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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
8/25/2023

2021+ RZR Trail and Trail S Front Upper A-Arm Removal and Installation

Required Tools and Supplies

  • 15mm Socket
  • 19mm Socket
  • T25 TORX® Socket
  • 15mm Wrench
  • Ratchet
  • Torque Wrench
  • Soft-Face Hammer
  • Breaker Bar
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

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 Trail or Trail S, follow these steps:

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

2. Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground, but do not remove them at this time.

3. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.

4. Once safely elevated, remove the lug nuts and set aside. 

5. Remove the wheel and set aside.

6. Remove and retain the brake line fastener with a T25 TORX® socket.

7. Counter hold and remove the lower shock fastener and nut from the upper control arm with a 15mm socket and wrench, and discard the nut.

8. Remove and retain the stabilizer bar linkage bushing assembly with a 15mm socket.

9. Remove the upper ball joint pinch bolt and nut from the bearing carrier with a 15mm socket and wrench. Discard the nut.

10. Using a soft-face hammer, turn the bearing carrier and tap on the carrier to loosen the upper A-arm ball joint while lifting upward on the upper control arm. 

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

12. Counter-hold and remove the upper A-arm through-bolt fasteners, washers and nuts with a 15mm socket and wrench. Discard the nuts. Note: Use care not to damage the tie rod boot when removing these fasteners.

13. Move the shock out of the way and lift the upper A-arm up and out over sway bar link. 

14. Remove the lower sway bar linkage bushing and inspect the linkage bushings for wear or damage and replace if necessary.

15. Reinstall or replace the lower sway bar link bushing.

16. Inspect the shock bushings for any wear or damage and ensure they are fully seated.

17. Inspect the A-arm bushings and pivot tube for damage and wear and replace as necessary.

18. If reusing the A-arm, inspect the ball joint and ball joint boot for wear, tears or damage and replace if necessary.

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

20. If replacing the A-arm, new A-arm bushings, pivot tubes and a ball joint will need to be installed into the arm.

21. Lift the shock up and position the A-arm under the brake line.

22. Align the A-arm with the mounting holes on the chassis and lower the A-arm while inserting the sway bar link through the mounting hole. 

23. Reinstall the retained fasteners and washers through the front of the chassis and secure with new nuts. Note: Use care not to damage the tie rod boot when installing these fasteners.

24. Insert the A-arm ball joint end into the bearing carrier and secure with the retained pinch bolt and a new nut.

25. Reinstall the upper bushing into the sway bar link. 

26. Align the shock with the mounting holes on the A-arm and reinstall the retained fastener and secure with a new nut.

27. Counter hold the shock fastener, and torque the fastener to 42 ft-lbs (57 Nm).

28. Counter hold the Upper A-Arm mounting fasteners, and torque to 42 ft-lbs (57 Nm).

29. Torque the pinch bolt to 42 ft-lbs (57 Nm).

30. Torque the linkage bushing to 40 ft-lbs (54 Nm).

31. Reinstall the retained brake line fastener, and torque the fastener to 35 in-lbs (4 Nm).

32. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.

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

34. Once lowered, torque the lug nuts to specification in a crisscross pattern: steel wheels to 60 ft-lbs (81 Nm) and aluminum wheels to 120 ft-lbs (163 Nm).

35. 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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