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.
PartShark.com
877-999-5686
Summary of Contents for 2009 Sportsman XP 850
Page 10: ...NOTES GENERAL INFORMATION 1 10 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 44: ...NOTES MAINTENANCE 2 34 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 148: ...5 56 ENGINE Balance Shaft Timing P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 154: ...NOTES ENGINE 5 62 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 202: ...NOTES CLUTCHING PVT 7 30 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 256: ...NOTES BODY FRAME 9 10 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 323: ...12 31 ELECTRICAL 12 Instrument Cluster Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 327: ...12 35 ELECTRICAL 12 Battery Charging Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 329: ...12 37 ELECTRICAL 12 Constant Power Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 335: ...12 43 ELECTRICAL 12 Engine Start Command Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 338: ...12 46 ELECTRICAL AWD ADC Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 341: ...12 49 ELECTRICAL 12 Radiator Fan Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 343: ...12 51 ELECTRICAL 12 Gear Selector Switch Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 356: ...WD 20 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL EFI P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 358: ...WD 24 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL EPS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 367: ...WD 5 WIRE DIAGRAM 2009 SPORTSMAN XP 850 AWD ADC P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 374: ...WD 19 WIRE DIAGRAM 2009 SPORTSMAN XP 850 EFI P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...
Page 376: ...WD 23 WIRE DIAGRAM 2009 SPORTSMAN XP 850 EPS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...