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Installation Instructions for the
Polaris Power Crank
Thank you for purchasing your new "POWER CRANK". This is the
finest steering bellcrank that is made. It is lighter, by 25%, it is
stronger, it eliminates the play normally associated with the
bellcrank, and it looks "Hot".
The "POWER CRANK" is made from aircraft quality 4130 chrome moly
steel, TIG welded, stress relieved, heat treated and is epoxy powder
coated. The bearing is an oversize full length needle roller with a
precision ground inner race that is fully greasable, or in some of the
Storms, Extras, or Ultras, there is a pair of ball roller bearings
that are greasable. It has been designed so that the thrust washers
seal out the elements but allow enough clearance so that grease can
pass through.
As with any performance oriented product, the full benefits can
only be realized if the other parts of the assembly are in proper
order. This bellcrank eliminates all the play normally found in the
stock steering arm. It is to your advantage to make sure the other
components in the front suspension and steering are set properly and
are not worn out!
BEFORE YOU TAKE THIS APART, LOOK AT IT!
All of the components are assembled as they will be on your sled.
Components Included
- "POWER CRANK"
- Needle roller bearing(s) with inside race (installed)
- (Ball roller bearings, if applicable) (installed)
- Thrust washers----2 (1/2" x 1 1/2"
- Locknut
- Stud, steering pivot--Storm only
Installation Instructions
- Lift up the front of the sled and support it by the front
bumper. (jack stands work well for this.)
- Remove the 3 bolts that secure the tie rod and drag link ends
from the bellcrank. (Notice whether the rod ends mount on top side
of the bellcrank or the bottom. The drag link rod end is normally on
the top side, but sometimes the tie rod ends are mounted on the
bottom side depending upon the model. Make a note so the pieces are
assembled in the proper order.) Then pull out the original cotter
pin and discard, take off the castellated nut and remove the
assembly.
- Check the condition of all the rod ends at this time and replace
if they are worn. (The better aviation grade last much longer than
the original type).
- Take some grease from your grease gun, remove the inner race
from the bearing and pack the inner rollers of the bearing with
grease. After greasing, put the inner race back in place.
- Disregard taking the bearing apart on the Storm, Extras, or
Ultra--these feature the ball roller bearings. They are greased
through the fitting only.
- The thrust washers are the same, take either of them and install
on the center bolt.
- Slide the "POWER CRANK and bearing assembly over the bolt next.
Next, slide the other thrust washer over the bolt.
- The Storm uses the new stud in place of the factory bolt, this
allows you to tighten the lock nut on the new Power Crank properly.
Put red Loctite on the coarse threads on the stud, insert like the
bolt and tighten. Follow the rest of the instructions as indicated.
- Place the new washer over the center bolt and install the
locknut. Tighten the nut until it is tight against the upper washer.
Insert the hairpin cotter in the hole. Put grease in the grease
fitting while turning the "POWER CRANK" from side to side. Pump in
enough so that the grease comes out top and bottom around the thrust
washers. Wipe away the excess. If you ride in a lot of powder, you
should grease more frequently. Also, grease the "Power Crank" before
putting the sled away for the season.
- Install the tie rod ends and the drag link end. Double check
everything to make sure that it is tight.
- Set the toe on the skis at this time. Use the settings as
described in the owners manual or the shop manual of 0--1/8" toe out
as measured from the center of the wear bar carbide front to rear.
- If, after many miles, some wear should occur to the thrust
washers, remove the cotter pin and slightly tighten the nut, and
install the cotter pin. (New thrust washers are available from your
supplier at a minimal cost, as well as locknuts, washers, and
hairpin cotters).
ENJOY THIS AND WATCH FOR THE OTHER NEW PIECES FOR YOUR STEERING AND
SUSPENSION.
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