Front A-Arms; Removal / Replacement - Polaris 2011 RANGER RZR Service Manual

FRONT A-ARMS

Removal / Replacement

The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle.
1. Elevate and safely support the front of the vehicle and
remove the front wheel.
2. Remove lower shock fastener (A) from the upper A-arm.
3. Remove upper ball joint pinch bolt (B) from bearing carrier.
4. Using a soft face hammer, tap on bearing carrier to loosen
the upper A-arm ball joint end while lifting upward on the
upper A-arm. Completely remove the ball joint end from
the bearing carrier.
5. Remove the front bumper to allow A-arm bolt removal.
6. Loosen and remove the upper A-arm through-bolt fastener
(C) and remove the upper A-arm from the vehicle.
7. Examine A-arm bushings and pivot tube (see "Exploded
View"). Replace if worn. Discard hardware.
WARNING
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation.
8. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tube.
9. Install new ball joint into A-arm. Refer to "Ball Joint
Replacement" section.
10. Insert new A-arm bushings and pivot tube into new A-arm.
11. Install new upper A-arm assembly onto vehicle frame.
Torque new bolt to specification.
12. Insert upper A-arm ball joint end into the bearing carrier.
Install upper ball joint pinch bolt (B) into the bearing carrier
and torque bolt to specification.
13. Attach shock to A-arm with spacer (D) and fastener (A),
(see "FRONT STABILIZER BAR - Exploded View").
Torque lower shock bolt to specification.
14. Remove lower ball joint pinch bolt (E) from bearing carrier.
15. Using a soft face hammer, tap on bearing carrier to loosen
the lower A-arm ball joint end while pushing downward on
the lower A-arm. Completely remove the ball joint end
from the bearing carrier.
16. Loosen and remove the lower A-arm through-bolt fastener
(F) and remove the lower A-arm from the vehicle.
17. Examine A-arm bushings and pivot tube (see "Exploded
View"). Replace if worn. Discard hardware.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION
18. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tube.
19. Install new ball joint into A-arm. Refer to "Ball Joint
Replacement" section.
20. Insert new A-arm bushings and pivot tube into new A-arm.
21. Install new lower A-arm assembly onto vehicle frame.
Torque new bolt to specification.
22. Insert lower A-arm ball joint end into the bearing carrier.
Install lower ball joint pinch bolt (E) into the bearing carrier
and torque bolt to specification.
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
Front Upper / Lower A-arm Bolts:
RZR: 37 ft. lbs. (50 Nm)
RZR S / RZR 4: 40 ft. lbs. (54 Nm)
Front Ball Joint Pinch Bolts: 23 ft. lbs. (31 Nm)
Shock Mounting Bolts:
RZR: 30 ft. lbs. (41 Nm)
RZR S / RZR 4: 37 ft. lbs. (50 Nm)
A
D
B
E
= T
= T
= T
C
F
Standard RZR Shown
5.31
5