I have an 04 Sportsman 400 that I purchased new for maintaining my property. I bought it the same time in bought my house so it was in the right price range at the time. It has been used solely for working. I haul, plow snow and dirt and log with it. I purchased it with the EBS addon and have added ITP 589 tires, a Dayco HP2002 belt and EPI blue secondary clutch spring for traction and low end torque. I also purchased 2 sets of Polaris coil spring spacers for the weight of my 60" moose plow. It has seen more than its share of hard work and has handled everything I've thrown at it, especially logging. It would be a Polaris / Warn poster child for ATV capabilities. I'd like to replace the front springs with a set of HD EPI springs and would like to know the best method to doing so. Any recommended threads appreciated. It seems it should be doable without removing the front skins if the front end is raised. Also, what is the best reasonable spring compression tool to use? Seems like auto spring compressors would be too large to use. I've read about people raising the front, lowering with a block under one strut, adding weight for max compression, then using a 5" stainless hose clamp to hold the compression for removal.... tested it, but seems a little wild to me... I appreciate the help.

 

i used info in a few threads i found.
old springs cam out with just pushing down on the front and removing the nuts.
new HD EPI springs will require a spring compressor.
some say you dont need one, but i had 600 pd on the front end of the machine, and couldnt get the nut started.
be warned of your cv boot and joint.
i took mine out just to be safe.
glad i did.
you can really damage them the way the strut moves around once unbolted.
im still in the process of finishing up, so thats all i can really help you with.

 

Try replacement spring kit from Progressive Suspension, they even add adjusters. I have them on my 99 Sportsman 500, work great.

 

You may find this post helpful. Has links to pictures and everything.

EPI Spring Installation

 

Chinchgub - Thanks for the great information. I thought about the tie down starp method and now like that idea. I ended up buying front and rear EPI HD springs from Dennis Kirk and got them this week. I load my ATV down pretty good with equipment when logging so I figured I do the rear also since I have saws, mauls, chains and tools on a rear mounted rack that fits in my class 3 hitch isntalled on the back. I thought about the progessive but I'm not too concerned about adjusting the front for ride. Thanks again!

 

Chinchgub - As you read I finally installed the rear EPI HD springs. Although not as easy as the fronts, it was definitely worth the effort. Love the feel\ride of my HD EPI suspension. Both sets of HD springs for about $130 shipped from Dennis Kirk. Thanks again for the assistance.

 

i also used the rachet strap method to in stall my 2 inch lift spacers and it worked great.i would still like stronger springs in the ft .w/ the 2 inch lift the ft sets level with the rear.if i put the lift on the back it sets way high i want the front and back level with the 2 inch on the ft and rear.

 

My 04 does sit level and higher after installing the EPI HD springs. The rear EPI HD springs were much shorter that the stock springs. The fronts were shorter than the front stock but only a bit. They are stiffer and different coil than stock spings and do not sag.