Polaris Ranger RZR 800 - Installation

5.37
BODY / STEERING / SUSPENSION
5
6. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tubes.
7. Insert new A-arm bushings and pivot tubes into new A-arm.
Lower A-arm Removal (RZR S / RZR 4)
1. Remove the lower fastener (F) retaining the stabilizer bar
linkage to the lower A-arm.
2. Remove the fastener (G) retaining the lower portion of the
shock to the lower A-arm.
3. Remove the fastener (H) attaching the lower A-arm to the
bearing carrier (see previous illustration).
4. Remove the (2) fasteners (J) attaching the lower A-arm to
the frame and remove the lower A-arm from the vehicle
(see previous illustration).
5. Examine bushings and pivot tubes (see “Exploded View”).
Replace if worn. Discard hardware.
6. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tubes.
7. Insert new A-arm bushings and pivot tubes into new A-arm.
Installation
1. Install lower A-arm assembly onto vehicle frame. Torque
new fasteners to specification.
2. Attach lower A-arm to bearing carrier. Torque new fastener
to specification.
3. Route brake line on top of the lower A-arm and between
lower shock mounting tabs.
4. Reinstall the lower portion of the shock to the lower A-arm.
Torque shock fastener to specification.
5. Install upper A-arm assembly onto vehicle frame. Torque
new fastener to specification.
6. Attach upper A-arm to bearing carrier. Torque new fastener
to specification.
7. Install wheel and torque wheel nuts to specification.
F
G
H
J
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
= T
Rear Upper / Lower A-arm Bolts:
RZR: 33 ft. lbs. (45 Nm)
RZR S / RZR 4: 40 ft. lbs. (54 Nm)
= T
Lower Rear Bearing Carrier Bolts:
RZR: 38 ft. lbs. (52 Nm)
RZR S / RZR 4: 40 ft. lbs. (54 Nm)
= T
Shock Mounting Bolts:
RZR: 30 ft. lbs. (41 Nm)
RZR S / RZR 4: 37 ft. lbs. (50 Nm)
= T
Upper Rear Bearing Carrier Bolts:
RZR: 33 ft. lbs. (45 Nm)
RZR S / RZR 4: 40 ft. lbs. (54 Nm)
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