Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 134 / 289

GENERAL INFORMATION
5.8
A-ARM REPLACEMENT
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.
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).
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.
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.
Vehicle Frame
Grease Fitting
Nut
Cotter Pin
Ball Joint
Stud
CV Joint Shield
(AWD Models)
A-Arm Tube
A-Arm Shaft
Bolt 30 ft. lbs.
(41 Nm)
Washer
25 ft. lbs
(35 Nm).
8 ft. lbs.
(11 Nm)
Bolt 30 ft. lbs.
(41 Nm)
242
242
Apply Loctite
t
242 to
the bolt threads.
A-arm Attaching Bolt Torque:
30 ft. lbs. (41 Nm)
Ball Joint Stud Nut Torque:
25 ft. lbs. (35 Nm)