Gorilla Axle 7” Suspension Lift 2008 Polaris RZR 800 PRODUCT

Gorilla Axle 7” Suspension Lift
2008 Polaris RZR 800
www.gorilla-axle.com
318.345.8186
[email protected]
PRODUCT SAFETY WARNING
Read before installation!!
Installation of suspension lift kits will raise the center of gravity. For this
reason, Gorilla Axle Inc. strongly urges that extreme caution is used when
encountering potentially hazardous driving conditions such as hill climbs, side
hills, or traversing deep ruts and mud pits. Also, the driver’s field of vision and
judgment will not be as good due to the elevated ride height. The installation
of larger diameter tires will cause the speedometer to read slower than the
actual true ground speed in addition to affecting braking performance which
may alter the predicted stopping distance needed.
It is the owner’s
responsibility to caution and warn any potential driver of the vehicle about these
driving and handling conditions. Wider tires and wheels are suggested to help
accommodate the lifted ATV/RUV and offer more stability. Gorilla Axle Inc.
strongly recommends the use of helmets AT ALL TIMES. It is strongly
suggested that a qualified professional mechanic install all Gorilla Products as to
insure correct installation. Do not add, alter, or fabricate any factory or
aftermarket products to add height to the intended lift of the Gorilla Lift Kit.
Doing this could result in product malfunction, injury, death or loss of warranty.
Do not jump or exceed speeds over 25mph. Gorilla Axle Inc. will not be held
liable or responsible for damages or personal injuries resulting from the use of
lifted ATVs, altered products, improper installation, or improper use of lifted
ATVs. Review your parts list for missing or damaged parts. Please call us at
318.345.8186 with any questions concerning product design, function, or the
correct usage.
When possible, keep all bolts uniform for a clean appearance.
DO NOT TIGHTEN ANY BOLTS UNTIL INSTALL ON LIFT IS COMPLETE.
Parts List
GFRA-U
Front Right Upper A-Arm
GFRA-L
Front Right Lower A-Arm
GRRA-L
Rear Right Lower A-Arm
GRRA-U
Rear Right Upper A-Arm
GFLA-U
Front Left Upper A-Arm
GFLA-L
Front Left Lower A-Arm
GRLA-L
Rear Left Lower A-Arm
GRLA-U
Rear Left Upper A-Arm
GRP-R
Gorilla Rack & Pinion (Boot)
Bolt Kit
WARNING LABEL-APPLY TO DASH
A
GFSM P
(4) Shock Mount Plates
GTR-R
Heavy Duty Tie Rod Right
GTR-L
Heavy Duty Tie Rod Left
GRSM-A
Right Rear Shock Mount-Front Plate
GRSM-B
Right Rear Shock Mount-Back Plate
GRSM-C
Left Rear Shock Mount-Front Plate
GRSM-D
Left Rear Shock Mount-Back Plate
GRP-L
Gorilla Rack & Pinion (Boot)
(4) Gorilla Lift Axles (Gorilla Axle should be legible)
FRONT ASSEMBLY
Remove Wheel, Wheel Hub, Front Shock, A-Arms & Tie Rods.
A-1. Remove front bumper and headlight cowling. Remove Right Side front wheel and wheel
hub. Leave Brake Lines attached.
A-2. Remove Front Shock Assembly, Upper A-Arm, Front Axle and Lower A-Arm.
A-3. Remove Tie-Rod assembly. Remove boot off of Rack & Pinion. Remove R & P and install
GRP-R and new Rack & Pinion boot.
A-4. Repeat Steps A-1-3 for Left Side.
A-5. Remove all Ball Joints from Stock A-Arms and install in Gorilla Lift A-Arms.
B
Install A-Arms, Axle’s, Shocks, & Wheel Hub.
B-1. Install front Right Lower A-Arm (GFRA-L) using stock bolts and nuts. Attach bottom of
Wheel Hub to Lower A-Arm using stock bolts.
B-2. Install Front Gorilla Axles. (See directions in axle box)
B-3. Install Upper A-Arm using supplied bolts.
B-4. Install upper shock mounts to Upper A-arm. Attach lift shock mount outside of A-Arm
shock mount holes.
B-5. Attach upper shock mount to Original shock mount on frame.
B-9. Attach bottom of hub to A-Arm and insert axle through hub. Attach stake nut loosely.
B-10. Install upper A-Arm and attach shock mount.
B-11. Install Heavy Duty. Be sure outer tie rod is connected beneath the hub mount not above
it.
B-12. Repeat on left side.
C
REAR ASSEMBLY
Remove Wheel, Wheel Hub, Rear Shock, A-Arms & Sway Bar
C-1. Remove Right Side Rear Wheel and Wheel Hub.
C-2. Unbolt Sway Bar from Lower A-Arm and Remove from RUV.
C-3. Remove Rear Shock, and A-Arms. Remove Rear Axles.
D
Install Rear Shock Mount Plates, A-Arms, Hubs & Axles
D-1. Install Lower Rear A-Arm (GRRA-L) using stock bolts.
***NOTE*** Rear Hub is Directional*** Repeat on Left Side.
D-2. Install rear Axles. See instructions in Axle box.
D-3. Install rear shock mount with supplied spacer into stock location.
D-4. Install Upper A-Arm (GRRA-U) using supplied bolts. Attach Rear Hub to Upper A-Arm
Using bolts, supplied washers and attach lock nut. Repeat on Left Side.
D-5. Install Lower Shock Assembly to Lower A-Arm (GRRA-L) using supplied bolts and nuts.
Install upper Shock Assembly to Shock Mount (GRSM-A & GRSM-B) using Bolts and washers
on softest setting. Attach lock nut. Repeat on Left Side.
TIGHTEN BOLTS AND LIFT IS COMPLETE.
Brake Lines
Remove the stock brake lines from the front of unit. Install new longer brake lines on front.
Rear- There is an extension for the rear right brake line. Trace the brake line behind driver
seat under the frame and add supplied extension there. The left brake line will reach.
Bleed brakes according to Polaris Owners Manual.
TEST RIDE
Perform a test ride at slow speeds to insure all parts are installed correctly.
Re-inspect all bolts and nuts are tight. Repeat this procedure every 30 days or 50 miles to
insure the RUV Suspension is being maintained.
See pictures at