High Lifter Lift Kit for Yamaha Big Bear 400 2x4, 4x4 (00-06) - Manual (Page 2)

Front Lift
1) Place jack under center of ATV front end and lift until front wheels clear the ground. Be careful to
support ATV properly so that it is securely supported but so that A-arms and shocks can droop to full
extension.
2) Remove front wheels, unbolt bottom shock mounting bolt, and remove.
3) Slide bottom of lift bracket “A” over A-arm shock mount and place spacer “E” between the shock
mount ears, then place a washer on the head of the new 10x55mm bolt, and insert it through the
bottom of spacer “E”, bracket “A”, spacer “E”, and the bottom shock mount. Place a washer and nut
on the end of the bolt to hold the bolt in place.
4) Slide bottom of shock into top of lift bracket “A”. Place 3 washers between the bottom of the A-arm
shock mounting bracket and the inside of lift bracket “A” (on the front side). Placing a washer on the
head of the bolt, insert a new 10x65mm bolt through the top bracket hole, shock, and spacer (from the
back side).
5) Place the short bend end of bracket “B”, on the front side and now on the bolt protruding from the top
of bracket “A”. Place a washer and nut on the end of the bolt to hold the bolt in place.
6) Place bracket “C” on the front and rear of the front side of the A-arm. Place a washer on the head of a
8x55mm bolt and place the bolt through the top bolt holes of brackets “C”, and then place the longer
end of bracket “B” on the top bolt protruding from the front of bracket “C”. Place a washer and nut on
the end of the bolt to hold the bolt and brackets “C” in place.
7) Place a washer on the head of a 10x55mm bolt and place the bolt through the bottom bolt holes of
brackets “C”. Place a washer and nut on the end of the bolt to hold the bolt in place.
8) Repeat the procedure for the other side.
9) Tighten all bolts to manufacturer’s torque specifications.
10) Install the wheels, torque wheel lug nuts to manufacturer’s specifications, lower and remove jack.
Check for clearance problems or misalignment.
Note: On some models, the guard protecting the CV boots will rub the A-arm during full suspension
travel when the wheels are turned. In these cases, approximately ¼” of the bottom edge of the factory
stick guard must be ground off.
Rear Lift
1) Place jack under ATV at the rear of the bottom skid plate (not the differential) and lift until the weight
is off of the suspension. Be careful to secure the ATV properly so as not to fall off the jack.
1) Disconnect the bottom of the shock and remove the pin.
2) After removing the shock, jack the ATV up 1”-2” further.
3) Insert a new 7/16” bolt through bottom of bracket “F”, the shock mount, spacer “I”, and the bottom of
bracket “G”. Then place a 7/16” thin nut on the end of the bolt to hold the brackets and bolt in place.
(Notice that bracket “F” is slightly thicker than bracket “G” on the end. Bracket “G” goes closest to
the differential.)
4) Install the remaining 7/16mm bolt through the top hole of the lift brackets and shock. (Bracket “H”
should go between the inside of bracket “G” and the left side of the bottom shock eyelet.
5) Install lift bracket “H” on the top of the differential housing.
6) Tighten all bolts to manufacturer’s torque specifications.
7) Install the wheels, torque wheel lug nuts to manufacturer’s specifications, lower and remove jack.
Check for clearance problems or misalignment.