High Lifter Lift Kit for Polaris Magnum 500 (99-03) - Manual (Page 2)

spring compressors for around $25 for a very basic model. If you do not have experience working with
this type of tool, we strongly recommend that an authorized factory dealer install this lift kit.
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”.
2) Remove front wheels and boot guards.
Warning: In the next step DO NOT let the A-arms drop to full extension. You can use a jack stand to limit
downward travel. 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.
3) Using a spring compressor, compress the front springs. Take the top nut off, loosen the bottom two bolts on
the strut housing and slide the strut cartridge and spring 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 of the strut
housing.
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 on the housing 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.