Long story short i have a early 2004 sportsman 400.I did all the left front bearings.There still was a slight amount of play in the left front wheel.Today i hit a rock with the left front wheel hidden under some leaves.I noticed the axle seal was leaking.I jacked the front end up and there is a fair amount of up and down play in the wheel.I took it all apart and notice the strut knuckle outer bearing race will move up and down in the knuckle.This is with both knuckle bearings in place and me holding them in firmly while i rock the axle up and down.I am assuming the outer bearing race area of the knuckle is damaged under the sleave and coil that engages the wheel in awd? Is this a common problem.I am thinking i may have to buy a new knuckle?

 

This is not normal! Depending on what you find when you tear it down,may need a new hub strut assy. Comes with both races installed,ball joint,coil,coil sleeve.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse If finances are tight you could try a good used one,if available. Here's one,but you never know on buying used parts. Same part # that's used on your model also,but from a 500.http://www.budkestoys.com/POLARIS-SP...-p/b5-1018.htm

 

Hi thanks ! I guess i will have to bite the bullet and buy a new one.It looks like that 500 knuckle is sold.We have put more money into this than i thought we would.But i dont see any that cheap either.and i would think a lot of the ones for sale need stuff to. I do see a few knuckles on ebay but never know what i am going to get as you said.To have this movement this knuckle has to be cracked or something under that sleave and coil. I assume the knuckle is completely aluminum

 

Yes,plus the weak link areas on the struts are where they are milled down for the coil and the sleeve.Usually had no problems with races unless like you say the strut area may have cracked,races possibly damaged when installed,or improper torque on the hub nut.

 

Don,t give up there are lots on ebay Canada polaris atv struts in United States | eBay I,m sure there are more for better price on ebay USA. Many models and years shared the same strut.

 

I am parting out an 01 magnum 325 4x4 have both front spindles with coils one side is missing a ball in the cv joint but if they will fit yours can sell one or both thanks Danny

 

Will interchange if he's interested and if he hasn't ordered a new one.

Usage : 1820950 (left hub strut)

Year Product Model Assembly
2006 ATV SCRAMBLER 500 4X4 STRUT, FRONT - A06BG50AA/FA (4999201549920154B03)
2006 ATV SPORTSMAN 6X6 STRUT, FRONT - A06CL50AA (4999201649920164B02)
2005 ATV SCRAMBLER 500 4X4 FRONT STRUT - A05BG50AA/FA (4954855485B006)
2005 ATV SPORTSMAN 6X6 FRONT STRUT - A05CL50AA (4959905990B007)
2005 MIL SPORTSMAN 6X6 MV SUSPENSION, STRUT, FRONT - A05CL50MA (4959905990B007)
2004 ATV A04BG50AA SCRAMBLER 500 4X4 FRONT STRUT - A04BG50AA/FA (4954855485B006)
2004 ATV A04CH42AA SPORTSMAN 400 FRONT STRUT - A04CH42AA/AE/AG (4959905990B007)
2004 ATV A04CH50AA SPORTSMAN 500 FRONT STRUT - A04CH50AA/AC/AE/AG (4959905990B007)
2003 ATV SCRAMBLER 500 4X4 FRONT STRUT - A03BG50AA (4954855485B006)
2003 ATV SPORTSMAN 400 FRONT STRUT - A03CH42AA/AB/AC (4959905990B007)
2003 ATV SPORTSMAN 500 HO FRONT STRUT - A03CH50AA/AB/AC/AD/AE/AH/AJ (4959905990B007)
2002 ATV SCRAMBLER 400 4X4 FRONT STRUT - A02BG38CA (4954855485B006)
2002 ATV SCRAMBLER 500 4X4 FRONT STRUT - A02BG50AA/AC (4954855485B006)
2002 ATV SCRAMBLER 500 4X4 FREEDOM FRONT STRUT - A02BG50AA/AC (4954855485B006)
2002 ATV MAGNUM 325 4X4 FRONT STRUT - A02CD32AA/AB/AC (4949304930B005)
2002 ATV MAGNUM 325 4X4 FRONT STRUT - A02CD32AA/AB/AC (4949304930B005)
2002 ATV MAGNUM 325 4X4 FREEDOM FRONT STRUT - A02CD32AA/AB/AC (4949304930B005)
2002 ATV XPLORER 4X4 FRONT STRUT - A02CG25CA (4954855485B006)
2002 ATV XPLORER 400 FRONT STRUT - A02CG38CA (4959905990b007)
2002 ATV SPORTSMAN 400 FRONT STRUT - A02CH42AA (4959905990b007)
2002 ATV SPORTSMAN 400 FRONT STRUT - A02CH42AA (4959905990b007)
2002 ATV SPORTSMAN 400 FRONT STRUT - A02CH42AA (4959905990b007)
2002 ATV SPORTSMAN 500 ALL OPTIONS FRONT STRUT - A02CH50 ALL OPTIONS (4959905990b007)
2002 ATV XPEDITION 325 FRONT STRUT - A02CK32AA (4959905990b007)
2002 ATV XPEDITION 425 FRONT STRUT - A02CK42AA/AB (4959905990b007)
2001 ATV XPLORER FRONT STRUT - A01AG25CA (4954855485B006)
2001 ATV SCRAMBLER 500 4X4 FRONT STRUT - A01BG50AA (4954855485B006)
2001 ATV SCRAMBLER 500 4X4 FRONT STRUT - A01BG50AA (4954855485B006)
2001 ATV MAGNUM 325 4X4 FRONT STRUT - A01CD32AA (4949304930B005)
2001 ATV MAGNUM 325 4X4 MOSE FRONT STRUT - A01CD32AA (4949304930B005)
2001 ATV 325 MAGNUM 4X4 HDS FRONT STRUT - A01CD32AA (4949304930B005)
2001 ATV XPLORER 400 FRONT STRUT - A01CG38CA (4959905990b007)
2001 ATV SPORTSMAN 400 FRONT STRUT - A01CH42AA (4959905990B007)
2001 ATV SPORTSMAN 400 FRONT STRUT - A01CH42AA (4959905990B007)
2001 ATV SPORTSMAN 400 FRONT STRUT - A01CH42AA (4959905990B007)
2001 ATV SPORTSMAN 500 HO FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV SPORTSMAN 500 HO FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV SPORTSMAN 500 HO FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV SPORTSMAN 500 DUSE HO FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV SPORTSMAN 500 RSE HO FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV SPORTSMAN 500 HO FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV WORKER 500 FRONT STRUT - A01CH50AA (4959905990b007)
2001 ATV XPEDITION 325 FRONT STRUT - A01CK32AA (4959905990b007)
2001 ATV XPEDITION 425 FRONT STRUT - A01CK42AA (4959905990b007)
2001 ATV XPEDITION 425 FRONT STRUT - A01CK42AA (4959905990b007)
2001 ATV XPEDITION 425 FRONT STRUT - A01CK42AA (4959905990b007)
2001 ATV DIESEL FRONT STRUT - A10CH46CA (4959905990B007)

 

Thank you all for that info,.I did wind up buying a new one and its on the way.

 

I am fast now at taking the lower knuckle off .I leave the spring and strut in the ATV. I wire the spring with mechanics wire compressed.

 

Just a update i installed the new knuckle and all is well no leaks or play or anything now in the left front. The old knuckle looks to me like it has a steel insert pressed into the aluminum houseing which holds the bearings,That appears to have come loose in the houseing.Not real loose but enough to cause some good play in it