Installation Manual X-TREME Control Arm Kit · Unscrew the bolt located on the lower control arm of...

Installation Manual X-TREME 36 Control Arm Kit

Installation Manual

X-TREME Control Arm Kit Product Number: X-TREME 36

487100007


Table of Contents SAFETY INSTRUCTIONS ...............................................................................................................................................1

PARTS AND TOOLS ......................................................................................................................................................1

1. Parts List .........................................................................................................................................................1

2. Required tools ................................................................................................................................................1

INSTALLATION INSTRUCTIONS ...................................................................................................................................2

3. Preparation .....................................................................................................................................................2

4. Removing the shock absorber from the lower arm .......................................................................................2

5. Removing the stabilizer bar ............................................................................................................................3

6. Removing the leg and ski ................................................................................................................................5

LOWER ARM ...........................................................................................................................................................6

7. Removing the OEM lower arm .......................................................................................................................6

8. Removing the OEM pivots ..............................................................................................................................7

9. Installing the lower B-PWR arm .....................................................................................................................9

UPPER ARM ......................................................................................................................................................... 10

10. Removing the upper OEM arm ................................................................................................................ 10

11. Installing the arms on the leg .................................................................................................................. 11

12. Installing the stabilizer bar ...................................................................................................................... 12

13. Installing the shock absorber on the lower arm .......................................................................................... 13

14. Verification and alignment ...................................................................................................................... 14

Appendix A .............................................................................................................................................................. 17

A. Installation and adjustment of steering rods .............................................................................................. 17


SAFETY INSTRUCTIONS

Thank you for choosing a B-PWR product, designed

by passionate riders who focus on what users really

need.

To avoid any unfortunate situations, we recommend

that you get to know how your modified vehicle

handles before using it in extreme conditions.

1. Read all the instructions carefully before installing

this product.

2. Refer to your vehicle’s manufacturer’s instructions for

the tightening torques.

3. If you do not have the tools or technical knowledge

needed to ensure proper installation, have the

product installed by an authorized dealer.

WARNING

It is essential that you follow the installation

procedures, possess general mechanical knowledge

and use appropriate tools to ensure a safe and reliable

installation of this product.

Any modifications made to your vehicle will change

how it handles. Under certain conditions, you may be

more likely to lose control of or overturn your modified

vehicle, which could result in SERIOUS INJURIES or even

DEATH. You are responsible for understanding how

your modified vehicle handles. Wear protective

equipment, including head protection, as required.

Improper use or installation of the product, or any

modifications made to adapt the product for use in a

context other than that for which it was intended, voids

the warranty and may result in SERIOUS INJURIES.

B-PWR and all its affiliated companies, as well as its

suppliers and distributors, are not responsible for any

consequences whatsoever resulting from a poor

installation or an improper use of the product.

INSTALLATION INSTRUCTIONS

This manual provides detailed instructions for

installing the product.

We recommend working on one side at a time.

COMPATIBILITY

Polaris snowmobile (2016 to 2020 editions) with an

Axys chassis.

WARNING

For safety reasons, this kit needs to be installed by a

person with general mechanical knowledge using the

proper tools.

The illustrations in this document indicate the typical

structure of the various assemblies. It is therefore

possible that they do not represent the exact form of

the parts or the manufacturing details. These

illustrations are intended to identify parts that

perform an identical or similar function. All of the illustrations show the right-side control arm. In this

document, the illustrations show a PRO RMK 2019

snowmobile with a React suspension.

During installation, always dismantle and assemble one

side at a time. Pay close attention to direction when

removing the parts.

Refer to your vehicle’s manufacturer’s instructions for the

tightening torques.

IMPORTANT

Pro-Ride chassis (2011 to 2015): Requires additional items

not included. Consult Appendix A.

Axys chassis (2016 to 2018): Installation of steering rods

(#555100007) included in the kit

Axys chassis (2019 to 2021): Installation of original vehicle

steering rods.


Page | 1

PARTS AND TOOLS

1. Parts List

Part Part Number Description Qty #1 X-Treme 36-LL-ASS-BARE-BL X-Treme lower left control arm 1 #2 X-Treme 36-LR-ASS-BARE-BL X-Treme lower right control arm 1 #3 X-treme 36-UL-ASS-BARE-BL X-Treme upper left control arm 1 #4 X-treme 36-UR-ASS-BARE-BL X-Treme upper right control arm 1 #5 234001410 M10 zinc finish flat washer 4

#6 999100023 M10 x 1.25 mm nylon insert locknuts 2

#7 207684046 M8 -1.25 x 40 mm Class 10.9 yellow zinc finish steel Hex cap bolt

2

#8 999100011 M8 1.25 x 55 mm highly resistant yellow zinc finish chrome Hex cap bolt

2

#9 233281416 M8 x 1.25 mm Class 10 yellow zinc finish steel nylon insert locknuts

2

#10 555100007 Aluminum steering rod 2

*** 2017 model and more recent: # 10 is not required

2. Required tools

• Snap-ring pliers

• 10 mm wrench

• 10 mm socket

• 13 mm wrench

• 13 mm socket

• 15 mm wrench

• 15 mm socket

• 17 mm wrench

• 17 mm socket

• Ratchet

• Nylon mallet


Page | 2

INSTALLATION INSTRUCTIONS

3. Preparation

3.2. Make sure you have enough space to work around the vehicle.

3.3. Make sure you have the required tools.

3.4. Read all the instructions carefully before installing the product.

3.5. Raise the front of the snowmobile until the skis no longer touch the ground.

CAUTION

If you are using a lift system, pay special attention to the area where you will be lifting the vehicle. There is a risk of being crushed under inappropriately positioned lifting equipment. Never place any part of your body under a vehicle that has not been properly installed and secured.

(Figure 1)

(Figure 2)

4. Removing the shock absorber from the lower arm 4.2. Unscrew the bolt located on the lower control arm of the suspension (Figure 3).


Page | 3

4.3. Remove the bolt and the cross brace that is located in the bolt hole of the shock absorber and set them

aside (Figure 4).

(Figure 3)

(Figure 4)

5. Removing the stabilizer bar 5.2. Unscrew the bolt located on the lower arm (Figures 5 and 6).

(Figure 5)

(Figure 6)


Page | 4


Page | 5

6. Removing the leg and ski

6.2. Unscrew the nut located in the middle of the leg (Figure 7).

6.3. Remove the bolt and the washers for easier access to the nut at the top (Figure 8).

6.4. Unscrew the nut at the top (Figure 9).

6.5. Remove the upper arm from the leg (Figure 10).

6.6. Pull the leg away from the upper and lower arms.

(Figure 7)

(Figure 8)

(Figure 9)

(Figure 10).


Page | 6

LOWER ARM

7. Removing the OEM lower arm

7.2. Unscrew the bolt (Figure 11) that goes through the chassis and remove the adjacent nuts (Figures 11 and

12).

7.3. Remove the three nuts that hold the lower arm in place. 7.4. Remove the lower arm.

(Figure 11)

(Figure 12)


Page | 7

8. Removing the OEM pivots

8.2. Remove the lower arm for the correct side from the B-PWR box.

8.3. Lay the B-PWR arm (Figure 13) and the OEM arm (Figure 14) on a table facing in the same direction.

Note: a B-PWR sticker indicates the front of the arm.

CAUTION

Pay attention to direction during assembly. It is important to disassemble and reassemble the parts on the B-PWR arm in an identical

manner to the OEM arm.

8.4. Hold one end of the OEM arm and using snap-ring pliers remove the snap ring that holds the pivot in place (Figure 15).

CAUTION

Be careful not to break the snap ring.

8.5. Remove the washer where the snap ring had been and remove the pivot with the washer on the other side.

Keep the washers and the pivot at hand (Figure 16).

8.6. Hold the B-PWR arm. Insert the washer and pivot assembly on one side. Place the washer on the other side

and add the snap ring. (Figure 17)

8.7. Repeat step 6 in its entirety for the other pivot.

(Figure 13)

(Figure 14)


Page | 8

(Figure 15)

(Figure 16)

(Figure 17)


Page | 9

9. Installing the lower B-PWR arm

9.2. Put the lower arm back in place (Figure 18).

9.3. Screw the nuts by hand and put the bolt back on.

ATTENTION

If the pivots have not been installed in the same direction, it will be impossible to install

them.

(Figure 18)


Page | 10

UPPER ARM

10. Removing the upper OEM arm

10.2. Unscrew the nuts (Figure 19).

10.3. Remove the four nuts holding the upper arm (Figure 20).

10.4. Remove the upper arm.

10.5. Repeat the steps carried out in sections 5, 6 and 7 for the upper arm.

(Figure 19)

(Figure 20)


Page | 11

11. Installing the arms on the leg

11.2. Insert the lower arm into the centre part of the leg (figure 21).

11.3. Insert the bolt and washers through the leg and lower arm (Figure 22).

11.4. Screw the nut onto the bolt.

11.5. Insert the upper arm (threaded rod) in the top part of the leg (Figure 23).

11.6. Using the washer (item #5) and the nut (item #6), attach the upper arm.

(Figure 21)

(Figure 22)

(Figure 23)


Page | 12

12. Installing the stabilizer bar

10.1 Insert the bolt (item #7) through the coupling (Figure 24).

10.2 Attach the lower arm coupling. It must be facing towards the shock absorber.

(Figure 24)


Page | 13

13. Installing the shock absorber on the lower arm

13.2. Insert the cross braces on the shock absorber.

13.3. Insert the shock absorber into the lower arm.

13.4. Attach the shock absorber using the bolt (item #8) and nut (item #9).

13.5. REPEAT ALL PRECEDING STEPS ON THE OTHER SIDE.

CAUTION

If you have to change the ball joints, consult APPENDIX A before continuing.

(Figure 25)

(Figure 26)


Page | 14

14. Verification and alignment

14.2. Make sure that you have tightened all bolts.

14.3. Using an elastic strap, attach the two skis (Figure 27).

14.4. There should be a light tension on the skis.

14.5. Install a straight rod, pressing along the length of the track (Figure 28).

CAUTION

Use a straight rod that is long enough to run along the track right to the ski.

14.6. Using one strap, attach one end to the tip of the handle bar and the other to the running board (Figure

29).

14.7. Repeat step 12.5 on the other side.

CAUTION

It is important to use straps of equal length and dimension to ensure the same amount of

tension is applied to both sides.

It is important to attach the straps in the same location on each side.

14.8. Identify two measurement points:

- The first point is on the handle (Figure 30).

- The second point is on the running board (Figure 31).

14.9. Measure between the two measurement points, on each side (Figure 32).

14.10. The difference between the two measurements must be within ± 1/8. This indicates that the handle

bar is straight.

14.11. Identify two measurement points on the ski:

- The front point: nut on the front of the runner (in front of the leg)

- The back point: nut on the back of the runner (behind the leg)

14.12. Measure, one side at a time, between the front point and the straight rod and the back point and the

straight rod (Figure 33).

14.13. The measurements have to be identical. If needed, adjust the ball joints according to the instructions

in Appendix A.

CAUTION

The nut in the safety guard is a left-hand thread nut.

14.14. Check the steering again to make sure it is still straight.


Page | 15

14.15. Remove the straps.

(Figure 27)

(Figure 28)

(Figure 29)

(Figure 30) +


Page | 16

(Figure 31)

(Figure 32)

(Figure 33)


Page | 17

Appendix A

A. Installation and adjustment of steering rods

A.1. Remove the protective covering for the ball joint on each side by unscrewing the (chrismastree) (Figures 35

and 36)

A.2. Unscrew the two nuts that hold the steering rod in place (Figures 37 and 38)

A.3. To install a new steering rod, remove the OEM rod and install the new one. Tighten the nuts on the ball

joints.

CAUTION

The left-hand thread on the rod is identified by two stamped lines.

A.4. To adjust the ball joints, tighten or loosen them until you have the same measurement on each side, as

indicated in section 12.12).

CAUTION

The nut in the protective covering is a left-hand thread nut.

(Figure 35)

(Figure 36)


Page | 18

(Figure 37)

(Figure 38)

Installation Manual X-TREME Control Arm Kit · Unscrew the bolt located on the lower control arm of...

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