2004 Polaris Sportsman 700 EFI ATV Service Manual, Page 128Get this manual
BODYSTEERINGSUSPENSION
A-ARM REPLACEMENT
1Elevate and safely support vehicle with weight removed from front wheel(s)Remove wheels2Remove 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
9Attach A-arm to hub strut assemblyTighten ball joint nut to 25 ftlbs(35 Nm)If cotter pin holes are not aligned, tighten nut slightly to alignInstall new cotter pin with open ends toward rear of machineBend both ends in opposite directions around nutWARNING