High Lifter Lift Kit for Polaris Sportsman 400_500 (03-06) - Manual (Page 3)

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.