Torque Specifications; Special Tools - Polaris SPORTSMAN 400 2003 Service Manual

ENGINE

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Fastener Size
Blind Plug (Oil 1/8 PT
Pressure) (28tpi)
Camshaft Sprocket 6mm
Camshaft Chain 6mm
Tensioner Lever
Camshaft Chain 6mm
Tensioner
Camshaft Chain 11mm
Tensioner Cap
Carburetor Adaptor 8mm
Crankcase 8mm
Crankshaft Slotted 28mm
Nut (Cam Chain
Drive Sprocket)
Cylinder Base 10mm
Bolts 6mm
Cylinder Head 11mm
Bolts 6mm
Drive Clutch Bolt 7/16 -
Flywheel 16mm
Oil Delivery Pipe 12mm
Oil Drain Bolt 14mm
(Crankcase)
Oil Filter Pipe Fit- 20mm
ting
Oil Hose Fitting 1/8 Pipe
Thread
Oil Pump 6mm
Oil Pump Case 5mm
Screw
One Way Valve 11mm
Recoil Housing 6mm
Rocker Cover 6mm
Rocker Support 8mm
Rocker Adjuster 6mm
Screw
Water Pump Impel- 6mm
ler Nut
3.2
EH42PLE/
EH50PLE
Ft. Lbs. (Nm)
6.5-11 (9-15 Nm)
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
14-19 (20-25 Nm)
12-14 (16-20 Nm)
14-15 (19-21 Nm)
35-51 (47-69 Nm)
45-49 (61-67 Nm)
6-8 (9-11 Nm)
Refer to Engine
Assembly for
torque procedure
40 (55 Nm)
20
58-72 (78-98 Nm)
11-15 (15-21 Nm)
14-17 (19-23 Nm)
36-43 (49-59 Nm)
6.5-11 (9-15 Nm)
5-6.5 (7-9 Nm)
1.5-2 (2-3 Nm)
14-19 (20-25 Nm)
5-6.5 (7-9 Nm)
7-8 (9-11 Nm)
8-10 (11-13 Nm)
6-7 (8-10 Nm)
5-6.5 (7-9 Nm)
Water Pump 6mm
Housing Cover
Stator Plate 6mm
Starter Motor 6mm
Spark Plug 14mm

SPECIAL TOOLS

PART NUMBER
2200634
2870390
2871043
2871283
5131135
2870569
2870975
PV- -43527
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
9-11 (12-15 Nm)
TOOL
DESCRIPTION
Valve Seat
Reconditioning Kit
Piston Support
Block
Flywheel Puller
Crankshaft/Water
Pump Seal Install
Kit
Water Pump
Install Kit
Crankshaft Truing
Stand
Mity Vact
Pressure Test Tool
OIl Filter Wrench