Just got finished going over my prairie after rolling it. I thought that I'd mention to everyone a loose bolt that I found because it would have been dangerous (to both my machine and myself)just above
right front a-arm there is a large brace that is just in from the disc brake (yes, the plain aluminum one). I had previously ignored them because they looked so solid and were cotter pinned for extra safety. I noticed that it was loose because I rolled the front tire back andforth with my hand and there was A LOT of play in the front end. CHECK THESE BOLTS! Mine is at the 100 hour mark. Oh yeah, the loose bolt was the bottom one, the two top ones seemed tight.

 

If you are talking about the knuckle, you may have damaged it. After I rolled mine over the front and it hit hard enough to bend the front wheel. The lower bolt in the knuckle became loose because the outer A-arm ball joint had "ovalled" the hole in the knuckle. The lower bolt tightens the joint to the knuckle. Check for play between the knuckle and joint by jacking up the front and pushing back and forth, sideways on the front wheels.

 

I heard of another guy that had his tie-rod end back out (strip) on him...actually it happened when he let someone else take his quad for a spin. He was riding behind him and watched him ride off the trail into the woods w/ no steering.

 

Sorry for the false info guys, it seems this is more than just the loose bolt. I took it to the dealer and he said it may be covered under warranty. It seems that it is either the bearing or the bushing. It seems to be exactly what prairie 633 described though. 633, what all did you have to replace and how much were the parts, and labor if you didn't do it yourself?

 

Thumpin650, I had to replace the knuckle and the lower ball joint. The ball joint I messed up when I tried to get it out the wrong way. I re-used the main bearing in the old knuckle, It has to be knocked out carefully though. The knuckle was around $130, and I think and the joint was about $25. You can get the part numbers from Kawasaki's web site and call for accurate pricing. The labor would be under 2 hours I would think for a shop. The service manual will tell you how involved it is. I installed new springs at the same time on both sides since I was half way there already.