Front Cab/Fender Removal/Installation - Polaris 2007 Sportsman 500 EF Service Manual

3. Place spacers on frame.
4. Install rear rack onto rear frame and cab.
5. Install the two bolts (B) and six (A) T-27 screws. Torque
the bolts (A) to 18 in.lbs. (2 Nm) and six T-27 screws to 36
in.lbs. (4 Nm). Refer to the illustration for torque values.

Front Cab/Fender Removal/Installation

1. Follow the "FRONT RACK / BUMPER REMOVAL"
section to begin removal of the front cab, rack, and
bumper.
2. Remove the plastic inserts (A) that secure the front cab to
the upper strut support.
A
BODY / STEERING / SUSPENSION
3. Remove the two screws (B) that secure the front cab to the
frame in the fuel tank mount area.
B
4. Remove the side panels (D), refer to the "SIDE PANEL
REMOVAL" section.
5. Remove the plastic inserts (E) that secure the front of the
foot wells to the front cab.
D
6. Remove the fuel cap and place a clean lint free shop towel
into the tank neck to keep any debris from falling into the
tank.
7. The front cab should now slide back over the fuel tank and
fuel tank neck.
NOTE: When removing the front cab use caution so
the plastic cab does not scratch or get caught on
other components.
8. Reverse the removal steps for installation. Torque two
front cab to frame screws to specification.
Cab to Frame Screws
24 in.lbs. (2.7 Nm)
B
A
E
= T
5.9
5