Decal Replacement - Polaris SPORTSMAN 600 2003 Service Manual

BALL JOINT REPLACEMENT CONT'D
8. To install new ball joint:
G Remove extension cap and attach
puller guide using
provided in the kit.
G Insert new ball joint (E) into driver (F).
G Slide ball joint/driver assembly into
guide.
G Applying heat will ease installation.
G Drive new joint into strut housing until
fully seated.
A
B
C
D
F
9. Apply Loctitet 242 (PN 2871949) to threads of
retaining plate screws or install new screws with
pre-applied locking agent. Torque screws to 8 ft.
lbs. (11 Nm).
10. Install A-arm on ball joint and torque castle nut to
25 ft. lbs. (35 Nm).
11. Reinstall cotter pin with open ends toward rear of
machine.
5.12
short bolts
E
E
BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION

DECAL REPLACEMENT

WARNING
The following procedure involves the use of an
open flame. Perform this procedure in a well ventilated
area, away from gasoline or other flammable materials.
Be sure the area to be flame treated is clean and free
of gasoline or flammable residue.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be "flame
treated" prior to installing a decal to ensure good
adhesion. A bonus of the flame treating procedure is
it can be used to reduce or eliminate the whitish stress
marks that are sometimes left after a fender or cab is
bent, flexed, or damaged.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be
applied until the surface appears slightly glossy.
This should occur after just a few seconds of
flame treating. Do not hold the torch too close to
the surface. (2--3 inches from the flame tip is
recommended) Keep the torch moving to prevent
damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over
the decal surface to eliminate any air bubbles
during the application.