HIGH LIFTER HDFFA-GEN1XP-B Polaris General XP HD Front Forward Arms Instruction Manual

HIGH LIFTER HDFFA-GEN1XP-B Polaris General XP HD Front Forward Arms

PRODUCT DISCLAIMER

The installation of products sold or manufactured by High Lifter Products, Inc. including, but not limited to suspension components such as lift kits, gear reduction lifts, frame stiffener kits, snorkels, and tires that exceed the original specifications for the vehicle, may change the vehicle’s center of gravity and handling characteristics both on- and off-road. You are aware that the installation of tires that are larger than original vehicle specifications may reduce the effectiveness of the braking system. Use of these products may place added stress to the original factory vehicle components which could cause them to weaken or possibly fail.

Products sold or manufactured by High Lifter Products, Inc. are intended for off-road use only. Operation of a vehicle modified with these products on a road could result in serious bodily injury or death, and such operation may violate the laws of your state or municipality. You agree to operate your vehicle exclusively in the manner intended by the vehicle manufacturer. You agree that failure to safely and reasonably operate your vehicle could result in serious bodily injury or death, and that, as a result of installation of this product(s) to your vehicle, extreme care must be taken to prevent vehicle rollover or loss of control, which may be more likely to occur as a result of said modifications. You will avoid unsafe maneuvers, including sudden sharp turns or other abrupt ich could make a vehicular accident more likely. You understand that High Lifter Products, Inc. is not responsible or liable for any damages or any injuries to yourself or your passengers that could occur upon possible accidents due to driver error, incorrect installations, bad judgment, incompatibility with other aftermarket accessories or natural disasters to the fullest extent allowable by law. You will have all vehicle occupants fasten seatbelts, if equipped, and wear proper safety equipment, such as DOT approved helmet and eye protection prior to operating the vehicle. You understand and acknowledge that failure to wear proper safety equipment may increase the risk of serious bodily injury or death to yourself and any passengers.

PARTS DIAGRAM

FRONT LOWER & UPPER ARMS

GENERAL XP TIE ROD ASSEMBLY

BALL JOINTS (optional)

REMOVING STOCK COMPONENTS

FRONT PASSENGER SIDE

KEEP ALL FACTORY HARDWARE.

Place jack under the FRONT center of the UTV and lift until the weight is off the suspension. Ensure that the vehicle is properly secured, so that it is stable on the jack. ONCE LIFTED, USE JACK STANDS TO PROPERLY SECURE THE UNIT. Remove the front wheels.

• Slide the brake lines out from under the clamps that hold the lines to the arm.
• Next, remove the bolts connecting the brake calipers to the knuckle and set them aside.
• DO NOT DRAIN BRAKE FLUID!

• Remove and keep the cotter pin, axle nut, and washers from the hub assembly. YOU WILL REUSE THE FACTORY HARDWARE to reconnect the new control arms to the frame.

Before removing the upper and lower arms from the front hub assembly, first disconnect

• A. Tie rod
• B. Lower sway bar link end
• C. Lower shock end
• D. Upper Ball ioint

_ NOTE: _Some models DO NOT have sway bar links.

• Remove the Lower Arm FIRST by disconecting the bolt from the knuckle and bolts at the frame.
• KEEP ALL FACTORY HARDWARE
• Disconnect the Upper arm by removing the bolts from the frame.

STEERING STOP

_ NOTICE: _DO NOT REMOVE THE STEERING ASSEMBLY. THE IMAGES FEATURED ARE FOR DEMONSTRATIVE PURPOSES ONLY.

BOOT REMOVAL

The rubber boots on the steering assembly are held on by zip ties. Cut the zip ties that secure the boots to the inside of the rack.

START WITH THE DRIVER’S SIDE This side has the least amount of room. If you install the spacer on the passenger side first, you will have less play on the driverr’s side. DO NOT REMOVE THE FACTORY SPACER ALREADY IN PLACE. Turn the steering wheel all the way to the RiGHT, place the steering stop (73-11678) between the inner tie rod joint and the rack and pinion. It is a tight fit, so you may have to force it on, this is to ensure that the spacer stays in place.

PASSENGER SIDE

• Turn the steering wheel all the way to the LEFT.
• Install the steering stop (73-11678) to the rack.

RESECURING BOOT

• Turn the steering wheel closer to the center to allow play in the boot. Slide the boot back down and secure it at both ends with an 8″ zip tie.

IF YOU ORDERED ARMS WITH PRE-INSTALLED BUSHINGS SKIP THIS STEP. IF YOU HAVE ACCESS TO A BLIND BEARING PULLER WE HIGHLIGHLY RECOMMEND USING THIS TOOL OVER. A PUNOH USING A PUNOH MAY CAUSE DAMAGE TO THE BUSHINGS.

UPPER & LOWER ARM

THE REMOVAL TECHNIQUE IS THE SAME FOR BOTH UPPER AND LOWER ARMS.

• Remove pivot caps and sleeves from the arm.
• Use a blind bearing puller or a flat punch to remove the bushings.
• Use caution when removing the bushings from the collar. There is a stop built into the factory arm that prevents the bushing from pushing out when installed. Because of this, the bushing must be pushed out from the opposite side.

If you use a punch, use caution. You will need to reuse your factory pivot caps, bushings, and sleeves. Make sure that you inspect your bushings for wear or damage. Replace as needed.

UPPER ARM

• IF YOU ORDERED ARMS WITH PRE-INSTALLED BUSHINGS SKIP THIS STEP.
• THE BUSHING WILL ONLY COME OUT FROM THE SIDE WITH THE SNAP RING. Remove the bushings and snap ring from the factory arms.

NOTE: Use caution when removing the bushing from the collar. There is a stop built into the factory arm that prevents the bushing from pushing out when installed.

IF YOU ORDERED ARMS WITH PRE-INSTALLED BUSHINGS SKIP THIS STEP.

On the new upper arms there is NOT a stop built into the collar on one side. Instead there will be new snap rings that will prevent the bushings from moving.

• Insert a snap ring (79-10051) into one side, then insert the bushing into the other side.
• Once the bushing is in place, use a socket of the same diameter as the outer race topress it in all the way. Apply grease to outer race to ease install.
• Once the bushing is seated place the other snap ring into place and place the pivot caps on the ends.
  • NOTE: You may need to free the snap ring grove of derbris with a pick. Debris will prevent the snap ring from seating.

BALL JOINTS

WARRANTY WARNING

The warranty for this product will not cover the improper installation of ball joints. Any claim relating to a ball joint issue will require inspection before eligibility for warranty can be determined. If the ball joint area shows damage due to improper installation such as, ridges, scarring, impact marks or other signs of improper installation, the warranty will be not be approved.

TIPS AND CHECKS

Review the following steps if you are installing ball joints into your new High Lifter Control Arm Kit

Verify the ball joint hole is free of paint or materials that could prevent a successful press fit. If there is overspray or paint build up on the top or bottom of the ball joint hole that was missed during manufacturing, use a razor blade, utility knife, or sharp edge to clean the openings on both sides of the ball joint hole. DO NO USEA GRINDER OR POWER TOOL! This will remove more than paint and can ruin the control arm.

IF YOU HAVE PRE-INSTALLED BALL JOINTS SKIP THIS STEP

NOTE: FOR DEMONSTRATIVE PURPOSES WE USED THE LOWER CONTROL ARM, BUT THE PROCESS IS SIMILAR FOR BOTH. A press or a vise is recommended for removing and replacing the ball joints.

• Back the ball joint with a large 36mm socket or something sturdy of similar diameter, then using a press or vice, press the ball joint out of the arm.

Flip the control arm over, and using the same process, press the ball joint in using a vice or press. If you press in the ball joint crooked, DO NOT TRY TO FORCE IT IN! If you try to force it straight you can “egg” the opening. Press the ball joint out and reinsert it into the opening, pressing it in with a vise. Verify that the clip snaps into place after installing the ball joints into the new Control Arm. You should always double check the ball joint snap ring for proper fit. Even if you use snap ring pliers, it may not seat. You can use a flathead screwdriver and a hammer to tap the snap ring to ensure that it is seated into the groove.

BALL JOINT ORIENTATION

• Snap the retaining clip down on to the base of the ball joint.

Installation

FRONT LOWER CONTROL ARM

• Connect the new LOWER arm at the frame using the factory hardware.
• Reinstall the knuckle. Connect the UPPER arm FIRST. Then connect the LOWER arm.

FRONT LOWER CONTROL ARM

• Connect the new LOWER arm at the frame using the factory hardware.
• Reinstall the knuckle. Connect the UPPER arm FIRST. Then connect the LOWER arm.

FRONT HUB ASSEMBLY

• Connect the hub at the LOWER pinch bolt FIRST, then slide the axle through AFTER.
• Reattach the rotor to the knuckle assembly.
• Install the washers, axle nut, and cotter pin.

INNER TIE ROD

• Use Red Loctite on threads of heavy duty inner tie rod.
• Install inner tie rod. Remove nut.
• Install stock boot. Zip tie to boot to rack.
• Install nut. Leave 1/4” threading between nut and boot.

TIE ROD BAR END

• Install tie rod bar to inner tie rod. Rotate left to tighten.
• Install misalignment cones, 12mm washer, and 12mm lock nut to end of tie rod. Leave 1/4” threads between tie bar and tie bar end.

TIE ROD BAR END

• Attach tie rod to knuckle.
• Secure with 12mm lock nut, 12mm washer, and misalignment cone.

FRONT BRAKE LINES

Connect the caliper to the hub assembly by securing the factory bolts. Make sure that you route the brake lines so that they DO NOT come in contact with moving parts and don’t become pinched. Connect the (3) brake line clamps (79-14813) along the rear of UPPER the arm -similar to the stock routing.

ADJUSTING WHEEL CAMBER

BEFORE STARTING

• Tires must be off the ground
• Tires must have equal air pressure
• Suspension components must be completely assembled

The new High Lifter lower control arms will comme pre-adjusted to factory length, which is .937″ If you need to re-adjust the collars, place the factory arm and new control arm on a flat surface. Measure from eyelet to center mount on the factory arm, and then adjust the new arms to those lengths.

NOTE: When re-adjusting, leave the jam nuts loose. Do not fasten tight until installed on UTV, after all final adjustments have been made.

Make all adjustments in small increments.

Do this by disconnecting control arms at the frame and adjusting collars. Once small adjustments have been made. Take the UTV off the jack and roll it back and forth several times before checking the camber. Repeat steps as needed. After alignment is complete, tighten jam nuts to 80 ft-lbs and secure it with blue loctite.

Positive Camber

• If you have a positive camber you will need to adjust the collar OUTWARD or lengthen the control arm. The maximum amount outward is “1.250” which could give up to 3°of negative camber.

Correct Camber

• For this application, we recommend a camber setting of 0°. Collars are preset to .937”

Negative Camber

• If you have a negative camber you will need to adjust the collar INWARD or shorten the control arm. The maximum amount inward is zero threads exposed and could give over 3° of positive camber.

FRONT WHEEL ALIGNMENT

IF YOU HAVE ADJUSTBLE CONTROL ARMS, YOU MUST ADJUST THE CAMBER FIRST BEFORE PROCEEDING. DO NOT INSTALL WHEELS ONTO UTV UNTIL PROPER ALIGNMENT HAS BEEN ACHIEVED.

• Straighten steering wheel
• Make sure that the brake rotors are straight to sight or level.
• Using a tape measure, measure from inside to inside on the front and back ends of the rotors.

INCORRECT TOE

• If the toe alignment is incorrect, measure the distance between vehicle center and the back of the rotors. This will indicate which tie rod needs adjustment.

ADJUSTING TOE

• Adjust tie rods until BOTH measurements are the SAME, then adjust toe tolerance.

TOE ADJUSTMENT CHART

The recommended vehicle toe tolerance is 1/8” to 1/4” (3.175-6.35mm) toe out. This means the FRONT MEASUREMENT IS WIDER THAN THE REAR MEASUREMENT.

• If the FRONT OF THE WHEELS are facing OUT, adjust the tie rods OUT or INCREASE the length of the tie rod. Measurement at the front of the tires will be GREATER than the rear, if the TOE IS OUT.
• If the FRONT OF THE WHEELS are facing IN, adjust the tie rods IN or REDUCE the length of the tie rod. Measurement at the front of the tires will be LESS than the rear, if the TOE IS IN.

IMPORTANT NOTE: When tightening the tie rod jam nuts, the tie rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

After alignment is complete, tighten & torque tie rod end jam nuts to specifications. [12-14 ft ibs]

Setting to ZERO

STEERING CHECK

IF YOUR STEERING IS ALREADY CENTERED SKIP THIS STEP.

Factory steering for some makes and models may NOT be centered. This can cause the tie rod ends to have more engagement on one end than the other. This also causes the steering wheel to be off center.

• When the steering is zeroed, check the steering wheel to make sure that it is properly positioned.
• If the steering wheel is not centered, you will need to remove the center cap with a flat head screwdriver to gain access to the steering wheel nut.
• Using a ratchet, turn the steering nut counter clockwise or left. Continue this until the steering wheel locks at full turn, then loosen the nut. DO NOT remove the nut yet.
• Once the nut is broken loose, back it oft Just enough leavinga few threads. Use a hammer to tap on the nut while pulling up on the steering wheel until it breaks loose. But DO NOT hammer too hard, it could damage the nut or threads. Now remove the nut and steering wheel.
  • NOTE: A puller may be needed to remove the steering wheel if it can’t be broken free.
• Now will be the time to adjust the steering wheel accordingly. Re-place the wheel and make sure the wheels are turned back straight. The steering wheel should be straight up and down.
  • NOTE: Rolling vehicle back and forth may help straighten the wheels.
• Once the wheel is straight, thread the nut back on and turn the nut clockwise until the steering wheel locks at full turn, then tighten the nut. Reinstall the steering wheel cap.
  • NOTE: Loctite may be needed for the steering nut.

HIGH LIFTER LIMITED LIFETIME WARRANTY

High Lifter offers a Limited Lifetime Warranty to the original purchaser that our product shall be free from defects in material and workmanship for the life of the product if utilized in accordance with the manufacturer’s instructions for installation and operation of said products.

LIMITED LIFETIME WARRANTY EXTENDS TO THE FOLLOWING PRODUCT LINES

• Lift Kits (Signature, Standard and Big Lifts)
• Control Arms
• Trailing Arms
• Radiator Relocation Kits
• Portal Gear Lifts
• Wheel Spacers
• Tow Hooks
• Control Arm Link Kits

Damages to vehicle or any other object during the installation, use, or removal of High Lifter products are not covered under this warranty. Normal wear items included with any of the products covered under this Limited Lifetime Warranty are excluded from coverage. These items include, but are not limited to heim joints, tie rods, bearings, bushings, seals, gaskets, zinc plating, painted and powder coated finishes. Other exclusions of coverage under this warranty include, but are not limited to: damage or product failure due to improper installation, lack of maintenance, product modification, abuse, collision or use on vehicles for which product was not designed, repairs performed by anyone other than approved High Lifter personnel or made using non-High Lifter components. This warranty is valid for the original purchaser only and is non-transferable. High Lifter reserves the right to inspect any product before determining if the claim is valid and covered under this warranty. Claimns determined to be caused by reasons other than a manufacturer defect will be rejected and an estimate for repair or cost of a replacement product if a repair is not possible, will be provided.

This warranty is exclusive and is in lieu of any implied warranty of merchantability, fitness fora particular purpose or other warranty of quality, whether express or implied, except the warranty of title.

WARRANTY PROCESSING

If you suspect your product is defective, DO NOT disassemble the product to determine the cause without prior approval as it may void your warranty status. This is especially true with our Portal Gear Lift. To begin the claim process, please e-mail our warranty team at warrantycare@highlifter.com and include the following in the e-mail:

• Your full name, address and contact phone number.
• The year, make and model of your vehicle
• The part number of the product
• Photos of the product installed, and vehicle product is installed on
• Proof of Purchase (Required for all warranty claims and you must be the original purchaser)

Once a claim is created, you will receive a return authorization number (RMA). Write this number on the outside of the box containing your defective product and include it along with your name and contact information inside the box. Product must be returned in the original box or a box of equal strength and packaging. Product sent without an RMA number visible on the outside of the box or sent COD will be refused. Ship your product to the following address:

High Lifter Products, Inc.

Attn: Returns 7455 Atkinson Drive, Shreveport, LA 71129

Once your product is received, we often have your replacement or repaired product shipped back to you within 3-business days of receiving it. Please note that High Lifter is not responsible for shipping charges on product returned for warranty or repair, including duties and fees required by those residing outside the United States.

THANK YOU FOR CHOOSING HIGHIFTER

CONTACT

• sales@highlifter.com
• 800-699-0947 8:00am – 5;00pm CST
• 7455 Atkinson Drive, Shreveport, LA 71129
• www.highlifter.com

References

• High Lifter Products, Inc.

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