Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 128 / 289

GENERAL INFORMATION
5.2
TORQUE SPECIFICATIONS
Item Specification
Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm)
Front A--Arm Ball JointStud
Nut
25 ft. lbs. (35 Nm)
Handlebar Adjuster Block 10-12 ft. lbs. (14-17 Nm)
Steering Post Nut 75 ft.lbs. (16 Nm)
Steering Post Bushing Nuts 12 ft. lbs. (17 Nm)
Steering Post Retainer Nuts 12 ft. lbs. (17 Nm)
Rear Axle Nut -
(Tapered Roller Bearings)
(Left side)
120 ft. lbs. (165 Nm)
Rear Axle Nut -
(Tapered Roller Bearings)
(Right Side)
8-10 ft. lbs. (11-14 Nm)
Rear Shock Bolt (upper) 25 ft. lbs. (35 Nm)
Rear Shock Bolt (lower) 25 ft. lbs. (35 Nm)
Rear Wheel Hub Nut 80 ft. lbs. (110 Nm)
Rear Wheel Nut 50 ft. lbs. (69 Nm)
Strut Rod Retaining Nut
(Top)
15 ft. lbs. (21 Nm)
Strut Casting Pinch Bolt 15 ft. lbs. (20 Nm)
Tie Rod End Jam Nut 12-14 ft. lbs. (17-19 Nm)
Tie Rod End Castle Nut 23-24 ft. lbs. (32-33 Nm)
Tie Rod End Attaching Bolt 25-30 ft. lbs. (35-41 Nm)
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
2871199 Seal Sleeve
Installation Tool Kit
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 5.6)
S
Remove: Seat
S
Disengage tabs at front and rear
Headlight Pod (See Page 5.5)
Front Cover
S
Remove: Front rack
S
Disengage tabs at front and rear
S
Lift panel out
Cargo Box
S
Place box in the down position
S
Disconnect taillight harness
S
Remove 6 bolts holding hinges to frame
S
Raise rear of box with assist from
dump box shock
S
Remove bolt from shock at box
S
Lift box off frame with assistance
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 mud flap
S
1 screw, nut and washer at rear of inner
right footrest
S
4 screws at bottom of right rear mud flap
S
4 bolts and flat washers from top of cab
assembly, under seat
S
2 screws at rear bottom of cab assembly
near tail light
Front Rack
S
Remove: 4 screws, lock washers, and
flat washers
Front Cab Assembly
S
Remove: Seat
S
Side panels
S
2 screws at rear of cab at fuel tank
mount bracket
S
Front rack
S
Front bumper
S
Front cover panel
S
3 screws from bottom left mud flap
S
3 screws from bottom right mud flap
S
1 inner screw from front cab to foot
rest on each side
S
2 screws under front panel