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5W0P3 05-10-2009 03:32 AM

Steering Stem Replacement
So you rolled it huh? Bent the stem? Or does it turn significantly more to one direction than the other? :lmao:

Mine did all of that, so I put a new stem in it tonight.

Time: 2 hours.
Needle Nose Pliers
5mm Alan wrench
14mm open end wrench
8mm socket
10mm socket
14mm socket (deep)
19mm socket
3/8 Drive Ratchet

I took quite a few pics of how I did this... its really pretty easy, there is just alot that you have to take off to get to actually pulling the stem out - but its not too bad at all. Here we go, i'll explain each picture.

This is how we start. You'll need the 5mm Alan Wrench to take the 6 alan head screws out of the red piece of plastic.

Once that is off, pull the plastic piece behind the light off.

There are 2 10mm Bolts on each side of the headlight that you need to remove to take the headlight out. Once those bolts are removed, the headlight has to slide up or down to come out. Make sure you unplug it as well.
You will also want to take the plastic grill off. Just pull the 4 - 10mm bolts out of it and it slides right out.

These next few pics are what you need to look for if your steering stem is indeed bent. It will ripple up like this.

Use the 8mm socket to undo the brake line from the steering stem clamp. then remove the wires out of the wire catches. Take the handle bars off by undoing the four bolts on top with a 10mm socket for the clamps.

My Quad was on an ATV jack so it made this easy, but once you get under it, this is what you'll see. Use a pair of needle nose pliers to pull the cotter pins out. Once all the pins are out, start by removing the inside ball joints. They are a 14mm on the bottom and you'll need a 14mm wrench on the top of them so they don't spin. Then the larger center nut is a 19mm, loose and remove the nut.

Back up on top is the clamp that has 2 - 12mm bolts holding the stem in place. Remove these two bolts and fish the stem out. You might need to give the stem a tap on the bottom with a hammer to get it going.

Once the stem was out, I just kinda looked it over, sorry for the blurry pictures. The rubber piece will need to be saved and used on the new stem. I made sure I put A LOT of wheel bearing grease on the top part of the new stem and the bottom part where it goes into the frame.

Reverse this procedure for installation of the new stem. I tightened up the large nut at the bottom before I put the clamp on at the top of the stem.

I remounted my dash under the red piece as you can see because I plan to get some new handle bars and the dash would fit on them. I personally like how this looks as well. Now if the key and reverse lever could be moved up there as well!

scuzz 05-10-2009 12:39 PM

the_hawk 06-19-2009 02:53 PM

vary cool..... glad i came acrost this as i think mine is bent one way or another hahah

hector700 06-19-2009 08:00 PM

hey cool way too keep the lights.i had to do it another way,i drilled holes on the fender on the side they fit allright i think it looks preety cool.http://DSC0010.JPG

hector700 06-19-2009 08:01 PM

hector700 06-19-2009 08:05 PM

sorry guys having trouble loading the pictures

kelodwro 09-25-2009 09:14 PM

couple of quick ones..
1) how do you just adjust the steering? I hit a tree stump and it is off by alittle.
2) How did you make the indicator light deal?

5W0P3 09-28-2009 01:33 AM


Originally Posted by kelodwro (Post 15710)
couple of quick ones..
1) how do you just adjust the steering? I hit a tree stump and it is off by alittle.
2) How did you make the indicator light deal?

1. I pretty much just guessed. I stuck a 2x4 along the side of the quad and made sure the tires were straight and the handle bars were straight. I think I rode it up and down the street to make sure it actually went straight.

2. Double side sticky tape. I recommend using velcro though. That way if you have to take it off you dont have to retape everytime. I had to shave just a little bit of that lip off so you could actually see the lights though. Makes it look A LOT better and you dont have to buy anything else if you change handle bars (next for me)

Baxter 09-29-2009 05:53 PM

Thats a good idea with the lights. Going to try that.

Atlanta 700xx 09-29-2009 09:19 PM


Originally Posted by kelodwro (Post 15710)
couple of quick ones..
1) how do you just adjust the steering? I hit a tree stump and it is off by alittle.
2) How did you make the indicator light deal?

Use 5WOP3's instructions for question #2.

For question #1, again use 5WOP3's instructions plus:
1) Sit on the quad and move the handlebars around until they look straight

2) Use a straight 2x4 and place it half way up the tires on either side of the quad.... you'll see that when your handlebars are straight the 2x4 will touch the back tire and either the front of your front tire or the back of your front tire..... it should touch the front and back of the front tire simultaneously if it is aligned properly

3) If it only touches the front of the front tire or only the back of the front tire, then it is not aligned properly.

4) In this case, there is a gold rod that runs from your front wheel to the steering column (you'll see it right there with your front A-arms).

5) Loosen the nuts on either end of this gold rod and make your adjustments with the long nut at the center of the gold rod.

6) Turn it two times in either direction.

7) Tighten the nuts at either end of the gold rod.

8) Sit on the seat and adjust the handlebars so they look straight again.

9) Check your wheel alignment with the 2x4 and repeat process until the front wheels line up with the back wheels

10) Check both sides of the quad

I am traveling right now, so I didn't have my quad to look at when I was writting this. I am sure I missed something, so if anyone has anything to add, please do so.

Hope this helps!

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