I am changing the front springs on my Xplorer this week. Is this an easy job to do myself? Any tips on how to make it go quicker and easier?

What would be the procedure?

Thanks.

 

Xplor:
Not sure how the Xplorer spring set-up is, but on my AC, I used the winch, to pull it up a tree so that the front tires were off the ground, and suspension was at full drop. Then, pull out the top bolt then the bottom bolt. The entire spring/shock assembly will pop right out now. You have to compress the spring itself in order to remove the top retainer clip. It would help if you had a spring compressor. I had to use my hands to do this, and needed an extra hand to pull the retainer almost. I did it myself, though it was fairly tough, and a small framed individual probably would not be able to do this by himself without a spring compressor. Anyway, once you get the top retainer clip out, the spring itself just slides right off.

Slip the new one on, re-install the top retainer, and then put the spring/shock back on the machine. Install bottom bolt first, then the top bolt. After it's tight, it's OK to let go of the winch, pick up your tools, and go for a ride. I didn't bother to pull the tires off myself, just worked around them. It would give you a little more room in there to work, but wasn't necessary on my 'Cat.

Hope that helps.

Mike

 

Thanks Mike. I am going to attempt it this week. I happen to be a small-framed individual so I will think of a way to compress the springs, using some clamps or tie-downs.


Brian

 

I've uses a small ratchet strap to compress springs before. Make sure, it's not a cheap strap, it'll be under a lot of pessure.

Bruce L. Hall
99 Sport 400

 

The Polaris set-up is a little different than on a Cat. The springs are not captive on the shock. When you remove the top bolt, the spring can come right off the shock. It is hard to reach unless you take the fender off. Also, with the fender off, it will be MUCH easier to replace the spring. I dono't know if you can get just the spring out without taking off the front fenders. Anyhow, with the fenders off, you should see a nut on the top of the shock shaft. If you notice, this is also what is holding the spring. Be careful when you take this nut off (and be sure the front end is supported with the wheels just off the ground). There might still be some spring tension left, even with all the weight off the front end. Now work the shock shaft far enough around the support so that you can take the old spring off & put the new one on. Be VERY CAREFUL when you do this so as not to pull apart the CV joint in the front driveshaft going to the wheel. Work the strut forward or backward of the top support rather than straight out the side to prevent this. I have never had one seperate on me, but am told they are a pain in the rear to get back together. Is much better to just be sure it doesn't seperate in the first place. With the new spring on the strut, tighten the top nut & fenders & go for a ride.
Farmr
PS While you are there, check the little plastic bushing/bearing thing at the top of the strut. They cost only a couple bucks & will eliminate a front end squeak that you may be hearing whenever the front suspension is working. If they don't look worn, don't worry about them.
Good luck

 

Changing the front springs on a 3 chain 4WD Polaris are much easier than on the new Sportsman . On my 95 Sportsman 400 you could just drop the strut, tilt it and replace the spring. There was no different suspension geometry on the front CV's to worry about, and no spring compression to worry about either.

Come to think of it, the 1998 Xplorer is a 3 chain isn't it?

 

It could be. Mine is a '99 & has the front shaft & concentric drive. The '97s are the 3 chain, but don't know about the '98 model. Now, I'm curious. Which is it? My guess would be with you on the 3 chain system

 

Xplor,
The easiest way to change out springs is to loosen the strut housing and push the shock up into the spring. It will go up far enough to remove the spring. Just bottom out the shock back into the strut housing and you are done. You may have to remove the tie rod, and on the front left you may have to unbolt the ball joint. This is how I install and remove my lift. Only takes a few minutes for each side. Be careful not to pull the axel out of the CV if you do have to remove the ball joint on the front left.

I hope this helps.

Greg

 

Mine has the 3-chain system.

 

There's more than one way to skin the 'ol cat.

Greg has done this before!