I've got my '96 SP500 in my shop, all torn to pieces for my yearly maint/upgrade session. This time I wanted to tighten the front-end and all the steering parts since I spent over $400 on my new Mudrunners. I bought one of those billet aluminum pieces from HPD that I thought would bolt right in....WRONG. The original is held in by rivets that have to be sheared, then the bolts that hold the new part are larger than the rivet holes. You already have to tear the entire steering post free, including the headlight pod, handlebars, upper steering post bushing, etc. The ONLY thing that will work is a right angle drill...unless you want to tear it down to the frame. Not only was it a 3 day job, but the plastic bushing that I thought would be worn out wasn't. It was the rubber washer on the bottom side that caused all the slack. Like I said, mine is a '96, and most of ya'll's in this forum seem to be alot newer, so unless the steering column is about to come completely out, just replace the rubber washer and don't worry about the plastic bushing.

Also, I looked at my buddies 400 Xplorer and there ain't no way to get to it!

 

TODD; I REPLACED MY RUBBER WASHER WITH A SMALL PIECE OF PVC PIPE AFTER IT FELL OUT.I HAVE A 96 TRAIL BOSS AND HAVEN'T HAD A PROBLEM SINCE.

 

What I have done after replacing the rubber washer twice was to find an old tire and cut out a chunk from the sidewall and then using a hole saw create my own washer that is reinforced and much more impervious to wear and greese. I have been using this set up now for over 2 years on the same homemade washer.


This to me is the best of both worlds, long lasting and still offering rubber shock effect (for free).