I have an 05 sportsman 700, i have all the a arms off and want to add grease zerks.
How can i install them without them hitting the pivot rod inside? I thought about getting the angled ones and cutting them down. Any suggestions?

 

Because Polaris Sportsmans use to have grease fittings anyways, I would imagine there is a space between the A arm and inner rod do to the end bushings ,thats the space where the grease will sit.
I would think just drill just enough to get through the a arm then stick a tooth pick in the hole to measure your clearance depth and I would bet the grease fitting will not touch the inner rod.
My Sportsman has 27 Grease fitting on it and one on every a arm.
The harder safer way is take the a arms off and drill the hole.

 

I can't seem to remember any of the model years not having grease zerks in the A-arms. As the models get newer I've noticed less and less zerks but my 07 has them in the A-arms, I can't believe your 05 wouldn't have them?

 

2005 700 shows to have zerk fittings on the a-arm,but if they have been replaced then this could be the problem? I've encountered this on replacement a-arms before that didn't have zerks,plus Polaris kinda got squirrelly during these years and started putting out machines that didn't have fittings some years and went back to fittings on other models? OPT

 

well it definately has no zerks on the a arms at all. The zerks i have look like they would go in too deep, and you can't cut them down because of the spring inside. I also have an 04 700 that has no zerks.

 

If they go in too deep, put them in part way and permanently secure them with JB Weld so the don't back out. It makes a difference to the ride after I grease my A arms so I think it would be worth the effort.

 

Should be as simple as this and is on a lot of older cycles and other machines also . Only thing is that the a arm shaft would have to be slotted to get the grease outwards and the a arm bolt would have to be drilled through(probably wouldn't be as strong?) I know I've seen em out there somewhere that would replace the Polaris bolts? http://www.ebay.com/itm/2-Trailer-9-...2499d4&vxp=mtr OPT

 

If you are worrried about them being to long, take a 1/4'' by 28 threads per inch (fine thread) nut and weld it over the hole. You will need to weld it all the way around or the grease will come out from under the nut and not go into the bushing. I have used this method many times on snowplows. Using a tig welder will work best. If you use a wire feed make sure you thread a bolt in there so you don't get spatter in there and mess the threads up.