|Required Tools and Supplies|
|10mm Socket||Torque Wrench|
|15mm Socket||Breaker Bar|
|19mm Socket||Cotter Pin|
|30mm Socket||Domed Washer|
|T25 TORX® Socket||Castle Nut|
|10mm Wrench||Outer Radius Rod Nuts|
|15mm Wrench||Bearing Carrier Nuts|
|18mm Wrench||Lower Shock Nut|
|Trailing Arm Nut||Safety Glasses|
|Shop Towels||Nitrile Gloves|
|Lower Stabilizer Bar Linkage Nut|
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 trailing arms on your RZR XP, follow these steps:
1. Park the vehicle on a flat, level surface and ensure it is PARK and remove the key.
2. Remove and discard the cotter pin from the wheel hub castle nut with pliers.
3. Loosen the castle nut with a 30mm socket.
4. Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground, but do not them remove at this time.
5. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
6. Once safely elevated, remove the lug nuts and set aside.
7. Remove the wheel and set aside.
8. Remove and retain the brake line cover fasteners and remove the cover with a 10mm socket and 10mm wrench.
9. Remove and discard the brake caliper fasteners and remove the brake caliper from the brake disc. Carefully remove the caliper from the hub. Ensure the caliper is supported with a wire hanger, rope or retention strap to avoid damaging the brake line.
10. Remove and discard the castle nut and cone washer from the wheel hub.
11. Remove the wheel hub assembly from the bearing carrier. Tip: A puller tool may be required to remove the bearing carrier.
12. Remove the bolts, washers and nuts from the upper and lower radius rods. Discard the nuts.
13. Swing the radius rod down and discard the nut. While supporting the trailing arm from underneath, remove the lower shock mounting bolt and nut. Discard the nut. Tip: Support the trailing arm with a suitable jack stand or support.
14. Remove the stabilizer bar mount bolt and nut. Discard the nut.
15. Remove the five remaining bolts that attach the rear bearing carrier to the trailing arm with a 15mm socket and 18mm socket. Discard the nuts.
16. Pull the bearing carrier away from the drive shaft and trailing arm to remove from the vehicle.
17. Remove and retain the four fasteners that secure the brake line retainers to the trailing arm with a T25 TORX® socket.
18. Remove and retain the front trailing arm bolt and remove the trailing arm. Discard the nut.
19. Inspect the trailing arm bushings and spherical bearings for wear or damage and replace if necessary.
20. If reusing the trailing arm, thoroughly clean with a shop rag before reinstalling.
21. Align the trailing arm with the mounting holes in the frame. Reinstall the retained fastener from the outside and loosely install a new nut.
22. Insert the half shaft through the bearing carrier and push the carrier against the shaft until fully seated.
23. Reinstall three retained fasteners through the bearing carrier and loosely secure with the retained washers and new nuts.
24. Torque the rear bearing carrier fasteners to 42 ft-lbs (54 Nm).
25. Insert the lower stabilizer bar linkage into the trailing arm and loosely secure with a new nut.
26. Align the shock with the mounting holes on the trailing arm.
27. Reinstall the retained lower shock fastener from the outside and loosely secure with a new nut.
28. Torque the trailing arm mounting fastener to 70 ft-lbs (95 Nm).
29. Torque the rear stabilizer bar linkage nut to 40 ft-lbs (54 Nm).
30. Torque the rear shock mounting fastener to 70 ft-lbs (95 Nm).
31. Align the radius rods with the bearing carrier and reinstall the retained fasteners from the rear of the vehicle
32. Loosely install new nuts.
33. Torque the outer radius rod mounting fasteners to 50 ft-lbs (68 Nm).
34. Align the hub assembly with the splines on the drive shaft and push the assembly against the bearing carrier until fully seated. Be sure to remove any straps or supports used.
35. Loosely install a new domed washer, dome side out, and a castle nut.
36. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads.
37. Install new brake caliper fasteners, and torque to 51 ft-lbs (70 Nm).
38. Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.
39. Reinstall the brake line cover and retained fasteners. Torque to 7 ft-lbs (10 Nm).
40. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.
41. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
42. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
43. Torque the wheel hub castle nut to 180 ft-lbs (244 Nm).
44. 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.
45. 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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