CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0
CHAPTER 4 A CHASSIS PAGE. 4A-
6
4.4 FRONT STRUT BALL JOINT REPLACEMENT ATV260/300/400/400-2B
1. Loosen front wheel nuts.
2. Elevate and safely support ATV under
footrest/frame area. .
CAUTION: Serious injury may result if
ATV tips or falls. Be sure ATV is secure
before beginning this service procedure.
3. Remove wheel nuts and wheels.
4. Remove cotter pin from ball joint
5. Remove castle nut and separate A-
arm from ball joint stud.
6. Remove screws and ball joint mounting
bracket.
7. Using ball joint cup removal/installation
toolkit, remove ball joint cup from strut
housing. Refer to photos at right.
zInstall puller guide (1) .
zThread bolt (2) with nut (3) onto bal
joint stud as shown .
zHold bolt (2) and turn nut (3)
clockwise until ball joint is removed
from strut housing.
8. To install new ball joint cup.
zInsert new ball joint into driver
(installation toolkit).
zDrive new bal joint cup into strut
housing until fully seated.
9. Apply Loctite 242 (blue) to threads of
mounting bracket new screws.
Torque screw s to 8 ft.lbs. (11 Nm).
10. Install A- arm on bal joint cup and
torque castle nut to 25 ft. lbs. (35
Nm ).
11. Reinstall cotter pin with open ends
toward rear of machine.
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