RZR Chassis Legs Installation Directions

Published on December th, 2008

Polaris RZR Chassis Legs replace the rear lower A arm bolts with one long grade 8 bolt, and uses a machined spacer to brace the 2 lower A arm mounts together. For those who can break a battleship with a rubber hammer, this kit helps add to the strength of the rear of your chassis and suspension. Utilized with our Chassis Bones and Frame Plates you can transform your stock RZR chassis into a bulletproof platform. Bolts and machined spacer come in a Black Oxide finish.

Name: Polaris RZR Chassis Legs (Lower A-Arm Support)

Part No: ATR-CHA-1003

Parts Included In Kit:

2 10mm x 286mm Long, 10.9 Grade Bolt

2 Machined Spacer, Black Oxide Coated

4 10mm Washers

2 10mm Lock Nuts

2 Shim Washers, .032” Thick

Tools Required For Installation:

Basic Hand Tools

Grease

Floor Jack (nice to have but not necessary)

Installation Procedure:

Step 1:

Please verify that all the parts are present. The included parts are listed in the above description. Please read the directions completely before proceeding with the installation. If you have any questions, feel free to give us a call or email.

Step 2:

If you have the ability, raise the rear of the RZR so the tires are off the ground with a proper lifting device. This step is not necessary but will make it easier to access the rear lower A-arm bolts. If the vehicle is raised, please take the proper safety precautions.

Step 3:

Locate the 2 lower rear A-arm bolts that hold the A-arm to the frame tabs. Remove these bolts from their respective locations. You may have to tap them out depending on how snug they are. To gain access, you may want to lower the rear section of your skid plate down. This will assist in removal and installation. Also you may need to remove other parts depending on what you have installed on your RZR. You will be placing the machined spacer between the two most inner tabs and under the CV assembly. Take note of the clearance offset machined into the spacer, as this will center under the CV assembly on the differential side.

Step 4:

Proceed to place a washer under the head of the ATR 10.9 bolt. Lubricate the length of the bolt shank with grease which will aid in sliding the bolt thru the frame tabs and A-arm bearings. As you push the bolt thru the first a-arm mount proceed to line up the machined spacer. Follow thru and push the bolt thru the spacer and into the next A-arm mount. It may take a little persistence to get it thru but it does line itself up and will push thru. If you get it started into the second mount, you can tap it thru with a soft face or dead blow hammer if necessary. You will notice there may be a small amount of play between the two inner tabs with the spacer installed. Once you start the bolt thru the rear tab and A-arm, line up the spacer thru hole with the bolt. As the bolt proceeds thru the spacer, check for clearance and see if you can insert the .032” shim washer between the spacer and inner tab. If you are able to insert it, use it. Do not force the spacer in if it does not easily fit. As you push the bolt thru the last A-arm mount and outermost tab, start the nut on the end of the bolt before it is fully thru. This is necessary due to the bolt clearance being tight against the engine case.

Step 5:

You can use the factory nut on the end of the bolt if you wish or use the ones we include. The included nuts are slightly smaller in height which will help if you are using this kit along with our ATR-CHA-1001 Chassis Reinforcement Plate Kit. The new nuts will compensate for the material thickness of the chassis plate and still function correctly as a locking nut. Tighten the bolt to 40 ft. lbs. . Check the spacer and make sure it does not spin. If it spins continue to tighten until it stops. It should not take much at all to snug it up as it only has to pull down less than .030” if you did not insert the washer.

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