Gorilla 6” Suspension Lift Kit 2004-2008 Polaris Ranger

Gorilla 6” Suspension Lift Kit
2004-2008 Polaris Ranger 500 IRS and 700
www.gorilla-axle.com
318.345.8186
[email protected]
Gorilla Axle Inc.1289 Hwy 594 Monroe, LA 71203 V.318.345.8186 F.318.343.5678
www.gorilla-axle.com
PRODUCT SAFETY WARNING
Gorilla Axle
Gorilla Suspension Lift Warranty and Product Use Information
Applicable for any Gorilla Axle Suspension Lift
READ BEFORE OPERATING!!!
Generally a Gorilla Lift installed on an ATV/RUV will be make the vehicle taller than most other ATV/RUV’s,
possibly causing it to roll over easier. To offset this factor it is strongly recommended that you operate
Gorilla Lift kits with wider tires. This will give the vehicle much more stability and traction from rollover.
Many ATV Riders have the stock tires and wheels for their ATV for non-season use; always use a tire and
wheel combination that will ensure ATV/RUV stability.
We strongly recommend wearing a helmet while operating any ATV or RUV. Avoid situations where a side
rollover may occur such as, steep hills, river banks, creek crossings or any uneven terrain. Do not jump or
exceed speeds over 25mph.
Braking & steering performance and capabilities are decreased when significantly larger / heavier tires and
wheels are used. Take this into consideration while driving. Your Gorilla Lifted ATV/RUV may need a larger
turning radius. Allow for this when trail riding and be aware of riders behind you as to not cut them off.
Also, taller and more aggressive tires will cause most vehicles' speedometers to read slower.
Do not add, modify, or fabricate any factory or aftermarket parts to increase ATV height over the intended
height of the Gorilla Lift purchased. Combining any lift component from other manufactures components is
not recommended and will void your warranty.
A qualified professional ATV Technician must install all Gorilla Axle products to insure Warranty and Safety.
Gorilla Axle Inc. makes no claims regarding lifting devices and excludes any and all implied claims. Gorilla
Axle Inc. will not be responsible nor will warranty for any altered product, improper installation, or improper
use of our products.
Gorilla Axle products are warranted to be free from material and workmanship defects for one year as the
original purchaser owns the vehicle that the Gorilla product was originally installed on (proof of purchase is
required). This warranty is non-transferable. Gorilla Axle’s limit of liability under this warranty is to repair or
replace the product at Gorilla Axle’s option. Consequential costs such as, but not limited to labor fees, loss of
use, loss of time or freight charges are not covered. Product paint or color finish is excluded from this
warranty. Items that are subject to wear are not considered defective when worn and are not covered. Any
product that has been abused, altered, incorrectly installed or used in competition is not covered. The
Warranty is void if the "Warning to Driver" decal is not properly displayed on the vehicle. No other
warranties are expressed or implied. Gorilla Axle reserves the right to make changes in design, materials
and specifications without prior notice.
Failure to abide by any of the following recommendations or procedures can and will void your warranty.
We will be happy to answer any questions concerning the design, function, and correct use of our products.
All products sold by Gorilla Axle Inc. as OEM Equivalent (New Outer Joints, Neoprene Boots and Rebuild Kits)
carry the same warranty as the parts you would purchase from your OEM dealer--NO WARRANTY. Our
GORILLA AXLE warranty is stated below for heavy duty and conversion axles. Gorilla Duty Axles can be
repaired if necessary, for a minimal charge after the warranty has expired.
LIMITED WARRANTY
GORILLA AXLE warrants to the ORIGINAL buyer of any axle that it is free from any defects in workmanship and material for one year,
subject to the following conditions: a) The product is properly installed, used and maintained. b) Determination as to the
existence and nature of any defect in workmanship or product shall be made by GORILLA AXLE, and all such determination shall be final.
c) If the unit has been disassembled or modified in any way by any other party other than GORILLA AXLE, the warranty shall be
considered null and void. Our warranty covers only parts REPLACED by GORILLA AXLE. Any OEM housing or axle bar is not
covered under the warranty. If by chance an OEM part of the axle fails we will try to replace this part for you at cost. Furthermore, not
covered under the warranty- Repair or replacement following collision. Excessive damage to components due to torn boots is not
covered. Inspection of boots should be part of regular ATV maintenance. d) Purchaser must have original invoice number and date. e)
GORILLA AXLE is not liable for any incidental or consequential damages. Also not covered are the labor and materials that may be
necessary to remove a defective unit or to install a replacement unit.
Shipping to and from Gorilla Axle is the responsibility of the consumer.
THIS WARRANTY CANNOT BE TRANSFERRED AND IS ONLY VALID FOR THE ORIGINAL RETAIL PURCHASER. If all of the above terms are
met GORILLA AXLE will replace the defective parts.
RETURN AUTHORIZATION (RA) AND RETURN INFORMATION
ALL RETURNS FOR WARRANTY MUST BE PRE-APPROVED, WITH AN RA NUMBER DISPLAYED ON
THE BOX.
FREIGHT CHARGES FOR RETURNED PRODUCTS ARE NOT REFUNDABLE.
ABSOLUTELY NO RETURNS ON ANY CUSTOM AXLE / NON-STOCKING ITEMS.
All returns for warranty must be pre-approved, with an RA number clearly displayed on the box. The return must be received by Gorilla
Axle Inc., within 15 calendar days from the day the RA number is issued, otherwise the return will be refused. The RA
number does not imply a replacement or refund on any product, but only that we will inspect the merchandise you purchased based on
the claims you have made. Returns must be sent freight-prepaid, and insured by the sender. Original shipping and
handling charges for returns are non-refundable. For orders outside the United States, any fees associated with customs or duties are
non-refundable. All authorized returns must be accompanied by a photocopy of the customer's sales invoice, a written
explanation of the problem, and a contact telephone where you can be reached. Items returned freight-collect or unauthorized will be
refused. Customers must be aware that they will be subject to inbound and outbound freight to handle and / or process their warranty
claim. We accept returns on new, un-installed, undamaged items in original packaging (all parts and paperwork must be included) within
14 days from the delivery date to the consumer. During this time period, a return authorization must be initiated by the consumer. After
this time period, no return authorizations will be given. A returned authorization (RA) number must be
issued before any returns can be made. Any return without an RA number will be refused or automatically assessed a 25%
restocking fee less freight charges. It is the sole responsibility of the customer and/or the installer to verify that the parts
purchased are the correct parts for your application PRIOR to installation. We assume no liability for costs or inconvenience
incurred as a result of incorrect parts. If the installer/user damages these parts in an attempt to install them, we will access an
appropriate fee determined by the extent of the incurred damage. We reserve the right to charge up to a 25% restocking fee for ANY
and ALL returned items, regardless of reason, including but not limited to manufacturing defects.
Refused Shipments/ Order Cancellation:
Refused shipments are subject to a 25% restocking fee plus return freight. If a customer wishes to cancel an order (provided it is not a
special order product), it is the responsibility of the customer to cancel the order prior to the product being shipped. If a customer
cancels an order after product has been shipped, the refused shipment, cancellation, or return will be subject to a 25% restocking fee
and any freight charges incurred. For orders outside the United States, any fees associated with customs or duties are non-refundable.
Damaged Shipments:
All claims for damaged shipments must be made within 72 hours of delivery to the point of destination. Any damage to package should
be noted with carrier at the time of delivery if possible. We will not be responsible for damage claims made over 72 hours after delivery
to the point of destination.
When possible, keep all bolts uniform for a clean appearance.
DO NOT TIGHTEN ANY BOLTS UNTIL INSTALL ON LIFT IS COMPLETE.
Parts List
GFSM-L
Front Strut Mount Extender-Left
GFLA-R
Front Lower A-Arm-Right
GRRA-A
Rear Right A-Arm Extender-A
GRRA-B
Rear Right A-Arm Extender-B
GRSM-L
Rear Shock Mount Extender-Left
BRAKE LINES (2)
Bolt Kit
Tie Rod Extension (2)
Sway Bar Extension Mount (2)
WARNING LABEL-APPLY TO FENDER
GFSM-R
Front Strut Mount Extender-Right
GFLA-L
Front Lower A-Arm-Left
GLRA-C
Rear Left A-Arm Extender-C
GLRA-D
Rear Left A-Arm Extender-D
GRSM-R
Rear Shock Mount Extender-Right
GSM-R
Steering to Strut Mount-Right
GSM-L
Steering to Strut Mount-Left
Aluminum Strut Spacer (2)
(4) Gorilla Lift Axles
A
FRONT ASSEMBLY
Remove Wheel, Wheel Hub, Front Strut, A-Arms, Axle & Tie Rods.
A-1. Remove Right Side front wheel, wheel hub, brake caliper and steering tie rod.
A-2. Unbolt top of strut and remove strut from lower a-arm using a ball joint separator.
A-3. Remove stock axle from unit and remove lower a-arm.
A-4. Repeat Steps A-1-3 for Left Side.
B
Install Gorilla Front Strut Mount Extender
(GFSM-F, GFSM-R, GFLA-R, GFLA-L, Front Brake Lines).
B-1. Install (GFSM-R) using supplied 7/8” bolt through original strut mount location.
Tighten this bolt.
B-2. Install brake line extensions on front as shown in pictures. Do not damage threads.
Route brake lines to allow proper length to brake caliper.
B-3. Install front right lower A-Arm (GFLA-R) using bushings from stock A-Arms. Grease
bushings before install. Install axle per axle instructions.
B-4. Install Aluminum strut spacer on strut housing. Place strut assembly on a flat surface
and remove top bolt. Loosen bottom bolt slowly. Do not face strut assembly while
loosening bolt. Strut may “spring” out of assembly and injure persons or property. Be sure
no one is near the strut assembly! Refer to a Polaris Maintenance manual if need be.
B-5. Grind or machine for boot clearance out of lower strut area. See pictures.
B-6. Install Strut Spacer on top of strut housing and strut into housing. Spray lubricant on
strut before placing into housing. Compress the strut assembly together until the shock
cylinder bottoms. With strut compressed, bolt the steering bracket (GSM-R) provided in
your kit, once bolts are tight, release pressure off of strut.
B-7. Install outer joint of axle through bearing carrier in strut and place wheel hub on with
axle nut.
B-8. Attach lower A-Arm using a ratchet strap to compress strut assembly. Align a-arm hole
with ball joint and attach lock nut and cotter pin. Stock CV boot guard may need trimming
if it is used.
B-9. Repeat B-1 thru B-8 for left side.
DO NOT TIGHTEN BOLTS UNTIL LIFT IS COMPLETE.
C
Install Heavy Duty Tie Rods.
C-1. Install Tie Rod Extension with extension closest to wheel.
C-2. Repeat step C-1 for Left Side.
C-3. Steering will need to be adjusted once tires are on unit and unit is on a flat surface.
DO NOT TIGHTEN BOLTS UNTIL LIFT IS COMPLETE.
E
REAR ASSEMBLY
Remove Wheel, Wheel Hub, Rear Shock, A-Arms & Sway Bar
E-1. Remove Rear Wheel and Wheel Hub.
E-2. Unbolt Sway Bar from A-Arm.
E-2. Remove Rear Shock, and A-Arms. Remove Rear Axles.
F Install Rear Shock Mount , A-Arm Extenders, Sway Bar,
Hubs & Axles
F-1. Install rear shock mounts. See picture.
F-2. Install rear A-Arm extender in original A-Arm holes. Install with “3 hole” side of
bracket on frame rail. See picture.
F-3. Attach lower A-Arms to extenders. Install rear axles.
F-4. Attach upper A-Arms to extenders. Attach rear hubs.
F-5. Attach sway bar extension to A-Arm.
Tighten all bolts on unit.
** Bleed brakes per Polaris Maintenance manual.**
PICTURES