|Required Tools and Supplies|
|5mm and 6mm Allen Sockets||15mm, 18mm, 19mm, 27mm Sockets||15mm and 18mm Wrenches|
|Ratchet||Torque Wrench||Breaker Bar|
|Wire Hanger, Rope or Retention Strap||Pliers||Soft Face Hammer|
|Flathead Screwdriver||Anti-Seize||Brake Caliper Fasteners|
|Upper Ball Joint Nut||Tie Rod Nut||Cotter Pin|
|Shop Rags||Safety Glasses||Nitrile Gloves|
To learn more about tools, read the Tools and Fasteners Guide.
To remove and install the front axle on your RANGER XP Kinetic, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key.
2. Remove the center cap from the wheel.
3. Using a pin, remove and discard the cotter pin.
4. Loosen the axle nut with a 27mm socket but do not remove.
5. Using a 19mm socket and breaker bar, loosen the lug nuts while the vehicle is on the ground but do not remove at this time.
6. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
7. Once safely elevated, remove the lug nuts and set aside.
8. Remove the wheel and set aside.
9. With a 15mm socket, remove and discard the upper and lower caliper mounting fasteners.
10. Carefully remove the caliper from the hub and support it with a wire hanger, rope or retention strap to avoid damaging the brake line.
11. Remove the castle nut and cone washer and set aside.
12. Pull the wheel hub off the assembly and set aside.
13. Using a 6mm Allen socket and 18mm wrench, remove and discard the tie rod nut.
14. Lift upward on the upper A-arm while tapping on the bearing carrier with a soft face hammer to separate the tie rod end from the bearing carrier.
15. Using 15mm socket and wrench, remove the upper ball joint fastener and discard the nut.
16. Lift upward on the upper A-arm while lightly tapping on the bearing carrier with a soft face hammer to separate the upper ball joint end from the bearing carrier.
17. Pivot the assembly down to separate the axle from the bearing carrier.
18. With a quick, sharp jerk, remove the axle from the front gearcase.
19. Clean the anti-seize off the axle splines using a clean shop rag.
20. Inspect the threads and splines on the axle for nicks or burrs and replace if needed.
21. Continue by inspecting the CV boots to ensure there are no cuts, wear, or damage and replace if needed.
22. If reusing the axle, remove and discard the compression ring with a flathead screwdriver.
23. Install a new compression ring into the groove on the end of the axle and ensure it is fully seated.
24. Apply new anti-seize to the inboard splines on the axle.
25. Before installing, inspect the anti-seize on gearcase and hub assembly for dirt or debris. Clean and apply new anti-seize if necessary.
26. Align the splines on the axle with the gearcase and push in firmly on the shaft until the compression ring is fully engaged in the gearcase.
27. Lightly pull on the axle to ensure the compression ring is fully engaged.
28. Continue by inserting the axle through the bearing carrier and push the carrier in to seat the axle.
29. Lift the assembly and install the upper ball joint end into the bearing carrier.
30. Reinstall the ball joint fastener from the rear of the vehicle and secure with a new nut.
31. Insert the tie rod end into the bearing carrier and secure with a new nut.
32. Torque the ball joint fastener to 44 ft-lbs (60 Nm).
33. Torque the tie rod nut to 30 ft-lbs (40 Nm) + 90 degrees.
34. Insert the axle through the wheel hub and push the hub in until fully seated.
35. Reinstall the washer with the domed side out, and reinstall the castle nut.
36. Carefully slide the caliper assembly onto the brake disc ensuring the brake rotor is between the two pads. Before continuing ensure any items used to secure the brake caliper are removed from the wheel well.
37. Install new upper and lower caliper mounting fasteners, and torque to 27-30 ft-lbs (37-41 Nm).
38. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.
39. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
40. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
41. Torque the castle nut to 180 ft-lbs (245 Nm).
42. Insert a new cotter pin and bend around the castle nut to secure. If necessary, tighten the castle nut to align the cotter pin holes.
43. Push the dust cap onto the wheel and ensure it is fully seated.
44. Lower the vehicle completely.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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