The Polaris factory service manual recommends setting pre-load by measuring distance down from the top of shock. This is flawed in that it's only good for factory new springs (with no sag) no accessories, no spring upgrades, and no cargo or other payload. Nor does it work for aftermarket shocks etc.
Dirtwheels, in cooperation with Walker Evans, published an article on setting preload based on ground clearance, and this method does allow for sag, accessories, upgrades, etc. This is the way to go, although they have some math errors in it regarding non-standard tires. With credit to Dirtwheels., here is the link to the article:
What follows is that process with corrected math, extensions to account for larger folks and loads, as well as a few “How can I tell” tips:
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And here:
Good Luck!
-d
Dirtwheels, in cooperation with Walker Evans, published an article on setting preload based on ground clearance, and this method does allow for sag, accessories, upgrades, etc. This is the way to go, although they have some math errors in it regarding non-standard tires. With credit to Dirtwheels., here is the link to the article:

TECH: BASIC SUSPENSION SETUP SECRETS - Dirt Wheels Magazine
— Walker Evans’ pros tell all — By the staff of Dirt Wheels with Reid Nordin. Recently, we had a unique opportunity to work with UTV suspension. Two friends have identical 2012 RZR 800 S models. These cars are basically clones of each other with almost identical aftermarket parts installed...
dirtwheelsmag.com
What follows is that process with corrected math, extensions to account for larger folks and loads, as well as a few “How can I tell” tips:
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- Make sure the stock suspension is moving freely. You won’t get good results if things are sticking.
- Lube sway bar mounts.
- Spray some Wd-40 on the shock shafts.
- Etc.
- Move the machine at least 30 feet to get the suspension to settle, and don’t push up or down on anything after that.
- An XP or XP Turbo should, from the measurement points shown in the pictures below, be:
- 13 3/4 inches at the front.
- 13 1/4 inches in the rear.
- Corrections should be made for the following:
- Larger tire sizes:
- For any tire increase add half the actual tire size increase (so the increase of the radius). EG: If you’ve moved from 29” to 32” you would add 1.5” to the above measurements.
- Extra weight:
- If you usually run “driver only” and are 200lbs or less you can use the numbers as is, loaded weight, per corner, isn’t going to matter enough to worry about.
- If you’re running larger loads, say driver and passenger, tools, coolers, and etc. you need to adjust based on “Race Sag.”
- Race Sag is just how the machine has squatted down under load. For a 500-600 of load this can be substantial.
- Load as you intend to ride it, move it the usually 30” and don’t get out. You need a buddy to measure where you are at.
- Larger tire sizes:
- How to adjust:
- Once you have your existing measurement take two full turns on the preload springs (both sides) and re-measure. You can calculate from there to get how many turns you need to get to the correct ride height.
- This won’t work if you don’t do both sides before you measure.
- If you’ve moved the suspension or tires you should move the machine 30’ again before you re-measure.
- Expect to fine tune a bit.
- Once preload is set you should readjust your crossover rings (if you have a dual rate system) to whatever value you prefer. If you don’t know what to think start at 2” for a performance guy, 3” for comfort focused, and experiment from there.
- Once you have your existing measurement take two full turns on the preload springs (both sides) and re-measure. You can calculate from there to get how many turns you need to get to the correct ride height.
- When are your springs just plain wrong?
- Too heavy:
- Jack the machine up by the frame and confirm the wheels are off the ground. If you can easily rotate the springs, and/or have no preload left, you’re sprung too heavy.
- You could perhaps use over-travel/limited straps to help.
- Too light:
- If the spring has compressed by 4” it’s sprung too lightly.
- This can vary a bit based on spring lengths etc., but basically you won’t want to be so spring compressed that your spring goes into coil bind before the shock/shaft can compress all the way.
- Otherwise you lose shock travel.
- Too heavy:
And here:
Good Luck!
-d