENSION COVER PANEL REMOVAL To Remove Side panels Headlight cover Radiator cap access panel Cargo Box aaa Rear cab assembly Front rack Front cab assembly 5 4 Perform These Steps Pull release lever at the rear of the seat Lift and pull seat rearward disengaging seat from tabs at the rear of the fuel tank Remove Seat Ignition key Side panels Fuel cap 2 retaining screws at rear of fuel tank cover 2 retaining screws at side of fuel tank cover Disengage tabs at front of cover on left and right side Remove Remove Seat 1 screw on left side front 1 screw on right side front Seat Fuel tank cover 2 Torx screws at rear of cover 1 screw on left front 1 screw on right front Disconnect headlamp wiring harness Turn fastener at front 1 4 turn Place box in the down position Remove 6 bolts holding hinges to frame Raise rear of box with assist from dump box shock Remove bolt from shock at box Lift box off frame with assistance Remove Remove Remove Seat Raise cargo box 3 screws nuts and washer plate at rear of left footrest 2 screws nuts and washer plate at rear of right footrest 6 bolts and flat washers from top of cab assembly under seat 2 screws at front of muffler guard 4 bolts nuts and wash
6. ers Seat Side panels Fuel tank cover Headlight cover Front rack Fuel pump bracket 3 screws nuts and washers from left footrest 2 screws nuts and washers from right footrest 2 rivets at top of cab beneath fuel pump bracket Gp POLARIS BODY STEERING SUSPENSION STEERING ASSEMBLY EXPLODED VIEW 25 30 ft Ibs 35 41 Nm Steering Post Right Hand Tie kar Rod End Positioned 1 4 NG Between Steering pa d Post Arms 1 30 ft Ibs 41 Nm Always use new bolts upon reassembly Gp POLARIS WA ing Post Arms NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod end studs A point down Be sure inner rod ends are positioned properly The right inner rod end must be placed between the steering post arms The left inner rod end must be below the lower arm as shown Steering Post Arm Frog i Left Hand Tie Cho Rod End Positioned Below Steer 12 14 ft Ibs 17 17 Nm 40 45 ft Ibs 54 61 Nm GENET l Loctite 242 8 ft Ibs 11 Nm Always use new cotter pins upon reassembly Install w open end to ward rear of machine 5 5 BODY STEERING SUSPENSION A ARM REPLACEMENT 1 Elevate and safely support vehicle with weight removed from front wheel s Remove cotter pin from ball joint stud at wheel end of A arm and loosen nut until it is flush wit
7. h end of stud Using a soft face hammer tap nut to loosen A arm from bolt Remove nut and A arm from hub strut assembly Loosen two bolts on A arm tube by alternating each about 1 3 of the way until A arm can be removed Examine A arm shaft Replace if worn Discard hardware oa F 9 N Insert A arm shaft into new A arm NOTE On AWD models install CV joint shields See Ill Bolt 30 ft Ibs 41 Nm Bolt 30 ft lbs gs97 41 Nm NG Ball Joint Stud Washer ne Loctite 242 pa 2 Nut NS 8 ft Ibs 25 ft Ibs Nut 11 Nm 35Nm 2 Ja S CV Joint Shield Cotter Pin AWD Models 7 Install new A arm assembly onto vehicle frame Torque new bolts to 30 ft Ibs 41 4 Nm The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during opera tion 8 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft Ibs 35 Nm If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends toward rear of machine Bend both ends in opposite directions around nut A arm Attaching Bolt Torque 30 ft Ibs 41 Nm Ball Joint Stud Nut Torque 9 Locate grease fitting in center of A arm tube and pump A arm full of grease 25 ft Ibs 35 Nm Upon A arm installation completion test vehicle at low speeds before putting into regular service BODY STEERIN
8. plate plate E 7 Using ball joint removal installation tool kit PN 2870871 remove ball joint F from strut housing Refer to photos at right Install puller guide A with extension cap B e 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 housing 8 To install new ball joint e Remove extension cap and attach puller guide using short bolts provided in the kit e Insert new ball joint E into driver F Slide ball joint driver assembly into guide Apply heat to ease installation J e Drive new joint into strut housing until fully E seated N A 9 Apply Loctite 242 blue to threads of retaining x plate screws or install new screws with pre applied gt ba wi sale F locking agent Torque screws to 8 ft Ibs 11 Nm Pro all eme 10 Install A arm on ball joint and torque castle nut to 25 ft Ibs 35 Nm o 11 Reinstall cotter pin with open ends toward rear of N machine F BODY STEERING SUSPENSION STEERING POST ASSEMBLY 12 ft Ibs 16 Nm Upper Grease Fitting 1 Hand tighten 2 Align cotter pin hole 3 Install cotter pin Bend both ends of cotter pin around nut in opposite directions 4 Check steering must move freely and easily from full left to full right without binding
9. trut Rod Retaining Nut Top 15 ft Ibs 21 Nm Strut Casting Pinch Bolt 15 ft Ibs 21 Nm Swing Arm Pivot Bolt 005 55 ft Ibs 76 Nm Tie Rod End Jam Nut 00005 12 14 ft lbs 17 19 Nm Tie Rod End Castle Nut 23 24 ft Ibs 32 33 Nm Tie Rod End Attaching Bolt 25 30 ft Ibs 35 41 Nm NOTE Refer to exploded views throughout this chapter for identification and location of components SPECIAL TOOLS Description Part No Strut and Ball Joint Tool Set 2870871 Shock Spanner Wrench 2870872 Shock Spring Compressor Tool 2870623 Strut Rod Holding Wrench 2871572 Strut Spring Compressor Tool LH 2871573 Strut Spring Compressor Tool RH 2871574 Optional Fox Shock Tools Body Holding Tool 2871017 Safety Needle 7052069 Shock Spring Compressor Tool 2870623 Gas Shock Recharging Kit 2200421 Damper Rod Holding Tool 2871352 Fox Shock IFP Tool 2871351 BODY STEERING SUSPENSION BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Fuel Tank Cover Front Cab Assembly Headlight Cover Front Cab All warning information labels must be in place when body parts are assembled BODY STEERING SUSPENSION DUMP BOX EXPLODED VIEW Tailgate All warning information lab
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