Plastic Insert Removal/Install; Ball Joint Replacement Tool - Polaris 2005 SPORTSMAN 500 Servise Manual

BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
COMPONENT
Front Wheel Nuts
Front Hub Nut
Front A-Arm Attaching Bolt
Front A-Arm Ball Joint Stud
Nut
Handlebar Adjuster Block
Master Cylinder Clamp
Bolts
Rear Shock Bolt (Upper)
Rear Shock Bolt (Lower)
Rear Wheel Hub Nut
Rear Wheel Nuts
Upper Stabilizer Support
Nuts
Upper Control Arm Mount-
ing Bolt
Lower Wheel Bearing Carri-
er Bolt
Strut Rod Retaining Nut
(Top)
Strut Casting Pinch Bolt
Tie Rod End Jam Nut
Tie Rod End Castle Nut
Tie Rod End Attaching Bolt
NOTE: Refer to exploded views throughout this
chapter for identification and location of components.
5.2
FT. LBS. NM
(IN.LBS.)
27 37
70 95
30 41
25 35
11--13 15--18
(45-55) 5.2-6.3
30 41
30 41
80 108
27 37
17 27
35 48
30 41
15 21
15 21
12-14 17-19
40--45 54--61
25-30 35--41
SPECIAL TOOLS
PART NUMBER
2870871
2870872
2870623
2871572
2871573
2871574
7052069
2200421
2871352
2871199
2870872
2871351
PLASTIC INSERT REMOVAL /
INSTALLATION
Some Polaris ATVs use a two piece plastic insert in
place of a metal screw. The plastic inserts are easy
to remove and install.
1. Use a a pair of diagonal side cutters to lift the
plastic insert (A) until you feel some slight
pressure or lift the insert approximately 1/4" (6.35
mm). Apply just enough pressure on the side
cutters to lift up on the insert. DO NOT apply too
much pressure on the side cutters, or damage to
the insert will occur.
A
TOOL DESCRIPTION

Ball Joint Replacement Tool

Shock Spanner Wrench
Shock Absorber Spring
Compression Tool
Strut Rod Wrench
LH Strut Spring Compressor
RH Strut Spring Compressor
Charging Needle
Gas Shock Recharging Kit
Shock Rod Holding Tool
Seal Sleeve Installation Tool
Kit
Shock Spanner Wrench
Foxt Shock IFP Depth Tool