The front struts on the newer models (I believe they started in '05) have @ 31mm more travel, not to mention the tube is longer...yeah, I know....duh!
Anywho,
The struts/springs I tried to use off an '08 were just way too much lift with axle boots rubbing and crazy axle angles. I could have done more modifying, but I was NOT out for lift, but rather a cheaper alternative compared to buying new struts and HD springs.
So next I tried using the newer struts with the old springs.
Well, now there was too much travel as the springs had way too much slop. The relaxed '08 springs are nearly 3" taller than the older ones.
So I needed some way to take up some of the gap without hitting the same height as the '08 springs which would have brought me back to square one.
Enter Rubberdown Customs.
He was the ONLY one that I found to make a smaller 1.5" spacer instead of the 2" ones, not to mention the pricing was more than fair. I bought the front end lift kit, but only used the spring spacers as the newer struts already had increased tube length and did not need to be lifted.
Soon my '08 SP WILL have a full Rubberdown 1.5" lift as all I want is just a little more height, nothing major. Strong, well made aluminum pieces. Highly recommended.
I will say if anyone is gonna try this also, that they make sure to get the the hardware ( mainly BOTH nuts) at the top of the struts. The newer struts use a larger diameter nut. My old rear lugs from my Scrambler were the same thread size. This is why you throw NOTHING extra in the trash!
The rear springs/shocks from the '08 will NOT work as the springs are wider and will hit the rotor on the older transmission setup.
It was a match made in heaven. No rubbing boot issues at all.
Just a small ride up the alley and the difference is just amazing.
Hitting curbs is barely noticeable now! Can't wait to field test the machine now.
Heres my cost savings:
Used struts/springs from '08 SP 800 incl. shipping $45.00
Rubberdown Customs front end lift $86.00
----------------------------------------------------------------------
TOTAL $131.00
2 new struts and HD springs from Polaris---------@ $300.00
Plus I would have the same short travel struts.
And now for the pics....
Before:
![Image](http://i490.photobucket.com/albums/rr262/wildhorse71/ATV%20RIDES/New%20Old%201999%20Sportsman%20500/100_2348.jpg)
AFTER:
![Image](http://i490.photobucket.com/albums/rr262/wildhorse71/ATV%20RIDES/1999%20Sportsman%20front%20custom/100_2450.jpg)
BEFORE:
![Image](http://i490.photobucket.com/albums/rr262/wildhorse71/ATV%20RIDES/New%20Old%201999%20Sportsman%20500/100_2347.jpg)
AFTER:
![Image](http://i490.photobucket.com/albums/rr262/wildhorse71/ATV%20RIDES/1999%20Sportsman%20front%20custom/100_2449.jpg)