I have noticed that on my SP500 the new mudlite tires I put on are slightly rubbing the front strut. There is a little tab on the strut tower that holds the bottom of the spring and I noticed that the tab was all shinny. Now I think it only happens when the tire is flexing over large bumps because the tires don't rub when the bike is sitting on a flat surface.
It looks like I only need 1/4" wheel spacers to solve my problem.
I looked at the 1" and 1 1/2" spacers online but I really didn't want to widen the stance of the bike.

I thought I would share it with you guys.So this is what I came up with.

I had my brother who works at a tool shop make me up a cad drawing and cut me some spacers out of 1/4" steel.



The only changes that I made to the drawings was I made the stud holes
.030. or 30 thousandths larger.


Final Product.


What they look like on the bike


The last thing that I had to do was to buy the longer studs from Polaris.
The longer studs are the ones that they use for aluminum rims.

I hope this helps if your looking for spacer options.

 

I originally did the same thing with 3/8" longer studs from ATVsuperstore.com and 3/8" steel. By using the 3/8" I was able to put on the wider XTRs without having to flip the tie rod ends. Great tutorial!!!

 

I just figured that the CAD drawings could help if anyone needed sizes to actually make some wheel spacers.