Polaris TRAIL BOSS 2003 User Manual

BODY / STEERING / SUSPENSION
5.8
CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION
(1) Nut 120 ft. lbs. (163 Nm)
(2) Washer
(3) Two-piece bushing
(6)
(8) Pivot Bolt
(5) Pivot Bolt
(4) Pivot Bushing, Right
Place flats of pivot bushing in vise to
hold while removing and installing nut
(7) Pivot Bushing, Left
150 ft. lbs. (207 Nm)
150 ft. lbs. (207 Nm)
150 ft. lbs.(207 Nm)
NOTE: Allow LocTitet to cure at least 24 hour
s before use.
Apply Loctitet 262 to
the bolt threads.
262
262
Assembly / In stallation
1. Install bushing (6) in left side of swingarm and
two-piece bushings (3) in right side.
2. Clean threads of nut (1), pivot bolts (5) and (8), and
pivot bushings (4) and (7) with Loctitet Primer T or
Primer N. Apply Loctitet 262 (PN 2871951)to
threads of pivot bushing (4) and nut (1).
3. Install right pivot bushing (4) through the two-piece
bushing (3).
4. Install washer (2) and nut (1). Hold pivot bushing (4)
in vise and torque nut (1) to 120 ft. lbs. (163 Nm).
5. Install left pivot bushing (7).
NOTE: There are stop plates attached to the inside
of the frame to prevent the pivot bushings from turning
when the pivot bolts are tightened. The flats of the
pivot bushings must be oriented correctly to align with
the frame plate, or the pivot bolt holes will not be
aligned. The top flat on the nut should be
approximately parallel with top surface of the
swingarm.
6. Install swingarm assembly in frame.
7. Apply Loctitet 262 (PN 2871951) to threads of
pivot bolts (5 and 8). Install and tighten pivot bolts
slowly until the flats of the pivot bushings (4) and (7)
engage the stop plate on the frame.
8. Torque pivot bolts (5) and (8) to 150 ft. lbs. (207
Nm).
9. Install lower rear shock bolt. Torque to 25 ft. lbs. (35
Nm). Assemble rear axle, brake caliper, caliper
mount, hubs, wheels and chain. (Refer to Chapter 7)

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English