Polaris Sportsman Lift kit Instructions [Archive]

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Rubberdown

12-13-2007, 10:47 PM

http://www.rubberdowncustoms.ca/Sportsman%20lift%20complete%20instructions.pdf

Full instructions in the link above, this info below is a tip for the front kit when putting it all back together, please read all of the instructions before starting the installation of the lift kit

INSTALLING THE FRONT KIT, NEW TIP ADDED!!!!

Okay, my machine is a 2004 so I was able to use the holes in the front rack for the strap to compress the front spring, I'm sure there will be somewhere on the newer machines under the front fender to do something similar, or somewhere on the newer front rack steel tie down bars?

Anyways, the pictures below show how I was able to compress the spring to make it easier to push the shock all the way down the strut housing. I used a ratchet strap and looped it down around the bottom of the strut, as I tightened the ratchet strap, it compressed the spring enough that I was able to push the actual shock all the way down inside the aluminum strut housing. Once it is all the way down and firmly pressed against the strut plug, you can tighten the top bolt on the aluminum strut housing, once its tight, you can let the strap loose. This is much MUCH easier than using the floor jack method with a second person leaning on the front rack. I was able to do this myself without calling the wife out to help me this time LOL.

http://i79.photobucket.com/albums/j158/rubberdown/lift%20kit/100_1465.jpg

http://i79.photobucket.com/albums/j158/rubberdown/lift%20kit/100_1466.jpg

Another new tip,

How to seperate the ball joint without a pickle fork!

I call this the HAMMER METHOD
Here ya go, keep in mind that you are aiming for the solid round part at the end of the a-arm, NOT the nut or the threads LOL. Also, if I werent so lazy, I would have looked around for my ball peen hammer and I only would have had to strike it 2 or 3 times to pop it loose.

http://i79.photobucket.com/albums/j158/rubberdown/lift%20kit/th_P4270846.jpg (http://s79.photobucket.com/albums/j158/rubberdown/lift%20kit/?action=view&current=P4270846.flv)

Riven

02-18-2008, 12:43 PM

I have an easy question about the sway bar links. Do i just unbolt them & the new ones fit on easy or will i have to pry on the sway bar to get them to line up.
I mean are the sway bars under any amount of load with the bike just sitting?

OnlyPolaris

02-18-2008, 02:49 PM

you can just unbolt them and put in the new ones.

i also have a question. when i installed mine the top bolts seem to be to long and they don't tighten down all the way. does anybody know the bolt size so i can get some shorter ones?

Riven

02-18-2008, 03:48 PM

Thanks I was worried that they were under load & would want to spring up when i unbolted them.

I dont know the length but they are a 3/8 coarse thread.
You could always tap the hole deeper if you have that kind of stuff around the house.

OnlyPolaris

02-18-2008, 03:53 PM

no i dont have that kind of stuff. i have to make a trip to the hardware store so i can pick up two bolts for the hole 20 cents they cost.

torkmonster

02-18-2008, 06:26 PM

i'm just curious as to if any, how much stress these lift kits put on the rest of the quad??? with everything else suspension and axle wise etc..????
I know the spacers will speed up the wear process of the bearings but what about the lift??

OnlyPolaris

02-18-2008, 06:35 PM

well i went out and bought a 3/8 x 2 1/2 bolt and it fixed my problem. cost a hole 77 cents in total. the stock bolt is 3 inches long.

Rubberdown

02-18-2008, 09:42 PM

well i went out and bought a 3/8 x 2 1/2 bolt and it fixed my problem. cost a hole 77 cents in total. the stock bolt is 3 inches long.

What bolt was it that was too long dude? I'm lookin at a kit right here and if I went shorter on either of them, I wouldn't get the nylock to reach the threads? Did you use the washers included with the kit?
hmmmm???????

Riven, are you telling me you have had those sway bar links all this time and you havent put them on yet???? You just might be as slow as me when it comes to doing things to the quad LOL :D

OnlyPolaris

02-18-2008, 10:13 PM

Riven

02-18-2008, 10:29 PM

Riven, are you telling me you have had those sway bar links all this time and you havent put them on yet???? You just might be as slow as me when it comes to doing things to the quad LOL :D

MY bike has been in the shop every day since i pulled your broken heavy a$$ 500 out of that hole last fall.:madgrin:
It should be fixed this week & then your bill will be in the mail. It should not be much over $2500.:D

The link extensions are on my to do list before i go riding this spring. Along with a 100 other things i did not get to do on my bike this winter.

Rubberdown

02-18-2008, 10:42 PM

Oh ya....***rd hold his head low***

Riven

02-19-2008, 05:38 PM

LOL. Just be glad it was only an axle & not a whole motor rebuild like me.

But just so you dont forget that day again here you go bud.

http://inlinethumb63.webshots.com/16638/2293351050084649699S600x600Q85.jpg
http://inlinethumb06.webshots.com/31365/2684453890084649699S600x600Q85.jpg

Rubberdown

02-19-2008, 05:50 PM

http://i104.photobucket.com/albums/m169/softailrebel/Wheel%20Spacers/DSC02724.jpg

i will use one of marks pics as an example. see how the rubber things on the sway bar are not tight. that is because the hole for the bolt is not tapped deep enough. that is as tight as you can get it. it was only like this on the top of one of them so i went out and bought a shorter bolt so i could tighten it down more. worked perfect.

So the taped hole in the sway bar extension was not threaded deap enough? hmmm, I wonder why, I do them on a manual lathe and I have the tap marked so I know when to reverse the chuck???? I wonder if it was full of sand from the sand blaster and it never blew out when I blew them all off after blasting them????

OnlyPolaris

02-19-2008, 09:05 PM

not sure but you got the idea.

gates

02-26-2008, 12:55 PM

OnlyPolaris

02-26-2008, 01:45 PM

Tks for the info guys, I was wondering why I couldn't get these tight, so the proper size required is 3/8" coarse thread by 2 1/2" long, I'll get some of these today, any grade, grade 5 should be ok ?

02-700
02-400

ya the stock bolt is 3" long. if you get a 2 1/2" you will be fine. i went with a grade 8 bolt as that is what the stock ones looked like to me.

OnlyPolaris

03-06-2008, 04:18 PM

hey rd i here you got another order from saskatchewan here. we have a local forum and everyone that asks about lifts i mention your name. one of the guys told me he ordered one of your lifts.

Rubberdown

03-06-2008, 04:29 PM

Yup, I think so, I know I just sent a rear kit out that way, and maybe even a full sportsman kit recently as well as a couple RZR kits....And thanks for the referals ;)

OnlyPolaris

03-06-2008, 05:44 PM

no problem man. i only want people to be using the best.

Kman

07-23-2008, 09:43 AM

I put the lift on my sportsman and now the tops of my tires lean outwards. (camber I think)

is this normal and will damage anything?

Rubberdown

07-23-2008, 10:12 AM

it is normal but it isnt a very big angle unless you went with the 3" front kit like I did, then it really stocks out there LOL.

Kman

07-23-2008, 12:00 PM

I have the 2" lift and it looks great but I was wanting to see if you guys had a fix for the tire tilting. If it's not that big of a deal then I will just drive like this.

Rubberdown

07-23-2008, 12:12 PM

There is no way to correct that as far as I know of, and mine has well over 2000 hard miles like that. It should be fine, every 2" lift kit made by any manufacturer will give you the same tire tilt.

KENH

07-23-2008, 09:17 PM

i like the tire tilt...makes it look mean

Rubberdown

07-23-2008, 09:36 PM

LOL, have you seen mine, it must look REALLY mean :D

hampster_rancher

07-23-2008, 10:35 PM

Heres mine with Rubberdowns 3inch

http://i162.photobucket.com/albums/t253/hampster_rancher/popo009-1.jpg[/IMG]

Kman

07-24-2008, 11:30 AM

that is a bit more because of the 3" instead of 2" like mine but if you have no problems with that then I should be fine also. here is what mine looks like.

I have not gone riding much so I am not sure if this will affect steering or not.

hampster_rancher

07-24-2008, 11:37 AM

The only thing I have noticed is that it tends to 'push' throught the turns a little. I think my problem is more from the tires than the lift.

badmaners

07-24-2008, 12:12 PM

Turk

07-24-2008, 02:03 PM

I have the 2" lift and it looks great but I was wanting to see if you guys had a fix for the tire tilting.

I also have the 2" lift but no tire tilt at all,mine are perfectly straight from bottom to top.I am still running the stock popo springs so maybe thats why.

http://pic20.picturetrail.com/VOL144/1427015/16921545/278448205.jpg

I have the a-arm gaurds off in this pic ^^^

Kman

07-24-2008, 02:14 PM

I have the polaris HD springs 128lbs/inch. It probably stands the bike up more. ??

hampster_rancher

07-24-2008, 02:18 PM

Mine also has EPI HD springs.

Turk

07-24-2008, 02:18 PM

Thats the only thing that I can think of as to why my front wheels dont have the "tire tilt" with the 2" lift.

KENH

07-24-2008, 05:04 PM

lol you should see my 6in with the sag taken out the springs...its just as bad

Kman

07-26-2008, 09:20 PM

lol you should see my 6in with the sag taken out the springs...its just as bad

lets see some pics of it.

my quad pushes through the turns also and I don't realy like it.

mm800

07-26-2008, 09:34 PM

nothing turns well with positive camber

Kman

07-26-2008, 11:21 PM

this may need to go to a new thread but; could a guy lengthen the a-arms to fix the camber problem? I guess also are Gorrila axles longer then stock?

hampster_rancher

07-27-2008, 01:02 AM

No, Gorrila axles are only longer than stock if you order them that way. For a Rubberdown lift you need stock length axles.

Kman

07-28-2008, 02:07 PM

I was just thinking if I lengthen the a-arms then I need longer axels. not sure what would happen to the angles with this mod?

KENH

07-28-2008, 04:29 PM

actually i think the gorilla axles are alittle longer...cuz of how they can plunge...thats how catvos are making a 4in lift for brutes, artic cats and can-ams and still using a "stock" length gorilla

stricker76

12-01-2008, 06:37 PM

Question about grinding the strut housings. How much should they be ground?? I didn't have the picture available to me when i did them at work today. I pretty much took them right down to the same depth and angle as the plug that came with the kit. Looking at the picture of the 2 housings now i think i took off alot more than i needed to. Not that it really matters, there is still a ton of material there for strength.

stricker76

12-01-2008, 06:40 PM

Looking at the picture in the instructions again, i don't see why it would need the angle on the plug if that is all that needs ground?

OnlyPolaris

12-01-2008, 08:12 PM

if you go to the tech info section there is a sticky at the top with a pic of how much to grind. trust me it is a good thing that the slant is there. if it was straight it would stick out the bottom about 1/4"

Rubberdown

12-01-2008, 08:20 PM

I use the angle on the plug as a guide, I brought mine to the plug and then a little bit more with my 3" kit, but when I had the 1-1/2" kit on the machine, it wasnt ground all the way to the plug. You should be just fine, and its better to take a little extra than not enough and have to change the boots, thats a pain in the arse the first couple of time....it does get easy if you have all the proper tools though.

stricker76

12-01-2008, 09:35 PM

Perfect. Thats what i kind of thought, but the other pic didn't look like they took off that much. Should have it all back together tomorrow night. Can't wait!

Rubberdown

12-01-2008, 09:51 PM

INSTALLING THE FRONT KIT, NEW TIP ADDED!!!!

Okay, my machine is a 2004 so I was able to use the holes in the front rack for the strap to compress the front spring, I'm sure there will be somewhere on the newer machines under the front fender to do something similar, or somewhere on the newer front rack steel tie down bars?

Anyways, the pictures below show how I was able to compress the spring to make it easier to push the shock all the way down the strut housing. I used a ratchet strap and looped it down around the bottom of the strut, as I tightened the ratchet strap, it compressed the spring enough that I was able to push the actual shock all the way down inside the aluminum strut housing. Once it is all the way down and firmly pressed against the strut plug, you can tighten the top bolt on the aluminum strut housing, once its tight, you can let the strap loose. This is much MUCH easier than using the floor jack method with a second person leaning on the front rack. I was able to do this myself without calling the wife out to help me this time LOL.

http://i79.photobucket.com/albums/j158/rubberdown/lift%20kit/100_1465.jpg

http://i79.photobucket.com/albums/j158/rubberdown/lift%20kit/100_1466.jpg

hampster_rancher

12-02-2008, 12:14 AM

RD gave me that tip over the phone a couple weeks ago....works REAL slick. It is no longer a chore to do by your self!

stricker76

12-02-2008, 04:07 PM

I'll have to try that tonight.

johnnydakota2001

06-24-2009, 11:15 PM

The hammer method worked great thanks for the info, only 4 smacks and it popped free. I did try the ratchet strap but was afraid I was going to crack my plastic or break something else. Didn't even consider asking the wife at 1:00 am to come out and help me so I ended up removing my shock completely, seating it inside the strut housing on top of the strut plugs, I tightened up the the two bolts on the housing to hold it in place and then reinstalled everything. Now all I need is some more overtime for the tires and wheels.

Rubberdown

06-24-2009, 11:33 PM

Glad you got it all figures out Johnny!

I just installed a 2" kit on my recently acquired 2004.5 500, and it has the HL springs on it, WOW, I was afraid I was gonna pul the rack extender off with the ratchet strap, so instead, I hooked the strap up into the frame right near the top of the shock. It actually worked better because it pulled it more straight up and down.

04 po po 700

07-22-2009, 09:55 PM

my 2inch lift screwed in to the the top of my strut took about 10 min on each side.

Rubberdown

07-22-2009, 10:58 PM

And theres a reason I dont make mine like that.... ;)

04 po po 700

07-23-2009, 01:17 AM

And theres a reason I dont make mine like that.... ;)

please tell me why
mine is made like this http://www.superatv.com/Polaris-C155.aspx
i didnt buy it from them,but its exactly like it.

Rubberdown

07-23-2009, 10:21 AM

check your PM's....

explorer

07-23-2009, 12:12 PM

Paul, can you send me that PM. I'm just waiting to install your front lift but have another PoPo owner that looked at one of those other kits. I'd like to give him all the pros and cons.

popowes

09-09-2009, 09:04 AM

what are the cons to a 2inch lift? i see the pros!! What to put a lift kit on my 2007 sportsman 500 but not sure about the cons on doing so. Excessive wear? Breaking axles? Anyone had any problems with a 2 inch lift?

John

09-09-2009, 09:13 PM

I have the 2" lift and ride my atv very hard and never had a problem with the lift or broken axles because of the lift. I broke my first C.V. joint when I put the Polaris HD front springs on. I repaired it with a rebuild kit from the C.V. Man and that lasted about 4 hours. IMO if you just have the 2" lift and stock springs you should be fine.

sfd_324

09-09-2009, 10:16 PM

please tell me why
mine is made like this http://www.superatv.com/Polaris-C155.aspx
i didnt buy it from them,but its exactly like it.

search photobucket for sfd_324, view my album and see if the pic of my front strut/tire leaning because it came unscrewed and came out, luckily I was going slow.

we also had it happen on a ranger.
they were real nice on the phone when I talked to them and problem was solved.

But NOW I ONLY BUY AND RECCOMMEND RDC LIFTS TO EVERY ONE

MidnightX

05-18-2010, 10:44 AM

Question about the rear kit??

I installed mine but the 01-03 axels are not as long as the newer ones...So what should my preload be on my rear struts?? I have them cranked up all the way now but I notice a good angle on the cv shafts.

any notes on this....

Thanks

hampster_rancher

05-18-2010, 11:05 AM

The rears will have a pretty good angle on them. The kit will stiffen up your ride as well. When we did my '03, we had the shocks on the lowest setting, rode stiffer than stock but not uncomfortable.

badmaners

05-18-2010, 11:43 AM

My 2001 are on the softest and it's pretty stiff. I only weigh 185...wet lol.

MudWeed

09-06-2011, 04:23 PM