A-Arm Replacement - Polaris Trail Boss 330 2003 Service Manual

BODY / STEERING / SUSPENSION

A-ARM REPLACEMENT

Bolt 30 ft. lbs.
(41 Nm)
Washer
1. Elevate and safely support vehicle with weight
removed from front wheel(s).
2. Remove cotter pin from ball joint stud at wheel
end of A-arm and loosen nut until it is flush with
end of stud.
3. Using a soft face hammer, tap nut to loosen A-arm
from bolt. Remove nut and A-arm from hub strut
assembly.
4. Loosen two bolts on A-arm tube by alternating
each about 1/3 of the way until A-arm can be
removed.
WARNING
The locking features on the existing bolts were
destroyed during removal. DO NOT reuse old bolts.
Serious injury or death could result if fasteners come
loose during operation.
5. Examine A-arm shaft. Replace if worn. Discard
hardware.
6. Insert A-arm shaft into new A-arm. NOTE: On
AWD models, install CV joint shields. See Ill.
7. Install new A-arm assembly onto vehicle frame.
Torque new bolts to 30 ft. lbs. (41 Nm).
5.6
Vehicle Frame
A-Arm Tube
A-Arm Shaft
Bolt 30 ft. lbs.
(41 Nm)
25 ft. lbs Nut
(35 Nm).
Cotter Pin
CV Joint Shield
(AWD Models)
8. Attach A-arm to hub strut assembly. Tighten ball
joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes
are not aligned, tighten nut slightly to align. Install
a new cotter pin with open ends toward rear of
machine. Bend both ends in opposite directions
around nut.
9. Locate grease fitting in center of A-arm tube and
pump A-arm full of grease.
WARNING
Upon A-arm installation completion, test vehicle at
low speeds before putting into regular service.
A-arm Attaching Bolt Torque:
30 ft. lbs. (41 Nm)
Ball Joint Stud Nut Torque:
25 ft. lbs. (35 Nm)
Apply Loctitet 242 to
the bolt threads.
Ball Joint
Stud
8 ft. lbs.
(11 Nm)