Cover/Panel Removal - Polaris SPORTSMAN 600 2003 Service Manual

SPECIAL TOOLS
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
Foxt Shock IFP
Depth Tool
TORQUE SPECIFICATIONS
Front A-Arm Attaching Bolt.............30 ft. lbs. (41 Nm)
Front A-Arm Ball Joint Stud Nut.......25 ft. lbs. (35 Nm)
Handlebar Adjuster Block.....10-12 ft. lbs. (14-17 Nm)
Master Cylinder ................45-55 in. lbs. (5.2-6.3 Nm)
Rear Shock Bolt (upper)..................30 ft. lbs. (41 Nm)
Rear Shock Bolt (lower)..................30 ft. lbs. (41 Nm)
Rear Wheel Hub Nut...................100 ft. lbs. (136 Nm)
Wheel Nuts............................30 ft. lbs. (40.6 Nm)
Upper Stabilizer Support Nut...........17 ft. lbs. (24 Nm)
Upper Control Arm Mounting Bolt....35 ft. lbs. (48 Nm)
Lower Control Arm Mounting Bolt....30 ft. lbs. (41 Nm)
Upper Wheel Bearing Carrier Bolt...35 ft. lbs. (48 Nm)
Lower Wheel Bearing Carrier Bolt....30 ft. lbs. (41 Nm)
Strut Rod Retaining Nut (Top)..........15 ft. lbs. (21 Nm)
Strut Casting Pinch Bolt.................15 ft. lbs. (21 Nm)
Tie Rod End Jam Nut............12-14 ft. lbs. (17-19 Nm)
Tie Rod End Castle Nut.........40-45 ft. lbs. (54-61 Nm)
Tie Rod End Attaching Bolt....25-30 ft. lbs. (35-41 Nm)
NOTE: Refer to exploded views for identification and
location of components.
5.8
PART NUMBER
2870871
2870872
2870623
2871572
2871573
2871574
7052069
2200421
2871352
2871351
BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION

COVER/PANEL REMOVAL

To Remove: Seat
Pull release lever at the rear of the
seat Lift and pull seat rearward,
disengaging seat from tabs at the
rear of the fuel tank
To Remove: Side panels (See Page 5.9)
Remove Seat Disengage tabs at
front and rear and pull away
To Remove: Headlight pod (See Page 5.4)
To Remove: Front Cover
Remove Front rack,Disengage
cover and lift out
To Remove: Rear Rack
Remove Seat, 2 bolts at rear of rack
and 2 bolts at front of rack
To Remove: Rear Cab Assembly
Remove Seat, Rear rack,1 screw--
nut and washer at rear of inner left
footrest, 4 screws at bottom of left
rear mud flap, 1 screw, nut and
washer at rear of inner right
footrest, 4 screws at bottom of right
rear mud flap, 4 bolts and flat
washers from top of cab assembly
under seat, 2 screws at rear bottom
of cab assembly near tail light.
Disconnect taillight harness
To Remove: Front rack
Remove 4 screws, lift off
To Remove: Front Cab Assembly
Remove Seat, Side panels, 2 screws
at rear of cab at fuel tank mount
bracket, Front rack, Front bumper (4
screws), Front cover panel, 3 screws
from bottom left mud flap, 3 screws
from bottom right mud flap, 1 inner
screw from front cab to foot rest on
each side, 2 screws under front
panel, Remove fuel tank cap (reinstall
on tank after cab is removed)
To Remove: Radiator Cover
Pull out slightly on the top of the
radiator screen, then pull out on the
bottom of the screen