Traded 06 in on 08 Friday, and while it is show-room fresh, thought I would add zerks to rear suspension, as I have broken 2 lower bolts on 2 different machines, and have had them back out as well. Picked up 10ea 1/4-28 zerks today, and planned to put them where my '99 had them. See on upper arm, may have to cut bolts due to CV in way of bolt coming out? Another way? Also did the older hubs have a zerk on top, as i see one in an older parts manual?? Just looking for any and all advice. Looks like the zerks i have may need to be trimmed, or will hit bushings? Thanks

I just drilled 1/8th inch holes and used a needle point to lube them. Nothing to break off and I never noticed excess water or dirt coming out when I lubed them, the grease always seamed to keep the hole filled. Nothing to break off that way.

That sounds a lot easier, might not have to disassemble to do it that way? What is a needle seat? available auto stores?
thanks.

It's a needle point and yes most auto parts stores should have it. You unscrew the end off your grease gun hose and screew the needle point on then just push hard on the hole and pump away. BTW if you have a zerk that doesn't want to take grease you can use a needle point in the little hole and most of the time make it work.

Congrats on your new ride.
Your newer Sportsman will have about 6 fewer zirks than your '99. However Polaris used a higher quality poly material on the upper and lower suspension joints that will do just fine with spraying a high quality lube such as Prolong Spray lube or ZEP45 NC. WD-40 would be too thin. Just part the material a little with a feeler guage and spray a little.
I recently notices that Polaris also increased the material on the CV boots using the same type of polyeurethan material that is not susceptible to drying out like the old rubber boots. I just changed the front CV's on my 700. They were rubber and sat for a year without use. When my buyer test rode it one of them tore. The replacements came in a kit with the improved boots, grease, and large & small clips for $32.
Just my 2 cents worth anyway.

wardog-thanks for reply. On the bushings, I had an 04 700 that broke a lower rear A-arm bolt, damaged arm, hub, and i replaced them and bearing and bushings, almost $400 repair. Machine had around 350 miles, and those bushings were wearing pretty good. THe large metal bushing had a good crown where the bushings don't quite meet. Hope they improved them. IMO was quite a bit of wear already...how bout some grease zerks? Wish they hadn't done away with them.

Quad daddy- thanks again. Went to couple of stores and saw 3 dfferent adapters. 1 looks like Dr's needle for getting behind seals I think. Another had long metal nozzle, to a tappered point. Another had rubber or plastic short rounded and tappered tip. Which one are you using?

Thanks.

The long Metal nozzle with the pointed tip is the one I use.

Thanks. I added the zerks to the 4 rear lower/outers. Thinking about using your idea on the upper/inners. The alum. hub used to have one also I believe.

I may have spoken too soon, especially after reading about all of the sheared A-arm suspension bolts. I read more about this 'phenomenon' since Polaris won't come about and recall the problem and do what is right. However I looked at my rear suspension and placing zirks in the original spots looks like a lot of work, since the rear axle's look like they must be removed, since the bolts that tend to shear cannot be removed with the A-Arms in their original position. Even just replacing the grade 5 bolts with grade 8's looks to be a job sinc ethe factory obviously install the suspension before the axles.
I am now interested if anyone has more info, pic's or shortcuts I would be interested.

wardog,

I just wound up doing the 4 outers. Those are the only ones i have broken. Wanted to do as my '99 had them, but one is (was) in alum. hub, and the bolts on the inside of the upper A arm are as you mentioned, hard to get to. Might do as quad daddy suggested on those. Wasn't bad doing lower outers. removed tires, bolts and bushings in arms. Center punch middle of bushing housing, drilled and tapped, screwed in zerks. I also put in grade 8's in these.