Waverspeed 4-inch Lift Kit for Polaris Sportsman ATV/UTV Models (1999-2024)

Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your Waverspeed 4-inch Suspension Lift Kit. This kit is designed to increase the ground clearance of your Polaris Sportsman ATV/UTV, allowing for larger tires and improved performance on challenging terrain. Please read all instructions carefully before beginning installation.

Professional installation is recommended for optimal safety and performance.

Compatibility

This Waverspeed 4-inch Lift Kit is compatible with the following Polaris Sportsman models:

• Polaris Sportsman 600, 700, 800 (1999-2020)
• Polaris Sportsman 500 (2000-2020)
• Polaris Sportsman 450 (2016-Present)
• Polaris Sportsman 570 (2015-Present)

Note: This kit is not compatible with Sportsman Touring, SP, or Premium models.

Package Contents

Please verify that all components listed below are present in your package before beginning installation.

• Rear Lift Brackets (2 pieces)
• Front Spacers (4 pieces)
• Front Lift Spacers (2 pieces)
• Hardware (various bolts, nuts, and studs)

Setup and Installation

Warning: Improper installation can lead to serious injury or damage to your vehicle. If you are not experienced with suspension work, seek professional assistance.

This lift kit is designed for direct bolt-on installation. A PDF instruction guide may be available for download. Always ensure your vehicle is securely supported on a level surface before beginning any work.

General Installation Notes:

• Ensure the vehicle is parked on a flat, stable surface.
• Engage the parking brake and block the wheels.
• Use appropriate jack stands to support the vehicle securely.
• Disconnect the battery before starting any electrical work (if applicable).
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.

Front Lift Installation:

1. Safely lift the front of the ATV/UTV and support it with jack stands. Remove the front wheels.
2. Locate the front shock absorbers. You will be installing the front spacers and front lift spacers here.
3. Carefully remove the existing shock mounting hardware.
4. Install the front spacers (ring-shaped) onto the shock body as per the specific instructions for your model.
5. Install the front lift spacers (threaded cylindrical pieces) at the top of the shock, ensuring proper alignment with the mounting points.
6. Reinstall the shock absorber with the new lift components using the provided hardware. Ensure all bolts are tightened to the manufacturer's specifications.

Rear Lift Installation:

1. Safely lift the rear of the ATV/UTV and support it with jack stands. Remove the rear wheels.
2. Locate the rear suspension mounting points where the rear lift brackets will be installed.
3. Remove any necessary components to access the mounting points.
4. Install the rear lift brackets using the provided hardware. Ensure the brackets are oriented correctly and all bolts are securely fastened.
5. Reassemble any components removed for access.

Operating Considerations After Lift Kit Installation

After installing the 4-inch lift kit, your vehicle's handling characteristics will change. It is important to be aware of these changes to ensure safe operation.

• Center of Gravity: The vehicle's center of gravity will be higher, which can affect stability, especially during turns or on uneven terrain. Exercise caution and reduce speed in such situations.
• Steering: You may notice a slight change in steering feel. Ensure the steering is aligned correctly after installation.
• Tire Clearance: The increased clearance allows for larger tires. If installing larger tires, ensure they do not rub against any suspension or body components during full suspension travel or steering lock.
• Braking: Braking performance should not be significantly affected, but always test brakes in a safe area after any suspension modification.
• Alignment: It is highly recommended to have a professional alignment performed after installing the lift kit to correct any changes in camber, caster, and toe angles. This will prevent premature tire wear and ensure proper handling.

Maintenance

Regular inspection and maintenance are crucial for the longevity and safe operation of your lift kit and vehicle.

• Initial Check: After the first 50-100 miles of driving, re-check all bolts and nuts associated with the lift kit for proper torque. Re-tighten as necessary.
• Routine Inspection: Periodically inspect all lift kit components for signs of wear, damage, or corrosion. Check for loose bolts, cracked welds, or deformed parts.
• Cleaning: Keep the lift kit components clean, especially after off-road use, to prevent dirt and debris buildup that could accelerate wear.
• Lubrication: If any moving parts are part of the lift kit (though this kit is primarily static), ensure they are lubricated according to your vehicle's maintenance schedule.

Troubleshooting

This section addresses common issues that may arise after installing a lift kit.

Issue: Uneven Ride Height

Possible Cause: Incorrect installation of spacers or brackets, or components not fully seated.

Solution: Re-check all installation steps, ensuring components are installed on the correct sides and fully seated. Verify all hardware is tightened evenly.

Issue: Excessive Tire Wear or Poor Handling

Possible Cause: Misalignment of suspension components.

Solution: A professional wheel alignment is critical after lift kit installation. This will correct camber, caster, and toe angles to prevent premature tire wear and restore proper handling.

Issue: Noise from Suspension

Possible Cause: Loose hardware, components rubbing, or incorrect installation.

Solution: Inspect all bolts and nuts for proper torque. Check for any contact between the lift kit components and other parts of the vehicle's suspension or frame. Ensure no debris is lodged in the suspension.

Issue: Difficulty Installing Components

Possible Cause: Incorrect part for the specific model year, or existing vehicle components are seized/damaged.

Solution: Double-check the compatibility list for your exact Polaris Sportsman model and year. If parts are difficult to install, do not force them. Consult a professional mechanic or contact customer support.

Specifications

Warranty and Support

Waverspeed offers support for its products. For specific warranty details, free returns, or exchanges, please refer to your purchase documentation or contact the seller directly.

If you require further information or assistance with installation, please contact Waverspeed customer service.