General Information; Torque Specifications; Special Tools; Decal Replacement - Polaris 2007 Sportsman 500 EF Service Manual

BODY / STEERING / SUSPENSION

GENERAL INFORMATION

Torque Specifications

Table 5-1:
C
OMPONENT
Front Hug Nut
Front A-Arm Attaching Bolt
Front A-Arm Ball Joint Stud Nut
Handlebar Adjuster Block
Master Cylinder Clamp Bolt
Rear Shock Bolt (Upper)
Rear Shock Bolt (Lower)
Rear Wheel Hub Nut
Upper Stabilizer Support Nuts
Upper Control Arm Mounting Bolt
Lower Wheel Bearing Carrier 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
components.
5.2
. .
FT LBS
N
M
( . .)
IN LBS
70 95
30 41
25 35
11-13 15-18
(45-55) 5.2-6.3
30 41
30 41
80 108
17 27
35 48
50 68
15 21
15 21
12-14 17-19
40-45 54-61
25-30 35-41
and location of

Special Tools

Table 5-2:
P N
ART UMBER
2870871
2870872
Shock Absorber Spring Compression
2870623
2871572
2871573
2871574
7052069
2200421
2871352
2871199 Seal Sleeve Installation Tool Kit
2870872
2871351

Decal Replacement

Flame Treating Decal Area
Plastic polyethylene material must be "flame treated" prior to
installing a decal to ensure good adhesion. The flame treating
procedure can often be used to reduce or eliminate the whitish
stress marks that are sometimes left after a fender or cab is bent,
flexed, or damaged.
WARNING
The following procedure involves the use of an
open flame. Wear the appropriate safety equipment
at all times. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials. Verify the area to be flame
treated is clean and free of gasoline or flammable
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. Keep the torch moving to prevent
damage.
2. Apply the decal.
D
ESCRIPTION
Ball Joint Replacement Tool
Shock Spanner Wrench
Tool
Strut Rod Wrench
LH Strut Spring Compressor
RH Strut Spring Compressor
Charging Needle
Gas Shock Recharging Kit
Shock Rod Holding Tool
Shock Spanner Wrench
™
Fox Shock IFP Depth Tool
residue.