Polaris RZR 800 2013, Manual

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5.34
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
4. Be sure the front wheels are pointing straight ahead
and install the steering wheel and retaining nut.
Torque the nut to specification and reinstall the
plastic wheel cover.
Steering Wheel Nut:
28 ft-lbs (38 Nm)
5. Install a new upper steering shaft pinch bolt and nut.
Torque pinch bolt to specification.
Upper Steering Shaft Pinch Bolt:
15 ft-lbs (20 Nm)
6. Reconnect both electrical harnesses onto the power
steering unit. Be sure the connectors snap into
place.
7. Reinstall the black plastic cover over the power
steering unit and install the (2) Torx-head fasteners.
8. Turn the key switch on and test EPS operation.
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 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 upper A-arm from 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 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) or washer (G)
and fastener (A). 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.
BODY / STEERING / SUSPENSION