Side Panel Removal; A-Arm Replacement - Polaris SPORTSMAN 600 2003 Service Manual

BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION

SIDE PANEL REMOVAL

NOTE:Side panel removal may be difficult until the
locking tabs and receivers have been snapped and
unsnapped a few times.
1. Remove seat. Grasp rear of side panel near rear
cab. With a quick and firm motion, pull the panel
forward and outward to disengage the two rear
tabs.
Step 1.
Pull forward and out to disengage
two rear tabs.
2. Place hand on top of side panel behind the fuel
tank. With a quick and firm motion, push down on
the side panel to disengage the top rear two tabs.
Then pull up on side panel to disengage front
upper and lower tab.
Step 2.
Push down to disengage top rear
two tabs.
3. To reinstall side panel, align panel tabs with slots
on front cab. Push panel upward and forward until
tabs lock. Bend rear of side panel and insert the
two tabs into the rear cab.
Step 3.
To reinstall, align panel tabs with
slots. Push upward and forward
until tabs lock.

A-ARM REPLACEMENT

1. Elevate and safely support vehicle with weight
removed from front wheel(s). Remove wheels.
2. Remove cotter pin from ball joint stud at wheel
end of A-arm and loosen nut until it is flush with
end of stud.
3. Using a soft face hammer, tap nut to loosen A-arm
from bolt. Remove nut and A-arm from hub strut
assembly.
4. Loosen two bolts on A-arm tube by alternating
each about 1/3 of the way until A-arm can be
removed.
5. Examine A-arm shaft. Replace if worn. Discard
hardware.
6. Insert A-arm shaft into new A-arm.
7. Install CV joint shields.
8. Install new A-arm assembly onto vehicle frame.
Torque new bolts to 30 ft. lbs. (41.4 Nm).
WARNING
The locking features on the existing bolts were
destroyed during removal. DO NOT reuse old bolts.
Serious injury or death could result if fasteners come
loose during operation.
A-arm Attaching Bolt Torque:
30 ft. lbs. (41 Nm)
Ball Joint Stud Nut Torque:
25 ft. lbs. (35 Nm)
5.9