High Lifter Lift Kit for Polaris Sportsman 500 - 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 secure, but so that the A-arms and shocks can drop about 2”.
Warning: DO NOT let the A-arms drop to full extension. If you allow the A-arms to drop to full
extension, the axle will possibly come out of the hub. If this happens, you will spend two more hours
fixing this. For those of you that got ahead of yourself and are already facing this dilemma, don’t
panic. Get a Polaris repair manual or have your local Polaris dealer correct this problem.
2) Remove front wheels and boot guards.
3) Using a spring compressor, compress the front struts. Take the top nut off, loosen the bottom two
bolts and slide the strut out. Tip: (When sliding the strut out, be sure it is completely collapsed. This
will make it easier to get out.) For the Novice: When you first start to pull the strut out it will want to
extend. Once several inches of the bottom shaft are exposed, you can hold the bottom and push the top
back down. You may have to do this several times in order to get the strut out of the socket.
4) Drop bracket “A” into the bottom of the strut socket and place bracket “B” on the top lip.
5) Place the factory washer over bracket “B” and slide the strut back into the socket. You may need to
use a screwdriver between the springs to push the bottom of the strut down into the socket.
(Note: Make sure the bottom of the strut is resting on the top of bracket “A”. You can feel bracket
“A” from underneath, to verify it’s touching the bottom of the strut. DO NOT put your finger up into
the hole.)
6) Tighten the bottom two bolts and reinstall the top nut on the top of the strut. (Be sure to reattach the
brake line to the top bolt if you took it off.)
7) After all bolts have been tightened, loosen and remove the spring compressor.
8) Repeat this process on the other side.
9) Install the wheels, torque wheel lug nuts to manufacturer’s specifications, lower and remove jack.
Check for clearance problems or misalignment.
Rear Lift
1) Place jack under ATV at the rear of the bottom skid plate and lift until the weight is off the
suspension. Be careful to secure the ATV properly so as not to fall off the jack.
2) Remove both rear shocks and wheels. (The lift can be installed with the bottom of the left shock on,
but this can make it more difficult to align the lift bracket.)
3) After removing the shocks, jack the ATV up an additional 1”-2”.
4) Remove the two spacers to the torsion bar.
5) Insert one of the new bolts through bracket “C”, the top shock mount and the bracket “D” (spacer).
(See diagram). (Place 2 washers on one side of the shock and 1 on the other.)
Note: It is generally easier to install bracket “C” and the washers on the top of the shock before
attaching the bracket to the shock mount on the right side because of the exhaust system.
6) Install the bottom of bracket “F” on the outside bolt of bracket “C” (bracket on top of shock), and
attach the top of bracket “F” to the rear utility rack mounting bracket. (See Diagram and *Note).
7) Install bracket “E” on the torsion bar and axle using the factory bolts. This bracket is just like the
factory bracket except it is slightly larger.
8) Repeat this process on the other side.