2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 131Get this manual
BODYSTEERINGSUSPENSION
SIDE PANEL REMOVAL
NOTE:Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped few times1Remove seatGrasp rear of side panel near rear cabWith quick and firm motion, pull the panel forward and outward to disengage the two rear tabsStep 1To reinstall, align panel tabs with slotsPush upward and forward until tabs lockStep 3
A-ARM REPLACEMENT
1Elevate and safely support vehicle with weight removed from front wheel(s)Remove wheelsPull forward and out to disengage two rear tabs2Place hand on top of side panel behind the fuel tankWith quick and firm motion, push down on the side panel to disengage the top rear two tabsThen pull up on side panel to disengage front upper and lower tabStep 22Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud3Using soft face hammer, tap nut to loosen A-arm from boltRemove nut and A-arm from hub strut assembly4Loosen two bolts on A-arm tube by alternating each about 13 of the way until A-arm can be removed5Examine A-arm shaftReplace if wornDiscard hardware6Insert A-arm shaft into new A-arm7Install CV joint shields8Install new A-arm assembly onto vehicle frameTorque new bolts to 30 ftlbs(41.4 Nm)WARNING