Front Spring Upgrades and Replacements

[BIG_T]

For changing the front spring on your Polaris Sportsman, here's a how-to.

Basic steps to installing new front springs.

1. Remove the front box by removing the 4 large screws inside and the 8 small screws which hold it to the front cab.

2. Remove the lock nut from the top of the strut. Use a 3/4" wrench to turn the thin locknut while holding the strut with a 3/8" wrench. An impact wrench also works very well.

3. With the top locknut removed, as well as the washer and plastic bushing, place a jack under the front of the frame and jack the bike up. As the bike is jacked up the struts should fall out of the top strut mount.

4. With the strut removed from the top strut mount, remove the next plastic bushing. Using a 3/4" wrench to turn the nut and a 3/8" wrench to hold the rod, remove this nut.
Note: It's very handy to have someone else there to help compress the spring while you remove the nut. The spring can be compressed easily be hand.

5. With the nut removed, remove the spring retainer/washer and remove the spring.

6. Place the new spring over the strut. Place the washer/spring retainer over the spring.

7. While pushing down on the spring (your helper comes in handy again) start threading the large nut onto the rod. If the shock is older or worn out it may drop down, so your helper may need to pull up on the rod while pushing down on the spring at the same time.

8. Once the nut is started, you can run it down to snug either with a wrench or with an impact driver. This nut doesn't need to be very tight, merely snug.

9. Place the plastic bushing with the hex cutout back in place over the nut.

10. Lower the jack while aligning the rod ends to come back through the top strut mounts.

11. Once the ATV is lowered again, replace the plastic bushing and washer, and replace the thin locknut, tightening down to about 25 ft-lbs.

12. Replace the front storage box.

[BIG_T]

For choices in front springs you have many choices. EPI and HL make decent springs but with limited color availability. Polaris has a number of choices as well which fit the front of a SPMN.

If you have a single and just want a little stiffer spring, you may be interested in going with a twin front spring, which is 7042301
The next stiffest spring is from an 05-07 MV7. This spring is 7043110. It will give you a bit more stiffness and less sag than stock, but won't affect your ride. These springs are also some of the more expensive.
Next stiffest is the Ranger front spring. If you have a lot of weight on the front (stereo, winch, brushguard, etc) then you may want to go with these. The number is 7043094.
One advantage to the Ranger fronts is they come in 4 colors, red, orange, black and silver. Ranger springs will pretty much keep your front suspension at full rebound but will make your ride a bit stiffer.

The Ranger spring color codes are:
Black: 7043094-067
Silver: 7043094-385
Red: 7043094-293
Orange: 7043094-446

If you just want black ranger springs you may be able to purchase them cheaper under part number 2876758 which are sold as Polaris HD springs.

There are stiffer springs than the Ranger springs, but I don't recommend them as they make your ride very stiff and don't really give you any advantage unless you are carrying an excessive amount of weight on the front end.

[Riblet]

Nice addition to the forum Tim. This section should come in pretty handy.

[x2rider]

For choices in front springs you have many choices. EPI and HL make decent springs but with limited color availability. Polaris has a number of choices as well which fit the front of a SPMN.

If you have a single and just want a little stiffer spring, you may be interested in going with a twin front spring, which is 7042301
The next stiffest spring is from an 05-07 MV7. This spring is 7043110. It will give you a bit more stiffness and less sag than stock, but won't affect your ride. These springs are also some of the more expensive.
Next stiffest is the Ranger front spring. If you have a lot of weight on the front (stereo, winch, brushguard, etc) then you may want to go with these. The number is 7043094.
One advantage to the Ranger fronts is they come in 4 colors, red, orange, black and silver. Ranger springs will pretty much keep your front suspension at full rebound but will make your ride a bit stiffer.

The Ranger spring color codes are:
Black: 7043094-067
Silver: 7043094-385
Red: 7043094-293
Orange: 7043094-446

There are stiffer springs than the Ranger springs, but I don't recommend them as they make your ride very stiff and don't really give you any advantage unless you are carrying an excessive amount of weight on the front end.

OK boys,
So I've noticed that the "ol X2 has some sag to it in the front end. With Plowin' season coming (snow is falling as I write this) I'm thinking that I need to get a set of new fronts. I'm trying to figure out if I should go with the MVs or the rangers. Any thoughts?

[sweeper]

I have the MV springs on mine and love them, but we dont get much snow to plow.As far as the ride it stiffins the front up alot.

[BIG_T]

I'd recommend Ranger springs. Ed will recommend the MV7 springs.

Since you already have the 2" lift, the MV7 springs would still be pretty good. The downside to the Ranger springs is that they ride stiffer.

[Rebel64]

OK boys,
So I've noticed that the "ol X2 has some sag to it in the front end. With Plowin' season coming (snow is falling as I write this) I'm thinking that I need to get a set of new fronts. I'm trying to figure out if I should go with the MVs or the rangers. Any thoughts?

I love the Rangers on mine, and I really don't think it rides that stiff at all.
Last year I had to let ALL of the air out of my front tires so the plow would hit bottom, but with your tires being a couple inches shorter hopefully you won't have that issue.

[x2rider]

I'd recommend Ranger springs. Ed will recommend the MV7 springs.

Since you already have the 2" lift, the MV7 springs would still be pretty good. The downside to the Ranger springs is that they ride stiffer.

T,
So if I understnd correct the Ranger springs will be stiffer than the MV7 springs. Correct?

[BIG_T]

That's correct. The MV7 are a two-stage spring, so you use up the first part quickly then it gets stiff.

[800Stealth]

I agree with Rebel, I don't find the Ranger springs that stiff either. I think of them as the way it should be and would definately recommend them, especialy if you've got a plow on it.

[shags]

hi guys. I'm new to this whole forum thing, but this site relly caught my eye with all the awsome info. I ride a 08 800 x2 and noticed as soon as the winch and front bumper went on, the suspenion went down and the wheels cambered. Are the stock x2 springs the same as a sportsman, even with all that extra stock weight? Will the ranger spring mentioned above fit a 08?

[BIG_T]

The twins use one spring and the single use a different spring, but the SPMN and the X2 both use the same front springs.

shags, for your combo I would definitely run either the MV7 or Ranger front springs. If you prefer going slow and mud riding, I'd recommend the Ranger springs, if you are more of a trail rider who likes a nice plushy ride then go for the MV7

[bud29.5]

Hey Big T thanks for the awesome write-up. It was a huge help for someone technically challenged like myself. Probably turned a 2 hour head scratcher into a 30 minute quick change.

I have one question regarding the spring change. When I pulled off the old ones, there was a rubber bumper inside that slide on the shaft of the shock absorber. It wasn't mentioned in the write-up, but I put them back on with the new springs. Is this just a special Touring model thing or maybe just on the later model years?

[BIG_T]

that's called the jounce bumper and it's to absorb the shock of bottoming out your suspension. It shouldn't come off with the old spring, and if it does it should be put back on. I guess I just assumed in my write-up that it wouldn't come off.

[bud29.5]

Right, I figured they should stay. Mine were both pushed up into the tops of the old springs a little bit. Had to give them a good shove to get them out. Anyway, excellent write-up and thanks again!

[shags]

Nice work on the stealth, thanks Big T, that clears up what springs i need. I trail ride on challanging trails and want to make an all around bike. What about if I added a 2" lift (since it's so long getting hung up) should I swap the springs or would the 1/2" difference form front to rear in the lift fix up the camber issue? Wouldn't adding such componets void the warranty? By the way, what made you go the 500 anyway?

[BIG_T]

Actually I don't have a stealth, if that comment was directed towards me.

a 2" lift will make you a bit tippier and will handle differently. It will affect camber certainly, but it has nothing to do with the 1/2" difference from front to rear. Because the strut design is based on a 3-bar linkage with a changing length member (shock) the camber is forced to change when you lengthen the strut assembly, the opposite way of what happens when you shorten it with weaker springs.

[shags]

woops... sorry Big T, I thought the x2 in your attachment was yours. Thanks for the info, it's becoming clearer now!

[BIG_T]

The X2 500 in my signature is mine. It's all black, but it's not a stealth. I custom made it black

[Fish N Quads]

Sorry but I have to ask only because I think my sportsman has alittle issue. I tried to order new springs from HL and they sent the wrong ones. After talking to them and doing alittle research I found out that the 05's and only some 05's were different then the rest. I looked at the build date on my 800 and it was june of 2005 when it was built. I would love to have stiffer spring in the front as well as the rear but I cant seem to find any. I carry alot of weight on my machine and need stiffer springs badly.

Here is a pic of the spring difference that HL sent me it was the same length as my spring compressed. I would'nt have to compress the new spring to put it on. Damn I was bumbed out.

http://i126.photobucket.com/albums/p104/jmgr8ride/stuf.jpg



Any info would be appreciated. Thanks in advance.

[mm800]

Sorry but I have to ask only because I think my sportsman has alittle issue. I tried to order new springs from HL and they sent the wrong ones. After talking to them and doing alittle research I found out that the 05's and only some 05's were different then the rest. I looked at the build date on my 800 and it was june of 2005 when it was built. I would love to have stiffer spring in the front as well as the rear but I cant seem to find any. I carry alot of weight on my machine and need stiffer springs badly.

Here is a pic of the spring difference that HL sent me it was the same length as my spring compressed. I would'nt have to compress the new spring to put it on. Damn I was bumbed out.

http://i126.photobucket.com/albums/p104/jmgr8ride/stuf.jpg



Any info would be appreciated. Thanks in advance.

They changed the lengths of the springs sometime in 05. I have the HL springs on the rear of mine and needed the longer ones, they sent you the wrong springs. I would call them and talk to Dan, he is the only one I will talk to over there.

[HAWSE700EFI]

They changed the lengths of the springs sometime in 05.

Does anybody know the date they changed them?

[Camo500EFI]

I would say just get the 2008 X2's for the rear. Your length will work to your advantage with the X2's.

[Fish N Quads]

So the 2007 X2's are stiffer then the MV7's? I just called the dealer and the 2007 X2's are 78.00 each. Is that good? Seems kinda high to me but if it will make it stiffer then it is worth it to me. I carry alot of stuff with me first im about 280 lbs, I have a rear box full of junk, sometimes an extra rider, rear bumper, gun boot and bracket, rear extention with a cooler and 2 1/2 gal. gas can. So there is some weight back there LOL.

[Camo500EFI]

MV7 rears will be way to stiff. The length on the X2's are one inch longer than the ones I had which are shorter than what you have now. The 07 X2's are stiffer than the 08 X2's just FYI.

[BIG_T]

MV7 rears are very stiff. They're actually stiffer than Ranger rear springs.
If you were to put MV7s on the rear it would make your rear rock solid, and would actually cause lots of problems with bolts, bearings, and bushings.

[mudbob]

I just put 2008 X2 on the rears of my 06 X2. Measured them out of the box and they were 13 1/2in and when I installed them I had to compress them 3in. Does that sound right 3 1/2in of preload. BTW with my new combo of MV7 up front and the 08 in the rear I find it a good combo. I do use a 60in glacier plow and trail ride.

[BIG_T]

3.5" of preload sounds pretty normal.

[Fish N Quads]

I just went out and measured my spring while it is in the shock and it measures exactly 12" what is a shock that will fit my rears then. I dont want the mv7. Man I wish I did'nt have such an odd ball year of sportsman. If the x2's are only 13 1/2 I will only compress mine 1 1/2" is that still enough for the weight I carry? I think I will go with the ranger/mv7s for the front. I also snow plow but since the mv7s ar dual rate I think that the mv7s will work better.

I found that the x2's are 130/150in for the rear that may be enough I guess for only compressing them 1 1/2". If I looked mine up right the rear stock is 100in. (whimpy)

[Fish N Quads]

So my next question is were you all are buying from and how much?

[BIG_T]

1.5" of preload isn't going to do very much for you.
What I would do if I were you is use X2 springs and get a spacer made which will get the preload to about the same place as newer models.

[mudbob]

I got mine from the dealer, but I am in canada. Cheap cycle parts . com had a good price but the exchange and shipping made the stealer the same price.

[Fish N Quads]

1.5" of preload isn't going to do very much for you.
What I would do if I were you is use X2 springs and get a spacer made which will get the preload to about the same place as newer models.

Does RD make a rear spacer? Are they the same as the rear?

Thanks BIG_T I know I have alot of questions.

[hunterdan]

Hey Big T

for the ranger springs, is this just a color change, or is the spring different ( stiffer ) as the color changes??

Thank you!

Dan