2005 Polaris Sportsman 400/500 Service Manual, Page 147Get this manual
BODYSTEERINGSUSPENSION
A-ARM REPLACEMENT
1Elevate and safely support vehicle with weight removed from front wheel(s)2Remove 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 shieldsVehicle Frame Bolt 30 ftlbs(41 Nm) Bushing Bolt 30 ftlbs(41 Nm) A-Arm Tube Washer A-Arm Shaft 25 ftlbs (35 Nm)CV Joint Shield Ball Joint Stud ftlbs(11 Nm) Cotter Pin
Apply Loctitet 242 to the bolt threads