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2024+ RZR XP Front Upper A-Arm Removal and Installation

Required Tools and Supplies

  • 15mm Socket
  • 15mm Wrench
  • Ratchet
  • Torque Wrench
  • Breaker Bar
  • Wire Hanger, Rope or Retention Strap
  • Upper A-Arm Nuts
  • Lower Shock Mount Nut
  • Upper Ball Joint Nut
  • Safety Glasses
  • Nitrile Gloves
  • Shop Towels

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris RZR.

To remove and install the front upper A-Arm on your RZR XP, follow these steps:

1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key. 

2. Remove the wheel from the vehicle. 

  • Loosen the lug nuts while the vehicle is on the ground with a 19mm socket with breaker bar, but do not remove them at this time.
  • Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques. 
  • Once safely elevated, remove and retain the lug nuts and set aside. 
  • Remove the wheel and set aside. 

3. Remove and discard the brake caliper fasteners and remove the brake caliper from the brake disc with a 15mm socket.

4. Remove the lower shock mounting fastener from the A-arm with a 15mm socket and 15mm wrench. Tip: Use a strap to support shock mount to keep out of your way.

5. Remove the nut retaining the front stabilizer bar link to the upper control arm with a 15mm socket.

6. Remove the upper ball joint fastener from the bearing carrier with a 15mm socket and 15mm wrench.

7. Lift upward on the upper A-arm to loosen the upper ball joint end. Note: You may have to use a soft face hammer to help loosen.

8. Completely remove the ball joint end from the bearing carrier.

9. Support the carrier with a wire hanger, rope or retention strap to avoid damaging the brake line.

10. For easier access to the upper A-arm bolt, remove the front bumper with a T40 TORX® and panel clip remover. Note: If equipped, the winch will need to be loosened to remove upper A-arm bolt.

11. Remove the upper A-arm with a 15mm socket and 15mm wrench, and discard the nuts.

12. Pivot the A-arm out from the vehicle.

13. If reusing the A-arm, thoroughly clean with a shop rag before reinstalling.

14. Inspect the ball joint and ball joint boot for wear, tears or damage and replace if necessary.

15. Inspect the A-arm bushings and pivot tubes for damage or wear and replace as necessary. When reinstalling the bushings, ensure the tapered side is facing out. Also ensure the control arm bushings are fully installed inside the arm before installing the pivot seals.

16. Reinstall the A-arm and align with the mounting holes in the frame. 

17. Reinstall the previously removed fasteners from the outside and secure with new nuts. 

18. Insert the upper ball joint end into the bearing carrier.

19. Insert the tie rod end into the bearing carrier and secure with a new nut.

20. Inspect the stabilizer bar link and shock bushings for wear or damage and replace if necessary.

21. Reinstall the stabilizer bar link fastener from the rear and secure with a new nut.

22. Reinstall the shock fastener from the front and secure with a new nut.

23. 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.

24. Install new brake caliper fasteners, and torque to 30 ft-lbs (41 Nm).

25. Re-route brake lines and install news rivets.

26. Torque the upper A-arm fasteners to 52 ft-lbs (70 Nm).

27. Torque the ball joint nut to 41 ft-lbs (55 Nm).

28. Torque the stabilizer bar link nut to 41 ft-lbs (55 Nm).

29. Torque the shock mount nut to 41 ft-lbs (55 Nm).

30. Install the wheel on the vehicle and tighten the lug nuts until fully seated.

31. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing. 

32. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern. 

33. Finally, 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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© 2023 Polaris Industries Inc.

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