1996 sportsman 400 strut replacement - Polaris ATV Forum
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post #1 of 2 (permalink) Old 01-22-2014, 10:19 AM Thread Starter
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Join Date: Sep 2011
Location: Oklahoma City
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1996 sportsman 400 strut replacement

Hello all,
I needed struts on my sportsman 400. I ordered a pair from a dealer off of ebay. I had a Polaris mechanic put them in to the tune of 500 dollars labor.
He said that the whole front body and fenders had to come off.
Turns out that the struts are bad. still slams open on every little bump. (good shock absorption but not dampening upon opening of the spring).
Is this a job that I can do myself without tearing the whole machine apart???They shouldn't be stuck in the hub since these were just placed recently.
Help with any tips or suggestions.

Thanks.
Bill
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post #2 of 2 (permalink) Old 01-22-2014, 11:27 AM
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Join Date: Oct 2013
Location: Sudbury, Ontario, Canada
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I'm 14 years old and before least spring I hadn't changed struts in a Polaris before in my life and all went well. Unfortunately to do it your going to have to remove all of the front bumper and rack, electrical cover and loosen the fenders near the floor boards and remove the bolts for the fender around the rad, then I used a stick to bend the fender up so I could get my ratchet on the top but of the shock assembly I then loosened those nuts and began disassembling the spring/shock assembly and removing it from the McPherson strut while the ATV was jacked up but beware that when you take off the top bolt for the shock assembly the a arm will drop down and my jack was set t9 high for one side and the bearing fell out inside the CV boot and that's a pain in the ass and costs an extra $25 so make sure to only jack up your ATV enough so the springs don't have any weight on them but the tires are touching the ground. It took me about 6 hours alone only because the bearings fell out and I had to find out what order to put the hub together.
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