Cover/Panel Removal - Polaris SPORTSMAN 400 2003 Service Manual

BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
COMPONENT
Front Wheel Nuts
Front A-Arm Attaching Bolt
Front A-Arm Ball Joint Stud
Nut
Handlebar Adjuster Block
Master Cylinder
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.
SPECIAL TOOLS
PART NUMBER
2870871
2870872
5.2
FT. LBS. NM
(IN.LBS.)
20 27
30 41
25 35
10-12 14-17
(45-55) 5.2-6.3
30 41
30 41
100 136
20 27
17 27
35 48
30 41
15 21
15 21
12-14 17-19
40--45 54--61
25-30 35--41
TOOL
DESCRIPTION
Ball Joint
Replacement Tool
Shock Spanner
Wrench
2870623
2871572
2871573
2871574
7052069
2200421
2871352
2871199
2870872
2871351

COVER/PANEL REMOVAL

To Remove: Perform These Steps:
Seat:
S
Pull release lever at the rear of the seat
S Lift and pull seat rearward, disengaging
seat from tabs at the rear of the fuel tank
Side Panels (See Page 5.3)
S
Remove: Seat
S Disengage tabs at front and rear
Headlight Pod (See Page 5.5)
Front Cover
S Remove: Seat
S
Disengage tabs at front and rear
S
Lift panel out
Rear Rack
S
Remove: Seat
S 2 bolts at rear of rack
S 2 bolts at front of rack
Rear Cab Assembly
S Remove: Seat
S Rear rack
S 1 screw, nut and washer at rear of inner
left footrest
S
4 screws at bottom of left rear mudflap
S
1 screw, nut and washer at rear of inner
right footrest
S 4 screws at bottom of right rear mudflap
S 4 bolts and flat washers from top of cab
assembly, under seat
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