Service Manual

9.2
BODY / FRAME
TORQUE SPECIFICATIONS
DECAL REPLACEMENT
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be “flame treated”
prior to installing a decal to ensure good adhesion. A bonus of
the flame treating procedure is it can be used to reduce or
eliminate the whitish stress marks that are sometimes left after
a fender or cab is bent, flexed, or damaged.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the
surface appears slightly glossy. This should occur after just
a few seconds of flame treating. Do not hold the torch too
close to the surface (2-3 inches from the flame tip is
recommended). Keep the torch moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the decal
surface to eliminate any air bubbles during the application.
SPECIAL TOOLS
Plastic Push Rivet Removal
Polaris ATVs use a two piece plastic push rivet to fasten most
body components. Using the “Multi-Function Pliers” eases
removal and prevents from damaging the push rivets and body
components.
Multi-Function Pliers
Included in the tool kit, the multi-function pliers is designed to
remove the plastic push rivets used to fasten body components.
ITEM TORQUE VALUE
ft.lbs. (Nm)
Upper RH Frame Support 30 ft. lbs. (41 Nm)
Lower LH Frame Support 30 ft. lbs. (41 Nm)
WARNING
The following procedure involves the use of an
open flame. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials. Be sure the area to be
flame treated is clean and free of gasoline
or flammable residue.
WARNING
Do not flame treat components that are installed
on the vehicle. Remove the component from the
vehicle before flame treating.
Pliers
Push Rivet