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Discussion Starter #1
Hello All,

I've been having an issue with my 2017 Sportsman 570 that pertains to the rear RH sway bar link contacting the exhaust muffler when the suspension is at near full travel. I brought the machine to my local dealer and tried to get it checked out under warranty. Since the service manager had never seen or heard of this exact issue, he assumed that I was hiding something from him "there's something going on here that we don't know about" (Jim, Tousley Motorsports Service MN). I pulled it out of the dealer as soon as I realized their priority wasn't to help me but to point a finger at me.

I've never towed or hauled anything; however, I do weigh 240 lbs and certain riding conditions and terrain must be causing this issue. I ride responsibly on state trails and the 4 wheels have never been off the ground. I've spent a lot of time trying to track this issue down online but cant find anything of significance. If anyone has experienced this same issue, please let me know so that I can inform Polaris about the problem.

Thank you very much!
 

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Same here on my 2011 800. No issue has come of it. It's just light contact of the upper sway bar bushing and the muffler at full suspension compression. Set the preload on your rear springs all the way up or purchase HD springs, these suggestions want stop the issue but will reduce it.
 
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Same issue on my 2013 and 2014 400's.
Nothing has ever come of it and my machines have over 4000 miles on them.
 

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Discussion Starter #6
Hello All,

Thanks for the prompt replies and suggestions, I really appreciate it! However, I don't think I should have to stiffen the springs up or put HD springs in. That only would reduce the ride quality and isn't the RIGHT fix for the problem. I bought the machine for its ride quality mainly, and that's why this is a big deal to me. The suspension should be able to move through it's full range of motion without contacting the exhaust components at all times. Like many of you, I've been riding for over 25 years; and, I've never experienced anything like this on any machine. Basically, the Polaris engineers designed the suspension to use the exhaust muffler as a hard stop, lol.

Like one of you has mentioned, I only noticed that the rubber was touching the exhaust at first, so I didn't think much of it; however, now a good portion of the washer is gone and about 0.020" of material is missing from the muffler. Also, the link arm is even scraping the muffler at this point. I only have about 600 miles on my machine.

If any of you that are experiencing this issue could please state if this happens when riding normally, or only when riding in EXTREME conditions or carrying massive payloads it would be most appreciated. In my case, I noticed the problem right after my very first easy trail ride with no load or towing.

Thanks again
 

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Discussion Starter #8
HD springs...or...just take it off.
Thanks for your suggestion Sir; however, I would like to keep the sway bar assembly installed at this point and maintain the smooth ride. Polaris shouldn't be using the muffler as a suspension hard stop IMO.
 

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I mean you can make a big deal out of it or accept it. Whether you feel it's acceptable or not. I have HD springs and 3,500 miles on my wheeler and it still rubs when I get after it. It doesn't damage nor affect anything. If that little rub mark bothers you selling your machine might be your only option lol.
 

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Discussion Starter #10
I mean you can make a big deal out of it or accept it. Whether you feel it's acceptable or not. I have HD springs and 3,500 miles on my wheeler and it still rubs when I get after it. It doesn't damage nor affect anything. If that little rub mark bothers you selling your machine might be your only option lol.
There's actually about 0.020" of material missing from my muffler at this point and the sway bar arm is scraping the muffler too. My machine only has 600 miles on it. The suspension components should be able to move through their full range of motion without contacting the exhaust is what I'm getting at. Thanks again for your suggestions and reply's.
 

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Have you turned up the preload on the springs?
 

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Here's a pic of mine and yours is worse! With 1/6 the miles I have. Our machines are very similar. So you are definitely going through a fuller range of suspension travel then I do. So its HD springs if turning the preload up doesn't do it. Remember the Polaris suspension gets softer the more miles you put on it. So it's not uncommon to upgrade the springs. They don't ruin the ride and most guys feel the addition of HD springs improve the performance of the suspension and machine.
 

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Discussion Starter #13
Have you turned up the preload on the springs?
No, as I like having the smoothest ride possible. I understand that's an option but I'm just amazed that the engineers didn't incorporate hard stops into this machine which would keep this from happening. I'd rather bottom out from time to time than have to stiffen the springs up. If this were a used machine I'd be much more open to accepting the problem. Thanks
 

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Bottoming out is not a smooth ride in my book.... I don't think you can have both. I love my EPI HD springs!
 

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Discussion Starter #15
Here's a pic of mine and yours is worse! With 1/6 the miles I have. Our machines are very similar. So you are definitely going through a fuller range of suspension travel then I do. So its HD springs if turning the preload up doesn't do it. Remember the Polaris suspension gets softer the more miles you put on it. So it's not uncommon to upgrade the springs. They don't ruin the ride and most guys feel the addition of HD springs improve the performance of the suspension and machine.
Thank you so much for your help and going out of your way to send me that picture, this is exactly what I was looking for! Also, thanks for the feedback from yourself and other riders about the HD springs, I'll keep them in mind but as you said, it will still probably happen periodically. I'm working with Polaris on this issue and the consumer resolution specialist will be reviewing this post for data capture. I know they won't redesign the machine for just one customer but this issue could be taken care of with some slight changes. If enough of us address it, future models may not have this problem.
 

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I'm in total agreement there shouldn't be any contact between the two.
 

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Discussion Starter #17
I agree that bottoming out isn't a smooth ride but if it happens less than 5% of my time riding, I'll take that over a stiffer ride any day of the week. Thanks for your reply and HD spring recommendation; I may have to end up looking into them.
 

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Just an FYI if you do go HD springs. The two aftermarket spring manufactures are EPI and Highlifter. EPI has a lower spring rate then HL. The EPI's will have a softer ride.
 
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Bottoming out is not a smooth ride in my book.... I don't think you can have both. I love my EPI HD springs!
A properly set up suspension will use all of its travel. Lightly bottoming a few times per ride is acceptable.
Using the full range of the suspension nothing should contact. This is a poor design or poor engineering.
 

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Discussion Starter #20
Have you turned up the preload on the springs?
No, as I like having the smoothest ride possible. I understand that's an option but I'm just amazed that the engineers didn't incorporate hard stops into this machine which would keep this from happening. I'd rather bottom out from time to time than have to stiffen the springs up. If this were a used machine I'd be much more open to accepting the problem. Thanks
Actually, there are hard stops incorporated into the shocks; so that's good. I weight 240 lbs and I can't recall ever bottoming the suspension out.
 
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