Polaris 2009 Sportsman XP 850 User Manual

10.13
STEERING / SUSPENSION
10
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 the lower shock fastener from the upper A-arm.
3. Remove the upper ball joint pinch bolt from the front
bearing carrier (see Figure 10-2).
4. Remove the brake line retainer from the upper A-arm.
5. Using a soft face hammer, tap on bearing carrier to loosen
the upper ball joint end while lifting upward on the upper
A-arm. Completely remove the ball joint end from the
bearing carrier.
6. Remove the upper A-arm through-bolt fasteners and
remove the A-arm from the vehicle (see “Exploded View”).
7. Examine A-arm bushings and pivot shafts (see “Exploded
View”). Replace if worn and discard the hardware.
8. If not replacing the A-arm, thoroughly clean the A-arm and
pivot shafts.
9. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
10. Insert new bushings and pivot shafts into the new A-arm.
11. Install new upper A-arm assembly onto vehicle frame.
Torque new bolts to 40 ft. lbs. (54 Nm).
12. Insert upper A-arm ball joint end into the bearing carrier.
Install the upper ball joint pinch bolt into the bearing carrier
and torque bolt to 21 ft. lbs. (28 Nm).
13. Attach shock to A-arm with new fastener. Torque lower
shock bolt to 37 ft. lbs. (50 Nm).
14. Remove the lower ball joint pinch bolt from the front
bearing carrier (see Figure 10-2).
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. Remove the lower A-arm through-bolt fasteners and
remove the lower A-arm from the vehicle.
17. Examine A-arm bushings and pivot shafts (see “Exploded
View”). Replace if worn and discard the hardware.
18. If not replacing the A-arm, thoroughly clean the A-arm and
pivot shafts.
19. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
20. Insert new bushings and pivot shafts into the new A-arm.
21. Install new lower A-arm assembly onto vehicle frame.
Torque new bolts to 40 ft. lbs. (54 Nm).
22. Insert lower A-arm ball joint end into the bearing carrier.
Install the lower ball joint pinch bolt into the bearing carrier
and torque bolt to 21 ft. lbs. (28 Nm).
23. Grease all (4) A-arm grease fittings after reassembly.
Figure 10-2
Front
Bearing Carrier
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.
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
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Polaris 2009 Sportsman XP 850 Specifications

General

Brand	Polaris
Model	2009 Sportsman XP 850
Category	Offroad Vehicle
Language	English