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Polaris Sportsman 400 Lift Installation Instructions Manual

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Polaris Sportsman 400 Lift Kit
Installation Instructions
Read Before Installation
This product is designed for use on ATVs and/or RUVs to increase ground clearance and fender
clearance. It is designed for utility type, slow-speed use on relatively flat terrain in deep mud or
snow. Although we have many thousands of satisfied lift kit customers and over 1,800 franchised
dealers selling and installing lift kits, purchasers should be aware that use of this product may
increase the frequency of required maintenance, part wear, and will raise the center of gravity on
your ATV and/or RUV, increasing risk of roll-over, injury and death on all types of terrain. It is
your responsibility to always inform other operators and passengers of this vehicle about the
added risks.
We recommend that wider tires and/or wheel spacers be used to achieve a wider stance and to
improve stability of the ATV and/or RUV. Riders should be advised that the handling
characteristics of a taller ATV and/or RUV are different and require extra care when riding,
particularly on side hills or off-camber situations. If you further raise the center of gravity by
adding taller tires, heavy loads to racks or seats, or by any other means, the ATV and/or RUV
must be operated with even more care, at slower speeds and on relatively flat ground. All turns
should be done at a slow speed, even on level ground.
Operation of an ATV and/or RUV with or without a lift kit, while or shortly after consuming
alcohol or drugs, subjects the rider to the risk of serious bodily harm or possible death. This risk
is compounded if the rider does not wear an approved helmet and other safety gear. High Lifter
urges that all approved safety gear be worn when riding an ATV and/or RUV as a driver or
passenger.
If this product is not what you expected, or is not consistent with your intended use, you should
return the product immediately to the seller, before installation, for a refund of the purchase
price; less any fees. After installation, product is warranted for 90 days for defects in
workmanship and materials. Warranty is limited to refund of the purchase price or replacement
of the kit, at the seller's option.
Dealers and other Installers
You are responsible for informing your customer and end user of the information contained above
and the increased potential hazards of operating an ATV and/or RUV equipped with a lift kit. If
you install the lift kit, it is your responsibility to also install the warning label prominently in view
of the driver and in prominent view of the driver and passenger on RUVs and multi-passenger
ATVs. They should also be instructed to notify anyone operating the vehicle, as well as any
passengers, that a lift kit is installed.
As discussed above, it is critically important that they be instructed in the need for slower speed
operation, regardless of terrain, after this lift kit is installed.
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Summary of Contents for Polaris Sportsman 400 Lift

  • Page 1 Polaris Sportsman 400 Lift Kit Installation Instructions Read Before Installation This product is designed for use on ATVs and/or RUVs to increase ground clearance and fender clearance. It is designed for utility type, slow-speed use on relatively flat terrain in deep mud or snow.
  • Page 2: Parts Diagram

    Parts Diagram...
  • 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 securely supported so that A-arms and struts are at full extension. 2) Remove front wheels.
  • Page 4 6) Using a 3/8 drill bit, drill a hole through the strut mount. 7) Once the hole is done connect the bracket, knuckle, and strut assembly using a 3/8 x 2 ½ bolt and 3/8 lock nut. 8) Connect the bottom of the lift brackets to the knuckle using the two small spacers and 3/8 x 2 ½ bolt and 3/8 lock nut.
  • Page 5 Rear Lift 1) Place jack under the center of the ATV, just forward of where the rear drive shaft connects to the engine, and lift until the weight is off the suspension. Be careful to secure the ATV properly so it is stable on the jack.
  • Page 6 7) Fasten the sway bar arm, brackets and shock together using the 3/8 x 4 ½” bolt and 3/8 lock nut. 8) Using two small support brackets connect the large support bracket to the control arm.
  • Page 7 9) Use the ¼ x 2” bolts and ¼ lock nuts to fasten the brackets to the control arm. 10) Repeat steps for the opposite side. 11) Place wheels back on ATV and tighten all lugs to factory specifications.