Yamaha YXZ1000R Ball Joints Replacement

Finding a bit of play in the suspension of a Yamaha UTV during the pre-ride inspection is an indication the ball joints have worn. Replacing both the upper and lower ball joints at the same time is recommended because when one wears out, the other will soon follow. 

Plus, if you’re going to the trouble of dismantling your machine, might as well get them both done.  Watch the video above and follow the steps below to replace the upper and lower ball joints on a Yamaha YXZ1000R. 

Tools and Parts – Yamaha YXZ1000R Ball Joints Replacement

• Ratchet and extensions
• 4mm, 10mm, 14mm, 17mm, 19mm, 22mm, 32mm sockets
• Hammer
• Torque wrench

• Snap ring pliers
• Ball joint (x2)
• Circlip (x2)
• Cotter pin (x2)

Removing Yamaha YXZ1000R Upper & Lower Ball Joints

Step 1. Raise the vehicle and support it on heavy stands positioned under the frame, then remove the front wheels.

NOTE: Don’t work on your side-by-side or any other vehicle using only a jack. Always make sure the vehicle is safely supported on axle stands.

Step 2. Remove the 32mm axle nut and washer.

Step 3. Remove the two 14mm brake caliper mounting bolts and slide the brake caliper assembly off the rotor. Unfasten the brake hose bracket (10mm bolt) from the lower A-arm, and use a zip-tie to hold the caliper assembly out of the way.

Step 4. Slide the wheel hub out from the steering knuckle assembly.

Step 5. Remove the cotter pin from the 19mm castle nut that holds the steering joint, then remove the castle nut and washer.

Step 6. Remove the steering joint from the steering knuckle assembly. Use a dead-blow hammer and/or a soft blow hammer to knock it out if necessary.

Step 7. Remove the shock absorber mounting bolt (14mm bolt, 17mm nut) and slide the shock absorber from the upper A-arm. Use a bungee cord to hold the shock absorber out of the way.

Watch the clip below to see the steering knuckle disassembly segment of our Yamaha YXZ1000R ball joints video.

Step 8. Remove the cotter pin from the 22mm castle nut holding the lower ball joint, followed by the castle nut itself.

Step 9. Thread a disposable 22mm nut onto the lower ball joint to protect it and knock the ball joint free from the lower A-arm with a hammer. Using a disposable nut prevents the castle nut from being damaged.

Step 10. Slide the CV joint out from the steering knuckle assembly.

PRO TIP: At this point you can remove the driveshaft to give yourself more room to work with. To remove the driveshaft, simply pull it out from the transmission housing.

Step 11. Remove the cotter pin from the 22mm castle nut holding the upper ball joint, followed by the castle nut itself.

Step 12. Remove the circlip from the top of the upper ball joint with a pair of snap ring pliers, then knock the ball joint down and out of the A-arm with a hammer.

Step 13. Remove the three 4mm bolts and the wheel guard from the steering knuckle.

Step 14. Remove the circlip from the lower ball joint, then hold the steering knuckle in a vice and use a hammer to knock out the upper and lower ball joints from the steering knuckle.

Watch the clip below to see the ball joint removal segment of our Yamaha YXZ1000R ball joints video.

PRO TIP: You’ll need to use a metal collar with an internal diameter that’s wide enough to fit over the new ball joint’s boot, but sits securely on the outer edge of the ball joint itself. We found a 54mm driver collar was a good fit, but you can use a section of metal pipe or something similar.

Installing Yamaha YXZ1000R Lower Ball Joint

Step 15. Drive the new lower ball joint into the steering knuckle using the collar and a hammer until it bottoms out.

Step 16. Install a new circlip over the head of the ball joint to lock it in place.

Watch the clip below to see the lower ball joint install segment of our Yamaha YXZ1000R ball joints video.

Installing Yamaha YXZ1000R Upper Ball Joint

Step 17. Unfasten the brake hose bracket (10mm bolt) from the upper A-arm.

Step 18. Remove the upper A-arm mounting bolts (14mm nut, 17mm bolt), followed by the A-arm itself.

Step 19. Drive the new upper ball joint into the upper A-arm using the collar and a hammer until it bottoms out.

Step 20. Install a new circlip over the head of the ball joint to lock it in place.

Watch the clip below to see the upper ball joint installation segment of our Yamaha YXZ1000R ball joints video.

Reassembling Yamaha YXZ1000R Suspension & Steering

Step 21. Reinstall the upper A-arm and torque the mounting bolts to 65 foot-pounds. 

NOTE: Make sure you use the torque wrench on the nut and not the bolt.

Step 22. Slide the upper ball joint into the steering knuckle, then reinstall the 22mm castle nut and torque it to 51 foot-pounds. Install a new cotter pin.

Step 23. Refasten the brake hose bracket (10mm bolt) to the upper A-arm.

PRO TIP: If you removed the driveshaft earlier, reinstall it now by tapping it back into the transmission housing.

Step 24. Grease the stub axle and axle splines, and slide them back through the steering knuckle.

Step 25. Slide the lower ball joint into the lower A-arm, then reinstall the 22mm castle nut and torque it to 51 foot-pounds. Install a new cotter pin.

Step 26. Reattach the shock absorber to the upper A-arm and reinstall the mounting bolt (14mm bolt, 17mm nut).

Step 27. Reinstall the steering joint through the steering knuckle assembly, and torque the 19mm castle and washer to 29 foot-pounds. Reinstall the cotter pin.

Step 28. Reinstall the wheel guard to the steering knuckle (three 4mm bolts).

Step 29. Grease the inside of the wheel hub and reinstall it onto the steering knuckle.

Step 30. Reinstall the axle bolt and washer and tighten them as much as possible.

Step 31. Refasten the brake hose bracket (10mm bolt) to the lower A-arm, then reinstall the brake caliper assembly and torque the 14mm mounting bolts to 35 foot-pounds.

Step 32. Reinstall the front wheel, then lower the vehicle to the ground, torque the 32mm axle nut to 268 foot-pounds and stake it in place.

Watch the clip below to see the reassembly segment of our Yamaha YXZ1000R ball joints video.