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Polaris SPORTSMAN 400 2003 - Cover;Panel Removal

Polaris SPORTSMAN 400 2003
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BODY / STEERING / SUSPENSION
5.2
TORQUE SPECIFICATIONS
COMPONENT FT. LBS.
(IN.LBS.)
NM
Front Wheel Nuts 20 27
Front A-Arm Attaching Bolt 30 41
Front A-Arm Ball Joint Stud
Nut
25 35
Handlebar Adjuster Block 10-12 14-17
Master Cylinder (45-55) 5.2-6.3
Rear Shock Bolt (Upper) 30 41
Rear Shock Bolt (Lower) 30 41
Rear Wheel Hub Nut 100 136
Rear Wheel Nuts 20 27
Upper Stabilizer Support
Nuts
17 27
Upper Control Arm Mount-
ing Bolt
35 48
Lower Wheel Bearing Carri-
er Bolt
30 41
Strut Rod Retaining Nut
(Top)
15 21
Strut Casting Pinch Bolt 15 21
Tie Rod End Jam Nut 12-14 17-19
Tie Rod End Castle Nut 40--45 54--61
Tie Rod End Attaching Bolt 25-30 35--41
NOTE: Refer to exploded views throughout this
chapter for identification and location of components.
SPECIAL TOOLS
PART NUMBER TOOL
DESCRIPTION
2870871 Ball Joint
Replacement Tool
2870872 Shock Spanner
Wrench
2870623 Shock Absorber
Spring
Compression Tool
2871572 Strut Rod Wrench
2871573 LH Strut Spring
Compressor
2871574 RH Strut Spring
Compressor
7052069 Charging Needle
2200421 Gas Shock
Recharging Kit
2871352 Shock Rod
Holding Tool
2871199 Seal Sleeve
Installation Tool Kit
2870872 Shock Spanner
Wrench
2871351 Foxt Shock IFP
Depth Tool
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
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