Dialing in Your Suspension: How to Correctly Set Crossover Nuts

When setting up a dual-rate spring system on your UTV, getting your crossover nuts positioned correctly is the key to unlocking a smooth ride over small chatter while maintaining enough bottom-out resistance for big hits.

However, setting crossover ring spacing is easily one of the most misunderstood tuning steps in the garage. Here is a quick guide on how to measure and set your crossover nuts like a pro.

Step 1: Set Preload and Ride Height FIRST

Before you touch your crossover nuts, stop right there. Crossover nut position must always be set AFTER your spring preload and ride height are established.

If you adjust preload or change your ride height later down the road, your crossover gap will change with it, so make sure your car is sitting where you want it before measuring.

Step 2: Full Extension (Get the Wheels Off the Ground)

To get an accurate measurement, your suspension needs to be completely unloaded.

• Jack up the vehicle so the tires are off the ground.

• Ensure the shocks are at full extension (droop).

Step 3: Measure the Gap

When measuring crossover gap, precision matters. You aren't just measuring to any random point on the spring assembly.

1. Top Point: Measure from the bottom edge of the crossover nut.

2. Bottom Point: Measure down to the inner lip on the spring divider.

Starting Target: For this specific setup, we shoot for right around 4.5 inches as a solid baseline setup.

Why Does This Measurement Matter?

The gap you measure at full extension determines when your secondary (main) spring engages during shock compression.

• Too small of a gap: The crossover nut contacts the spring divider too early, bypassing your tender spring almost immediately and causing a harsh ride over light chatter.

• Too large of a gap: The tender spring stays engaged for too long, allowing the shock to blow through its stroke and bottom out on harsh G-outs or jumps.

Setting it at a solid baseline like 4.5 inches gives your tender spring room to soak up small bumps before smoothly transitioning into the heavy main spring when the trail gets rough.

Spin those nuts down, lock 'em in place, and go test your setup on the trail!