CHAPTER 7

c SUSPENSION
Rear Suspension Operation . . . . . .. . .. .. . .. .. .... .... ... 7.1 -7.2
Rear Suspension Tuning .... .. . . . . .. . . . . . .. . . . .. .... .. 7.3
Tunnel Mounting ...... .. . ... ... . .... ... . .. ...... .. . .. 7.4
Hi-Fax Inspection/Replacement .. . . . . . . . . ........ ... .. . 7.5-7.6
Suspension Lubrication Points/Torque Specifications ... . .. 7.7
Wheel Kits . . . . .. . ... . . .. .. . . ........ . .. . . . .... . ...... 7.8-7.10
Widetrak LX Rear Suspension Exploded View . . . .. .. . . ... 7. 11
Rear Suspension Components Widetrak LX/Tran Sport . . . . 7. 12

c TranSport Rear Suspension Exploded View . . . ....... ... 7.13

Rear Suspension Adjustment, Widetrak LX/Tran Sport . . . . 7.14
XTRA Lite Rear Suspension Exploded View . . . . . . . . . . . . . . 7.15
Rear Suspension Components XTRA Lite .. . ..... ... . ... 7.16
Rear Suspension Adjustment, XTRA Lite .. . ....... . .. . . . 7.17-7.18
XTRA 10 Rear Suspension Exploded View ... . . . .. . . . .... 7.19
Rear Suspension Components XTRA 10 121" .. ... . . .. ... 7.20-7.21
Rear Suspension Components XTRA 10 133.5, 136" . . . . .. 7.22
Rear Suspension Adjustment, XTRA 10 .. .. . . .. . ... ... .. 7.23
Front Rear Scissor Stop (FRSS) XTRA-10 Style .......... 7.24

c
Rear Rear Scissor Stop (RRSS) XTRA-10 Style . . .. ...... 7.25
Rear Suspension Exploded View - XTRA 12 121" . .... . ... 7.26
Rear Suspension Exploded View - XTRA 12 133.5" .... .. . 7.27
Rear Suspension Components XTRA 12 .. . . . .. . . . . .. . .. 7.28-7.29
IFS Front Torque Arm Limiter Strap Adjustment, X-12 .. . . . 7.30
Rear Suspension Adjustments, XTRA 12 .. .. . ... . .. . .. .. 7.31-7.32
IFS Adjustments, XTRA 10 and 12 ....... . .. . . . .. . ... ... 7.33-7.34
Compression Adjustable Shocks ..... . ... . ...... .. ... . .. 7.35-7.36
Suspension Springs and Rails ....... . . . . .. . . ... .. . ..... 7.37
Optional Springs - 1999 XTRA Lite/Tran Sport!Widetrak LX 7.38
Optional Springs- 1999 XTRA-10 Style . .. . . .. .... . .. . ... 7.39

c
Optional Springs- 1999 XTRA-12 Style . .... . . ... ... . . ... 7.40
Front Track Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
XTRA-12 Suspension- Shock Removal . . . .. . .. . ...... .. 7.42
IFS Fox TM Shock Specifications ... . .. . . .. .. . . . . . ..... ... 7.43
Rear Suspension Fox ™ Shock Specifications . ... .. . .. . .. 7.44
Typical Shock Valving Arrangement . . . . . . . . . . . . . . . . . . . . . 7.45
1997-1999 Production Valving Chart . . . . . . . . . . . . . . . . . . . . 7.46
1999 Optional Valving by Shock Part Number .. . . . ... .... 7.47-7.48
Valve Washer Part Numbers ........ . . . .. ... ...... . .. .. 7.49
Fox TM Shock Maintenance . ..... ... . . . . . . .. .. . ...... . . . 7.50-7.58
Polaris Position Sensitive Shock (PSS) . . .. . .. .... . .. .. . . 7.59-7.68
Suspension Troubleshooting . . .. . . ...... . . ...... . .. .... 7.69-7.72
)

\
J
 SUSPENSION
Rear Suspension Operation

r
...._
Refer to Specifications Section in Chapter 1 for Suspension Type I Model Application

Rear Suspension Operation

The primary function of the rear suspension is to provide a comfortable ride in all types of riding conditions. It
separates the rider from the ground, while allowing for complete vehicle control. The rear suspension also must
provide weight transfer and maintain track tension.
The rear suspension has many adjustable features for fine tuning to achieve optimum comfort. The suspension
can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should
be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform
well in the moguls would not suit the preference of a groomed trail rider.

Weight Transfer
The shifting of weight from the
skis to the track is called weight
transfer. As engine torque is ap-
plied to the drive axle the torque
is transferred to the track, pulling
it forward. This energy also tries
to pull the suspension forward.
The front torque arm reacts to
this force by pushing down on
the front of the track, in effect ap-

c
plying more weight to the front of
the track and reducing the
weight on the skis. It is important
to note that energy used to lift
the front of the machine is not
available to push the vehicle for-
ward.

Changing the angle of the front torque arm changes the suspension's reaction to the force. Adjusting the length
of the limiter strap will change the front torque arm angle. Shortening the strap limits the extension of the front
of the suspension; reducing the angle of the torque arm and increasing ski pressure during acceleration. Length-
ening the strap allows the front of the suspension to extend further; increasing the angle of the torque arm and
decreasing ski pressure during acceleration. Limiter strap adjustment has a great affect on weight transfer. Limit-
er straps only affect acceleration. It is important to check track tension whenever limiter strap length is changed.

c Front track shock spring preload also affects weight transfer. A stiffer spring and/or more preload on the spring
transfers more weight to the track. A softer spring and/or less preload keeps more weight on the skis. Keep your
riding application in mind when choosing springs and setting spring preload. Soft springs/preload will increase
ski pressure, but may bottom out. Stiff springs/preload will provide more track pressure (reduced ski pressure),
but may result in a less comfo rtable ride.

During acceleration, the rear of the suspension will compress and the IFS will extend, pivoting the machine about
the front torque arm. Because of this pivoting effect, rear spring and spring preload also have some effect on
weight transfer. Softer rear springs, or less preload, allow more weight transfer to the track and reduce ski pres-
sure. Stiffer rear springs, or increased preload, allow less weight transfer to the track and increase ski pressure.
The main function of the rear torque arm is to support the weight of the vehicle and rider, as well as to provide
enough travel to absorb bumps and jumps.

( Shock valving also has an effect on weight transfer. Refer to shock tuning information in this chapter.
'- Scissor stops also affect weight transfer. See scissor stop information in this chapter.

Polaris Industries Inc. 7.1 8/98

SUSPENSION
Rear Suspension Operation

Springs
Two types of springs are employed in Polaris suspen-
sions, coil springs and torsion springs. Following is some
of the terminology used when referring to coil springs.
Coil Spring
• Free length- the length of a coil spring with no load ap- Length
plied to the spring Installed
Length
Installed length - the length of the shock absorber be-
tween the spring retainers. If the installed length of the
spring is less than the free length, it will be pre-loaded.
• Spring rate - the amount of force required to compress
a coil spring one inch. For example, if 150 pounds of
force are required to compress a spring 1 inch, the
spring rate would be 150 #/in.

• Straight rate spring - the spring requires the same amount of force to compress the last one inch of travel as
the first one inch of travel. For example, if a 150 #/in. spring requires 150 pounds of force to compress it one
inch, 300 pounds of force would compress it two inches, 450 pounds of force would compress it three inches,
etc.
Progressively wound spring- the rate of the spring increases as it is compressed. For example, a 100/200
#/in. rate spring requires 100 pounds of force to compress the first one inch, but requires 200 additional
pounds to compress the last one inch.
When a bump is encountered by the suspension , the force of the bump compresses the spring. If the force were
450 pounds, a 100 #/in . spring would compress 4.5 inches. A 150 #/in. spring would only compress 3 inches.
If the suspension had 4 inches of spring travel the 100 #/in . spring would bottom out, while the 150 #/in. spring
would have one inch of travel remaining.

Torsion springs are much like coil springs , although

shaped differently. The rate of the torsion spring is con- Torsion Spring
trolled by the free opening angle, the installed opening
angle, the wire diameter of the spring, and the number of
coils. Load reduces
opening angle

r~o~~ ~ ~ ~ ~

8/98 7.2 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Tuning
Many factors influence the overall handling characteristics of snowmobile suspensions. Rider weight, riding style,
course conditions, and the condition of suspension components are some of the things that you have to consider
when tuning a suspension.
On new mach ines, or whenever new suspension parts are installed, the sled should be ridden for at least one
tank of fuel to allow moving parts in the shocks and suspension to wear in. The shock springs will also take their
initial set and the setup will be more accurate.

• Front Suspension: The front suspension should sag (unloaded) about 1" (measured at the front bumper)
with the weight of the sled. Use stiffer or softer springs as needed to keep from bottoming too hard, and to ensure
the entire range of trave l is used.
Rear Suspension Tuning
To begin suspension tuning, check the condition of shocks and other suspension parts.
• Inspect and grease all suspension parts, making sure they pivot freely. All suspension components should
be greased when disassembled. Regular maintenance greasing shou ld be done with no weight on the component
to allow grease to reach important contact areas.
Loaded Sag: Set the preload on the rear springs for the correct sag . There should be 1 1/2" of sag on the
rear suspension when the rider on the snowmobile, measured at the rear bumper. Bounce on the suspension
a couple of times to overcome any "stiction" and settle the sled to an accurate reference point. The rider shou ld
have their weight placed correctly on the machine . Adjust spring preload to achieve the 1 1/2" sag dimension .

Unloaded (Free) Sag: When the rider gets off the machine, the suspension should return to 1/2" of sag.
If the sag is less than 1/2" stiffer springs may be needed. If it is greater than 1/2" softer springs may be needed.
This may seem backwards at first, but if the spring is too soft, the preload must be greatly increased to prevent
excess loaded sag. This shows up in the form of less unloaded sag. Therefore, a stiffer sp ring is required. If
the spring is too stiff, the preload will have to be backed off, and unloaded sag will be excessive. This is a very
important step because the proper spring will also help ensure correct weight transfer.
Shock Tuning
The shocks work in two directions. Compression damping prevents the shock from bottoming hard while rebound
damping keeps the shock from springing back too fast. Both compression and rebound damping can be adjusted
for high and low speed damping characteristics. On Indy Select shocks, the compression damping can be
changed by turning the adjuster screw. Refer to shock section in this chapter for adjustment. NOTE: When we
refer to high and low speed, we are referring to the speed of the shock shaft or valve, not vehicle speed.
Rebuildable Shocks
Begin by taking the shocks apart, inspecting all parts for damage, and changing the oil. Even new shocks should
get an oil change after break in to clean break-in material from the shocks and valve body.
If oil is low, inspect seal cap 0-Ring and seals for damage. If air or foam is evident in the oil, the 0-Ring in the
floating piston must be replaced. After changing the oil reassemble shocks, making sure oil level, floating piston
depth (IFP), and nitrogen pressure are correct.
The use of nitrogen in Fox™ shocks provides consistent damping at extreme temperatures . Don't overcharge
the shocks. Excess nitrogen pressure may cause seal "stiction" and prevent proper shock action. If too much
oil is added, or if the IFP depth is set incorrectly (too low) shock travel wil l be limited.

Polaris Industries Inc. 7.3 8/98

SUSPENSION
Tunnel Mounting

1999 Rear Suspension Set Up I Tunnel Mounting Positions

Model Front Limiter Rear Limiter Rear Torque Front Track Front Torque
Strap Strap Arm Tunnel Shock Mount Arm Tunnel
Mount Mount
340/340 Deluxe Std N/A No Options N/A
340 Touring Std N/A No Options N/A
Sport Std N/A No Options N/A
Sport Touring Std N/A No Options N/A
TranSport Std N/A No Options N/A
XCF Quick Adjust Quick Adjust No Options Lower
440 XCR Quick Adjust Quick Adjust No Options Lower
Trail Quick Adjust Quick Adjust No Options Lower
Trail Touring Std Std No Options Lower z
0
Trail RMK Std NIA No Options Upper 0
Super Sport
WideTrak LX
Quick Adjust
Std
Quick Adjust
N/A
No Options
No Options
Lower
N/A
-
"'0
-0 ·
::::s
Q)
500 Quick Adjust Quick Adjust No Options Lower
500 RMK Quick Adjust Quick Adjust No Options Upper s
0
500 XC/SP Quick Adjust Quick Adjust No Options Lower c
Classic
Classic Touring
Std
Std
NIA
NIA
No Options
No Options
N/A
N/A
-
::::s
::::s
(0

XLT Special Quick Adjust Quick Adjust No Options Lower "1J

-
0
(/)
XLT Touring Std NIA No Options N/A
XLT Classic Std N/A No Options N/A 0
::::s
600 XC/SP Quick Adjust Quick Adjust No Options Lower (/)

600 RMK Quick Adjust Quick Adjust No Options Upper

700 XC/SP Quick Adjust Quick Adjust No Options Lower
700 XCR Quick Adjust Quick Adjust No Options Lower
700 RMK Quick Adjust Quick Adjust No Options Upper
700 SKS Quick Adjust Quick Adjust Below(See Ill.) Lower
800 XCR Quick Adjust Quick Adjust No Options Lower

NOTE: There are no optional front torque arm mounting positions. Do not re-locate the front torque arm.

700 SKS stock mounting position.

Optional position - lower hole.

Optional mounting hole for deep snow.

*If mounting here place dummy bolt (PN Front torque arm
7517388) in upper hole to secure rear suspen- stock mounting position.
sion mounting pad. No optional positions.

8/98 7.4 Polaris Industries Inc.

 SUSPENSION
Hi-Fax Inspection I Replacement

Hi-Fax Replacement- All Models

Hi-Fax replacement on all Polaris models is simi lar. Hi Fax Wear Limit
When any area of the Hi-Fax is worn to 1/8" (.3 em), it
should be replaced. This will save wear on other vital
components.
Th e slide rail is designed to operate in conditions with ad -
equate snow cover to provide sufficient lubrication . Ex-

=
cessive wear may be due to improper alignment, improp-
er track adjustment or machine operation on surfaces
without snow. 5 ~ 5/16"

c Replace Hi-Fax when worn to 5/16" (.79 em) on XTRA

12 suspensions; 3/8" (.95 em) on XTRA 10 and Sport
style suspen sions; 7/16" (1 .1 em) on XTRA Lite style
suspensions.
~-XTRAf2 -l1---- t'

Suggested Hi Fax Wear Limit:

XTRA 12- 5/16" (.79 em)

XTRA 10- 3/8" (.95 em)

XTRA Lite -7/16" (1.1 em)

c Hi-Fax wear pattern s are somewhat different on machines equipped with the XTRA 12 suspension than on
conventional models. The rear of the rail will wear rapidly at first. After this initial break in period, the rapid wear will
cease. This area should be checked frequently, however, replacement is not necessary until a thickness of 5/16"
(.79 em) is reached .
New Hi-Fax are best used in deep snow conditions. Marginal snow or hard-pack conditions are better suited to
worn Hi-Fax, or Hi-Fax which have been cured or broken in.

Hi-Fax Removal

1. Remove suspension from machine .

NOTE: Some models may allow Hi Fax to be removed
( by sliding it through track windows with the suspension
mounted in the machine.

2. Remove front Hi-Fax retaining bolt as shown.

Polaris Industries Inc. 7 .5 8/98

SUSPENSION
Hi-Fax Replacement

3. Use a block of wood or a drift punch and hammer to

drive Hi-Fax rearward off the slide rail. J
4. With Hi-Fax material at room temperature, install
new Hi-Fax by reversing steps 1 - 3.
NOTE: Lightly coat Hi-Fax track clip area with a lubricant
such as LPS2 or WD-40 to ease installation.
NOTE: Wide Hi-Fax should be narrowed on the leading
sides to allow it to fit through narrow windows.

)
Track Clip Removal - All Types

1. Position removal tool jaws on edge of clip.

2. Squeeze handles together to spread clip.
3. Remove clip.

Track Clip Replacement - Yokohama

1. Install replacement clip and clipping tool as shown. __)

NOTE: For ease of operation, the tool may be placed in
a vise.

2. Tighten drive bolt against forming die until clip is

formed.

Track Clip Replacement - Camoplast

1. Place new clip in position on track.

2. Connect clip installation tool on top of clip.
3. Squeeze handles together to crimp new clip.

Track Clip Installation Tool (Camoplast)

PN 2871

Track Clip Installation Tool (Yokohama) ·

PN 2870380

8/98 7.6 Polaris Industries Inc.

 SUSPENSION
Suspension Lubrication Points I Torque Specifications

* LUBRICATION POINTS- XTRA LITE

Grease at fittings
* LUBRICATION POINTS - Widetrak LX!TranSport
Grease at fittings

**
*

*
Forward
Forward *
.-
*
(Both sides)

*LUBRICATION POINTS - XTRA-10 *LUBRICATION POINTS- XTRA-12

Grease at fittings Grease at fittings

*
*
(Both sides)
Forward
.- *
Forward
.- *
Suspension Torque Specifications
3/8" top shock mounting bolts . .. . . .. . .. .. . ..... .. . . .... . . . . .. .. 28-30 ft. lbs. (3.85 - 4.14 kg -m)
3/8" suspension mounting bolts . .. . .. . . ... . ... . .. .. ... . . . . ... . . 35 -40ft. lbs. (4.8 - 5.52 kg -m)
7/1 6" suspension mounting bolts .. . .. .. . . . .... . .... . . . . . . . . ... . 55 -60ft. lbs. (7.61 - 8.30 kg-m)
Shock rod bolts (do not over torqu e) . ... . .... . ...... . ...... . .. . . 12 ft. lbs. (1 .66 kg-m)
* Shock rods must pivot freely after torquing

Polaris Industries Inc. 7 .7 8/98

SUSPENSION
Wheel Kits

Wheel Kit Mounting Recommendations

The following illustrations indicate proper installation of optional wheel kits .

XTRA Lite

Inside NOTE: If installing optional rear

Kit PN 287165 1 wheel kit, rear scissor must be
mounted in rear hole.

XTRA 10 121"

Inside-
Kit PN 2870602 Outside-
Kit PN 2871582

8/98 7.8 Polaris Industries Inc.

 SUSPENSION
Whee l Kits

c Wh eel K"1t Mounting Recommendations

XTRA 10 133.5"

Outer -
Inner_ Kit PN 287 1582
Outer -
Kit PN 2871582
Kit PN 2870602

XTRA 10 136"

Outer-
Kit PN 2871582
Inner _
Kit PN 2871582
Outer-
Kit PN 2870602

(_

Polaris lndustnes
. Inc. 7.9 8/98
 SUSPENSION
Wheel Kits

Wheel Kit Mountmg

. Rec ommendations

XTRA 12 121"

Outer-
Kit PN 2870602

Outer -
Kit PN 2871582

XTRA 12 133.5"

No Wheel Kits r~comm ended

for this s uspensron

-
8/98
7.10 Polaris Industries Inc.
 SUSPENSION
WideTrak LX Style- Exploded View

'

Front Torque Arm Rear Torque Arm

'

c
Polaris Industries Inc. 7.11 8/98
SUSPENSION
Rear Suspension Components WideTrak LX I TranSport

Rear Torque Arm

Rear Shock

Adjuster
Eye bolt

Carrier Wheel

Rail Bumper
Rail Tip
Rear Pivot Arm

Front Track Shock Front Track Spring

-
Forward

Hi-fax

Bogie Wheel

Slide Rail

Rail Bumper

Idler Wheel

8/98 7.12 Polaris Industries Inc.

 SUSPENSION
TranSport Style - Exploded View

Front Torque Arm Rear Torque Arm

Polaris Industries Inc. 7.13 8/98

SUSPENSION
Suspension Adjustment - WideTrak LX I TranSport
The Polaris WideTrak LX and Tran Sport suspension has been designed and set up to deliver a soft ride under
average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension
action.
Th e suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

• IFS compression sp ring preload
• Rear torsion sp ring preload
• Rear shock compression (if equipped with Indy Select shock)
• Optional coil springs for front track shock

Adjustment Procedures
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) before fine
tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. The machine should be methodically tested under the same conditions after each adjustment (trail and
snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be
made to one area at a time, in order to properly evaluate the change.
The purpose of the front track shock coil spring is to control ride height. If you find that in order to obtain the desired
ride effect th e spring preload is at its maximum, consider removing the existing spring and installing the next high-
est rate spring.

Rear Suspension Adju stments - WideTrak LX

The primary adjustment for riding comfort is rear torsion spring preload adjustment. To check for the recom-
mended settings:
1. Lift the rear of the machine to relieve the rear springs.
2. Slowly lower the machine and measure the distance between the ground and the running board at the rear of
the tunnel.
3. Without letting the suspension settle, the rider shou ld carefully mount the snowmobile.
4. Measure th e distance between the ground and the same spot on the running board.
If the difference is greater than 1 1/2", the rear spring should be adjusted equally on both sides until the desired
1 1/2" drop is obtained.
Compensating adjustments for heavy or Torsion Springs
light drivers or cargo loads can be made
by adjusting the rear torsion spring eye
bolt (A) length . Adjust spring tension so
there is equal tension on the long leg of
each spring .
NOTE: Rear torsion spring settings will
affect ski-to-ground pressure. It may be
desirable to tighten rear torsion springs
for an increase in ski-to-ground pres-
sure. If ski pressure is too light, the ma-
chine will be hard to steer around curves
and will tend to push, or drive straight
through curves.
-
Forward

8/98 7. 14 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Exploded View - XTRA Lite

Front track shock spring

preload washers PN
5210953.

Rear Torque Arm

Front Torque Arm

Polaris Industries Inc. 7 .15 8/98

SUSPENSION
Rear Suspension Components - XTRA-Lite

Rear Track
Shock

Rail Bumper

Front Track Shock Front Torque Arm

Front Track

-
Forward Spring

Rail Tip

Rail
Bumper Bogie Wheel
Rear Track
Shock

Rail Bumper

8/98 7.16 Polaris Industries Inc.

 SUSPENSION
Suspension Adjustment- XTRA Lite
Suspension Adjustment

c The Polaris suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider
weight, riding styles, trail conditions, and vehicle speed each affect suspension action.
The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

• Rear torsion spring preload

• Optional coil springs for front track shock and spring preload washers
• Optional torsion springs
• Front limiter strap
• Optional coil springs for IFS shocks
Adjustment Procedures
It is a good idea to break the suspension in for approximately 150 miles (240 km) and re-grease all suspension
parts before fine tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. The machine should be methodically tested under the same conditions after each adjustment (trail and
snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be
made to one area at a time, in order to properly evaluate the change.
The purpose of the front track shock coil spring is to control ride height and front IFS preload. If you find that in
order to obtain the desired ride effect the spring preload is over four additional washers (total of five), consider
removing the existing spring and installing the next highest rate spring.

Polaris Industries Inc. 7.17 8/98

SUSPENSION
Suspension Adjustment - XTRA Lite
For Recommended Optional Settings, Refer to Suspension Set Up Decal Under Hood

Rear Suspension Adjustments

The primary adjustment for riding com-
fort is rear torsion spring preload ad-
justment. To check for the recom-
mended initial settings: Torsion Springs

1. Lift the rear of the machine to

relieve the rear springs.
2. Slowly lower the machine and
measure the distance between the
ground and the running board at
the rear of the tunnel.
3. Without letting the suspension
settle, the rider should carefully
mount the snowmobile.
Torsion Spring
4. Measure the distance between the
Preload Adjuster
ground and the same spot on the
running board.
If the difference is greater than 1 1/2",
the rear spring should be adjusted
equally on both sides until the desired
1 1/2" drop is obtained. See adjust-
-
Forward

ment information below.

Compensating adjustments for heavy
or light drivers or cargo loads can be
made by adjusting the preload adjust-
er. Remember, this is only the initial
settings. Final settings should be de-
termined by riding the snowmobile and
readjusting.
NOTE: Rear torsion spring settings will affect ski-to-ground pressure. It may be desirable to tighten rear torsion
springs for an increase in ski-to-ground pressure. If ski pressure is too light, the machine will be hard to steer
around curves and will tend to push, or drive straight through curves.
The XTRA Lite suspension comes from the factory with
the rear suspension pivot mounted in the second hole These holes
from the front of the rail. Do not move to the front used for
mounting hole. extra bogie
wheel
placement
only

#1 - stock position
#2 - use to stiffen

-
Forward rear suspension

8/98 7.18 Polaris Industries Inc.

 SUSPENSION
.
. n Exploded VJew
Rear SuspensJo - XTRA 10 Style

c
Front Torque Arm Rear Torque Arm

c
Polaris Industries Inc. 7.19 8/98
SUSPENSION
Rear Suspension Components - XTRA 10 Style

Rear Limiter Strap Adjuster

Compression Valve Adjustment Screw

(Ryde AFX /Indy Select Shocks)

_)

Rear Scissor

Rear Torsion Spring

Adjuster Cam (Low Posi-
tion Setting Shown)
Limiter Strap
(Quick Adjust)
FRSS (Front Rear RRSS (Rear Rear
Scissor Stop) Scissor Stop)

Limiter Strap (Adjustable)

Front Limiter

The front li miter strap controls the amount of weight transfer, ski pressure, and to some degree the ride height.
The rear li miter controls ride height and increases preload on the rear springs when tightened, which also de-
creases transfer (i .e. the lighter the torsion spring preload, the more weight transfer) .

Setting Ski Pressure Weight Tran sfer

Longer Decreased Increased
Shorter Increased Decreased

NOTE: RRSS has greatest affect on weight transfer on XTRA 10 suspensions. See pages 7.24-7.25.

_)

8/98 7.20 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Components - XTRA 10 121" Style

c
Rear Limiter
Front Track Shock Strap
Rear Track Shock
Limiter
Strap

Front Torque Pivot Arm

Arm Shaft Shaft
Rear Torsion
Spring
Rear Torque
Arm

-
Forward

Carrier Wheel
Rear Track Shock
Rear Torsion Spring

Front
Torque Arm

Limiter
Strap
Idler Wheel

~'Yl.l~- Bogie
Wheel

Slide Rail

c Hi-fax
Front Track Shock

Polaris Industries Inc. 7.21 8/98

SUSPENSION
Rear Suspension Components - XTRA 10 133.5" /136" Style

Rear Limiter
Front Track Shock Strap
Rear Track Shock
Limiter
Strap

Pivot Arm Pivot Arm

Shaft Shaft
Rear Torsion Spring

Forward

Carrier Wheel
Rear Track Shock

Rear Torsion Spring

Front
Torque
Arm

Limiter
Strap Idler Wheel

Rail
Bumper

Slide Rail

Front Track Shock

Hi-fax

8/98 7.22 Polaris Industries Inc.

 SUSPENSION
Suspension Adj ustment - XTRA 10 Style
The XTRA™ 10 suspension has been designed and set up to deliver a soft ride under average rid ing conditions.
Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action.
The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

Independent Front Suspension (IFS)

• Front shock spring preload (some models require washers)
• Optional springs
{ • Adjustable compression valving via Ryde AFX I Indy Select shock (on some models)
Rear Suspension
• Rear torsion springs
• Front rear scissor stop (FRSS)
• Rear rear scissor stop (RRSS)
• Optional coil springs for front track shock and spring preload (some models require washers)
• Optional torsion springs
• Adjustable compression via Ryde AFX I Indy Select rear track shock (on some models)
• Limiter straps - front and rear

Adjustment Procedures
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) before fin e
tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, veh icle speed, rid ing style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. The machine should be methodically tested under the same conditions after each adjustment (trail and
snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved . Adj ustments should be
made to one area at a time, in order to properly evaluate the change.

Polaris Industries Inc. 7.23 8/98

SUSPENSION
Front Rear Scissor Stop (FR SS) - XTRA 10 Style
The purpose of the front rear scissor stop (FRSS) is to control the bump attitude of the rear suspension . As the
front torque arm (FTA) hits the bump, it forces the rear scissor to collapse a predetermined amount, depending
on the FRSS block position.
This accomplishes two important things, it allows a lighter spring rate on the FTA because it can borrow spring
rate from the rear torsion springs; and it prepares the rear portion of the suspension for the bump, reducing secon-
dary kick back.
The FRSS is made of a resilient material allowing smooth action and preventing any suspension component dam-
age.
This unique feature is applied to the XTRA™ 10 rear suspension. Patents are pending.

Front Torque
Arm (FTA)

Rear Scissor

FRSS with short (low) leg to rear. Note the front torque arm must collapse further to collapse rear
torque arm.
Front Torque
Arm (FTA)

FRSS with long (high) leg to rear. Note this forces rear scissor to collapse with less front torque arm
movement than when in short position. This keeps the rails more parallel to the chassis.

8/98 7.24 Polaris Industries Inc.

 SUSPENSION
Rear Rear Scissor Stop (RRSS) - XTRA 10 Style
The RRSS controls weight transfer from the rear sus-

c pension to the skis. It also influences the stiffness of the

ride by controlling the amount of coupling action be-
tween the front and rear torque arms. To increase the
stiffness of the suspension, the RRSS should be set in
RRSS -low
position shown
the high position.
NOTE: On XTRA-1 0 models only, the RRSS can be to-
tally removed for maximum weight transfer. However,
unless the torsion springs and rear shock valving are
changed, the ride will be compromised. Always
maintain equal adjustment on both sides.
FRSS - low position shown

FRSS - medium position shown

Be sure rear scissor stop face is square with the face of

the scissor arm to ensure complete contact.
Scissor Stop Block Position

Medium

Rear Spring Tension

Low
0 Low

High
Rear spring tension adjustments are made by rotating
the eccentric spring block (A) as shown with the engine
spark plug tool. The block provides three spring tension
positions. This adjustment is easier if the long spring leg
is lifted over the roller and replaced after the block is
properly positioned. Always maintain equal adjustment
on both sides.

A 0 c

Soft Tension Long End to Front Medium Tension (Short End Up) Firm Tension (Long End Up)

Polaris Industries Inc. 7.25 8/98

SUSPENSION
Rear Suspension Exploded View - XTRA 12 121" Style

Front Torque Arm Assembly

Front Torque Arm Assembly Rear Torque Arm Assembly

8/98 7.26 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Exploded View - XTRA 12 133.5" Style

c
Front Torque Arm Assembly Rear Torque Arm Assembly

c
Polaris Industries Inc. 7.27 8/98
SUSPENSION
Rear Suspension Components - XTRA 12 Style

Limiter Rear Torsion

Strap Spring Adjuster Cam -
low position shown

Front Track
Preload Adjuster RRSS
Shock

FRSS

Front Track Spring

FRSS - "Front Rear Scissor Stop"

RRSS - "Rear Rear Scissor Stop"

J
8/98 7.28 Polaris Industries Inc.
 SUSPENSION
Rear Suspension Components - XTRA 12 Style

c
Front Track Shock
Rear Track Shock

Limiter
Strap

c
Coil Spring
Coil Spring
FRSS
Rear Torsion Spring RRSS

-
Forward

Rear Torsion Spring

Limiter Front Track Shock

Strap
Carrier Wheel

Rear Track Shock

Rear Torque Arm

Front
Torque
Arm

Slide Rail

Pivot Arm Rear Scissor

Shaft Pivot Arm
Rail Shaft
Bumper
Idler Wheel

Polaris Industries Inc. 7.29 8/98

SUSPENSION
Suspension Adjutment- XTRA-12 Style
The XTRA™ 12 suspension has been designed and set up to deliver a soft ride under average riding conditions.
Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action.

The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

Independent Front Suspension (IFS)

• Front shock spring preload
• Optional springs
• Compression adjust Indy Select I Ryde AFX shock

Rear Suspension
• Spring preload - front track shock
• Spring preload - rear track shock (Requires addition of washers)
• Rear torsion spring pre-load
• Front rear scissor stop (FRSS)
• Optional coil springs
• Optional torsion springs
• Limiter strap - front
• Compression adjust Indy Select Ryde AFX shock

Adjustment Procedures
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) and grease
all suspension pivots before fine tuning adjustments are made. Use Polaris Premium All Season Grease.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. The machine should be methodically tested under the same conditions after each adjustment (trail and
snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be
made to one area at a time, in order to properly evaluate the change.

8/98 7.30 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Adju stments - XTRA 12 Style
The primary rear suspension adjustments are the front track spring preload and the rear torsion spring preload .
It is important to note that adjusting the limiter strap does not change weight transfer from the rear suspension
to the skis as in a conventional suspension . Instead it will increase the entire rear suspension preload and de-
crease travel. To increase ski pressure the front rear sci ssor stop (FRSS) shou ld be set to low. To decrease ski
pressure the FRSS should be set to high.
To properly adjust the rear su spension, start with the lightest preload setting that will prevent heavy bottoming.
Remember: adjustments should be made to one area at a time, in order to properly evaluate the change .
NOTE : Rear spring settings wil l affect ski -to-ground pressure. If ski pressure is too light it may be desirable to
tighten rear springs for an increase in ski-to -ground pressure . It is also possible to reposition the FRSS for in-
creas ed ski pressure .
Front Track Shock Spring
Front track shock spring preload is adjusted by grasping
Forward
the spring and turning in a clockwise direction to in-
crease the preload. Turn in a counterclockwise direction
to decrease preload.
-----
Mount limiter strap
Rear Track Shock Spring on front of bracket
The rear track shock coil spring does not have a as shown
threaded adjuster. Washers can be added to increase
preload . One option to decrease preload for extremely
light non-aggressive riders is removal of the rear track
shock spring. @

Front Rear Scissor Stop (FRSS)

To adjust the FRSS compress the rear portion of rear
suspension until the rear scissor pivots away from the FRSS shown in high posi-
FRSS (Support front of track on object). Turn adjuster tion, as indicated by dot on Rear
to desired position . The dot on the stop indicates the stop
high position. High position is with the dot located toward
the rear of the machine (See illustration) . Medium posi - @low
tion is with the dot toward the front of the machine.
~medium

Be sure both blocks are in the same position or suspen- ~high

sion damage may occur.
NOTE: It may be necessary to loosen the FRSS mount-
ing bolts to adjust the position. Tighten after adjustment.
-
Forward
RRSS

If th e FRSS is in the low position but additional ski pres-

c sure is desired, move the FRSS to the optional front hole. Relocate FRSS to
Remove the attaching bolts and relocate the FRSS forwardmost hole in rail for
blocks in the forwardmost hole. Reinstall bolts and tight- additional ski pressure
en .
Rear Rear Scissor Stop (RRSS)
The RRSS is not adjustable but can be changed to pro-
vide more or less weight transfer. See chart below.

XTR A 12 RRSS Production Settings

Sus pension

121"
Length

Short
Color

Black
Part Number

541 0937 -more transfer

-
Forward

c 133" Long Gray 5411 041-less transfer

Polaris Industries Inc. 7.31 8/98

SUSPENSION
Rear Suspension Adjustments- XTRA 12 Style

Rear Torsion Spring

Rear torsion spring preload is adjusted by turning the two

~
position cams (A) on the short leg of the spring as shown
with the engine spark plug tool. This adjustment is easier
if the long spring leg is lifted over the roller and replaced
after the cam is properly positioned.
Always maintain equal adjustment on both sides. A
Soft Tension Long End to Front

~ A
Firm Tension (Long End Up)

IFS ADJUSTMENTS

IFS Adjustments - XTRA-Lite I Widetrak LX I TranSport

IFS spring preload is one of the adjustment options which

affects ride. Preload is the initial compression placed on
the spring. The longer the installed length of the spring ,
the less the amount of preload; the shorter the installed Shims
length of the spring, the more the amount of preload. In-
creasing preload on the IFS spring will result in more bite
on the skis, but will require more effort to turn. The IFS
compression spring preload can be increased by adding
shims (PN 521 0953) under the spring.
Always verify ski alignment before making adjustments
to the IFS. See Body and Steering section.

_)

8/98 7.32 Polaris Industries Inc.

 SUSPENSION
IFS Adjustments - XTRA 10 and 12 Style

Front Suspension Setup and Adjustments

Spring preload is one of the adjustment options which affects
ride. Preload is the amount of pressure at which the spring is
held. The longer the installed length of the spring, the less the
amount of pre-load; the shorter the installed length of the spring,
the more the amount of pre-load. An increase in IFS shock
spring pre-load will result in an increase in ski pressure.
Turning
To adjust front spring preload on threaded adjust models, grasp clockwise
the spring and turn in a clockwise direction (as viewed from the increases
bottom of the shock) to increase the preload. Turn in a counter- preload
clockwise direction to decrease preload.

In the adjacent illustration, high preload and low preload posi -

tions are depicted.
When adjusting, be sure springs on both the left and right sides
of the machine are at the same adjustment.
For the best ride the spring preload should be as low as possible.
Set the preload to use the full travel of the ski shock with occa-
sional light bottoming.

If
If the plastic nut is unscrewed from the threaded body the nut
tl
will break. Always leave one thread showing above the plastic
nut or the spring coils will stack, resulting in damage.

For the best ride the spring preload should be as low as pos- Always
leave at
sible. Set the preload to use the full travel of the ski shock with
least
occasional light bottoming. To determine if your machine is us-
one thread
ing full travel, push the shock jounce bumper down as far as it showing
will go on the shock rod and test ride the machine. above nut

The bumper will move up on the rod in direct relation to the

amount of travel. For example, if the shock travel is full, the
bumper will be seated at the top of the shock.
• Remove the existing spring and install the next highest
rate spring, or
• Reduce the preload on the existing spring and change the Shock rod
Push
shock valving to obtain the desired effect. NOTE: Shock jounce
valving can only be adjusted or changed on models bumper
equipped with Ryde AFX, Indy Select or Fox™ shocks. down as
far as it will
go on
shock rod

Polaris Industries Inc. 7.33 8/98

SUSPENSION
IFS Adjustments- XTRA-10 and 12 Style

A WARNING

Changing shock valving on models equipped with FoxTM shocks requires special tools and a sound knowledge
of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Shocks
contain high pressure nitrogen gas. Extreme caution should be observed when handling and working with high
pressure service equipment. See Fox™ Shock rebuilding information later in this chapter.
Always verify ski alignment before making adjustments to the IFS. If the skis are misaligned, we recommend the
camber adjustment be checked as this may also be affected.

Front Torque Arm Limiter Strap Adjustment- XTRA-10 and 12 Style

Front Torque Arm Limiter Strap Adjustment- XTRA-10
)
One method of chang ing ski-to-snow pressure is to change the
Turn nut to adjust
length of the front torque arm limiter straps. The limiter strap is
normally mounted in the fully extended position.
• Lengthening the straps decreases ski pressure under acceleration.
• Shortening the straps increases ski pressure under acceleration.

To adjust models with quick adjust front limiter straps,turn the

eyebolt nut to lengthen or shorten the straps. To shorten the
strap, turn the nut clockwise. To lengthen the strap, turn the nut
counterclockwise. Turning clockwise shortens strap.
NOTE: Both limiter straps must be adjusted evenly and remain Turning counterclockwise lengthens
equal in length to avoid improper Hi-Fax and track wear. strap.

Front Torque Arm Limiter Strap Adjustment- XTRA-12

One method of changing ski-to-snow pressure is to change the

length of the front torque arm limiter straps using the holes provided.
The limiter strap is normally mounted in the fully extended position.
It is important to note that decreasing limiter strap length will stiffen
the whole suspension.
• Lengthening the straps decreases ski pressure.
• Shortening the straps increases ski pressure.
The preferred method for changing ski pressure is 1. Turn FRSS to
a lower position. 2. Move the FRSS to the forward most hole. 3.
Increasing or decreasing IFS preload.

_)

8/98 7.34 Polaris Industries Inc.

 SUSPENSION
Compression Adjustable Shocks

Compression Damping Adjustable Shocks

Snowmobiles equipped with the Indy Select or Ryde AFX shocks allow the driver to make adjustments to the com-
pression valving by turning the screw located near the base of the shock.
Adjustment
Locate the adjustment screw near the base of the shock. NOTE: This adjustment is easiest to make with the
machine tipped on its side.

A WARNING

Be sure to shut off the fuel supply before tipping the machine to prevent fuel spillage and flooding of the carbure-
tors.
By turning the screw clockwise (a small screwdriver or dime work well), the compression valving is increased,
stiffening the ride. To soften the ride, reduce the compression by turning the screw cou nter-clockwise. A great
deal of ride performance is accomplished with a mere 1/2 to 1 turns. There are approximately 3 full turns of adjust-
ment available.
How to Adjust IFS
If the suspension is "bottoming," tighten the compression screw clockwise in 1/2 turn increments until the bottom-
ing stops. Backing off 1/4 turn counter-clockwise at this point should give you the best possible ride ensuring use
of the ful l travel of the suspension. The opposite procedure should be used if the suspension is too stiff upon initial
set-up.
If bottoming continues after the screw is turned in full clockwise, the compression spring should be adjusted with
the threaded adjustment collar. Back the screw out to the original starting position after the compression spring
has been adjusted.
Riding conditions are ever changing. Keep in mind the compression damping adjustable can be adjusted at any
time to achieve the best possible ride in any condition.

( NOTE: Whenever shocks are replaced or reinstalled for any reason, the adjustment screw should be located
toward the forward right side of the suspension. Access to the adjuster is not possible if reversed. Fox™ Shocks
should be installed with the charge fitting up.

c
Polaris Industries Inc. 7.35 8/98
SUSPENSION
Compression Adjustable Shocks

How to Adjust Rear Suspension

If the suspension is "bottoming," tighten the compression screw clockwise in 1/2 turn increments until the bottom-
ing stops . Backing off 1/4 turn counter-clockwise at this point should give you the best possible ride ensuring use
of the full travel of the suspension. The opposite procedure should be used if the suspension is too stiff upon initial
set-up.
If bottoming continues after the screw is turned in ful l clockwise, the torsion spring should be adjusted using the
adjustment block. Back the screw out to the original starting position after torsion spring preload has been in-
creased .
Riding conditions are ever changing. Keep in mind the Indy Select I Ryde AFX shocks can be adjusted at any
time to achieve the best possible ride in any condition .
NOTE: Whenever shocks are replaced or reinstalled for any reason, the adjustment screw should be located
toward the forward right side of the suspension. Access to the adjuster is not possible if reversed.

Turn spring
Turn screw clo_ckwise
clockwise to Increase pre-
to tighten load
compression ')
(stiffen) ..,-

~ Adjus-
ment
Xtra-10 Type

Screw

Xtra-12 Type

_)

8/98 7.36 Polaris Industries Inc.

 SUSPENSION
Suspension Springs and Rails
Round Springs vs Square Springs
( Many 1999 model snowmobiles now utilize a square profile rear torsion spring. Square springs are lighter in
weight (1.5 lbs.), and smaller in packaging. The square coils take up less room, therefore allowing the carrier
wheels to be positioned more inward in the tunnel. Another benefit of the square profile spring is the ability to
maintain the same characteristics of the round spring, but have fewer coils of wire. NOTE: The 1999 square
profile springs will not retrofit to 1998 and previous models. The length of the coil stack is shorter on the square
springs and the inside diameter of the coil stack is also smaller.

- 7··
Last 3 digits of part number
-ra
_l_ ---J
I
....

Last 3 digits of part number

Larger inside diameter Smaller inside diameter

(
Round Spring Square Spring

NOTE: The spring rates between the round wire springs and the square wire springs are identical. For example:
7041465-067 has same spring rate as 7041631-067 even though the wire diameter is different. The chart below
shows equal spring rates between round wire and square wire torsion springs.

NOTE: Square wire torsion springs will not fit in machines that come with round wire springs standard.

Spring Rates
.437" dia. wire spring rate=.375" dia. wire spring rate
.421" dicl. wire spring rate=.359" dia. wire spring rate
.406" dia. wire spring rate=.347" dia. wire spring rate

Polaris Industries Inc. 7.37 8/98

SUSPENSION
Optional Springs- 1999 XTRA Lite Style
Following is a list of all available springs for the XTRA Lite front and rear suspension. These springs can be used
to better suit individual riding preference.

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Torsion Spring Part No. Wire Dia./Degrees

7041 555-067 LH .393/77°
7041556-067 RH .393/77°
7041521-067 LH .406/82°
7041 522-067 RH .406/82°
7041463-067 LH .406/77°
7041464-067 RH .406/77°

Front Track Spring Part No. Spring Wire Dia. x

Free Length - Rate
7041571-067 70 #/in
7041570-067 80 #/in
7041520-067 90 #/in

Optional Springs - 1999 TranSport I Widetrak

Following is a list of all available springs for the TranSport front and rear suspension. Th ese springs can be used
to better suit individual riding preference.

Torsion Spring Part No. Wire Dia./Degrees

7041318-067 LH .375/75°
7041319-067 RH .375/75°
7041320-067 LH .406/75°
7041321 -067 RH .406/75°
7041239-067 LH .468/74°
7041240-067 RH .468/74°

8/98 7 .38 Polaris Industries Inc.

 SUSPENSION
Optional Springs - 1999 XTRA 10 Style
Following is a list of all available springs for the XTRA 10 front and rear suspension. These springs can be used
to better suit individual riding preference. NOTE: Square wire torsion springs cannot be substituted fo r round
wire springs.

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Torsion Spring Part No. (Round Springs) Wire Dia./Degrees

7041463-067 LH .406/77°
7041464-067 RH .406/7JC
7041461-067 LH .421 /77°
7041462-067 RH .421 /77°
7041465-067 LH .437/7JC
7041466-067 RH .437/77°

Torsion Spring Part No. (Square Springs) Wi re Dia./Degrees

7041627-067 LH .347/7JC
7041628-067 RH .347/7JC
7041629-067 LH .359/7JC
7041630-067 RH .359/77°
7041631 -067 LH .375/7JC
7041632-067 RH .375/77°

Front Ski Spring Part No. Length/Rate - Application

7041554-067 80# Fox
7041576-067 100# Fox
704157 5-067 120# Fox
7041 57 4-067 140# Fox
7041573-067 160# Fox
7041553-067 60# Gabri el/Arvin
7041552-067 80# Gabriel/Arvin
7041 551-067 100# Gabriel/ Arvin
7041 550-067 120# Gabriel/Arvin
7041549-067 140# Gabriel/Arvin

Front Track Spri ng Part No. Spring Wire Dia. x

Free Length - Rate
7041361-067 .343 x 7.0- 243 #/in
7041253-067 .3 12 x7.5 - 200Nar
7041362-067 .261 x 7.0 - 85 #/in
7041364-067 .283 x 7.5 - 126 #/in

NOTE: The XTRA Lite 136 suspension used on the 1999 Trail RMK uses the square wire tors ion springs listed
(_ above.

Polaris Industries Inc. 7.39 8/98

SUSPENSION
1999 XTRA-12 Optional Suspension Springs
Following is a list of all available springs for the XTRA 12 front and rear suspension. These springs can be used
to better suit individual riding preference.

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Xtra-12 IFS Shock Spring Part No. Rate - Application

7041398-067 75#/in
7041405-067 65#/in
7041554-067 80# Fox
7041576-067 100# Fox
7041575-067 120# Fox
704157 4-067 140# Fox
7041553-067 60# Gabriel/Arvin
7041552-067 80# Gabriel/Arvin
7041551-067 100# Gabriel/Arvin
7041550-067 120# Gabriel/Arvin
7041549-067 140# Gabriel/Arvin

Xtra-12 Front Track Shock Spring Part No. Spring Wire Dia. x
Free Length - Rate
7041351-067 .331 x 11 .88 - 75/125 #/i n
7041396-067 .283 x 11 .88 - 50 #/i n
7041398-067 .312 x 11.88- 75 #/in
7041 404-067 .343 x 11.88 - 90/150 #/in
7041405-067 .306 x 11 .88 - 65 #/in
7041484-067 .406 x 9.0 - 275 #/i n

Xtra-12 Rear Track Shock Spring Part No. Spring Wire Dia. x
Free Length - Rate
7041 361-067 .343 x 7.0 - 246 #/in
7041 362-067 .261 x 7.0 - 85 #/in
7041364-067 .283 x 7.5- 126 #/i n
7041484-067 .331 x 11.88 - 275#/i n
7041561-067 .261 x 7.5- 85 #/in
7041491 -067 .438 x 13.00 - 190 #/in

Xtra-12 Torsion Spring Part No. Wire Diameter I Degrees

7041394-067 - LH _ .406 I 7JO
7041395-067 - RH .406 I 7JO
7041406-067 - LH .421 I 7 JO
7041407-067 - RH .421 /7]0

8/98 7.40 Polaris Industries Inc.

 SUSPENSION
Front Track Springs

( For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Following is a list of all available front track springs for Polaris snowmobiles and their part numbers.

Front Track Shock Spring Information

Part Number #of Total #of Active Rate {#/in.) Free Wire Dia. End Dia. #1 End Dia. #2
Coils Coils Length
7041570-067 11 .7 9.7 80 #/in 10.50" .281 " 1.89" 1.89"

c 7041569-067
7041253-067
7041710-067
7041712-067
11 .8
10.0
8.0
8 .0
9.8
8.0
-
-
60 #/in
200/var
181 #/in
181 #/in
10.50"
7.50"
6 .68"-6.88"
7.50"
.263"
.331"
.312"
.31 2"
1.89"
1.90"
1.90"
1.90"
1.89"
1.90"
1.90"
1.90"
7041508-067 6.7 4.7 190 #/in 6.25" .343" 1.89" 2.25"
7041561-067 10.1 - 85 #/in 7 .50" .261" 1.90" 1.90"
7041484-067 10.2 8.2 275 #/in 9 .00" .406" 1.90" 1.90"
7041364-067 9.0 - 126 #/in 7 .50" .283" 1.90" 1.90"
7041361-067 9.0 - 246 #/in 7.00" .343" 1.87" 1.87"
7041362-067 9.0 - 85 #/in 7 .00" .261" 1.87" 1.87"
7041140 - 8.0 181 #/in 7 .50" .312" 1.90" 1.90"

c 7041127
7041509-067
7041510-067
8.38
8.52
- 8.0
-
-
181 #/in
140/240
165/245
6.88"
6.18"
6 .25"
.31 2"
.343"
.362"
1.90"
1.89"
1.89"
1.90"
2.25"
2.25"
7041511 -067 4.9 2.9 50 #/in 5.25" .225" 1.89" 2.25"
7041 512-067 5.3 3.3 85 #/in 5.25" .263" 1.89" 2.25"
7041513-067 5.9 3.9 135 #/in 5.25" .295" 1.89" 2.25"
7041 5 14-067 7 .0 - 100/180 5.25" .297" 1.89" 2.25"

Fox "' upper retainer ID= 1.85"

Fox "' lower retainer OD= 1.85"/2.15"

Polaris Industries Inc. 7.41 8/98

SUSPENSION
XTRA 12 Suspension - Shock Removal
XTRA 12 Suspension Shock Removal

Steps 1-4 (immediately below) may be used for either front or rear track shock removal.

1. Turn fuel valve to off position. Front Track Shock Installation

2. Loosen rear idler bolts (A), lock Fox Shocks - Gas fitting positioned downward
nuts (C), and track adjuster bolts (toward track)
(B). Indy Select Shocks - Adjuster screw positioned
upward
3. Remove (4) suspension mounting
bolts.
4. Place a protective mat along side
of machine. Tip the machine on its
side onto protective mat.
5. Note orientation of shocks before
removal - gas valve (Fox) or
adjuster screw (Select) up or down.
6. Remove suspension.
7. Lift rear torsion springs (D) from
their lower mounts.
8. Remove top bolt from front track
shock.
9. Remove lower front track shock
bolt (lift torque arm to gain
access).
10. With front track shock removed, Rear Track Shock Installation
loosen and remove top and bottom Fox Shocks - Gas fitting positioned upward (toward
bolts from rear track shock. rear)
Indy Select Shocks - Adjuster screw positioned
XTRA 12 Suspension Shock upward (toward rear)
Installation
1. Reverse steps above for
assembly, with the following
notes:
• Use new Flex-Loc™
nuts for installation. Tighten
shock bolts to 15-18 ft. lbs.
(2.07-2.48 kg/m). Be sure the
shock still pivots freely.
• Position torsion springs on top
eccentric and lower mount.
• Readjust and align track. See
pages 2.12-2.16.
Torque suspension mounting
bolts to 60ft. lbs. (8.28 kg-m).
Secure jam nuts and tighten
rear idler bolts.

8/98 7.42 Polaris Industries Inc.

 SUSPENSION
INDEPENDENT FRONT SUSPENSION Fox ™ Shock Specifications

- IFS SHOCKS
Body Shaft Max. *Max.
Shock PN IFP Depth (in) Shaft Part#
Length (in) Length (in) Length (in) Travel (in)
7041255 6.075 6.850 13.145 4.150 1.700 1500133
7041266 6.175 6.900 13.145 4.150 2.000 1500133
704129 1 6.380 6.800 13.250 4.050 0.728 1500008
7041292 6.380 6.800 13.250 4.050 0.728 1500008
7041346 6.380 6.800 13.250 4.050 0.728 1500008
7041349 5.850 6.350 12.270 3.600 0.616 1500076
7041385 8.995 9.125 18.150 6.375 1.142 1500068
7041401 8.180 8.310 16.560 5.810 1.139 N/A
7041474 6.380 6.800 13.250 4.050 0.728 1500008
7041490 6.040 6.350 12.710 3.850 0.600 1500076
7041494 7 .900 7 .730 15.700 5.230 1.000 15001 36
7041536 7.900 7.730 15.700 5.230 1.000 1500136
704 1537 8.720 7.600 16.140 4.850 2. 000 1500140
704 1540 7.900 7.730 15.700 5.230 1.000 1500136
704 1545 6.720 6.850 13.640 4.350 0.675 1500133
7041593 7.900 7.730 15.700 5.230 1.000 1500136
7041612 7.900 7.730 15.700 5.230 1.000 1500136
7041692 7.900 7.730 15.700 5.230 1.000 1500136
7041697 7.900 7.730 15.700 5.230 1.000 1500136

* Jounce Bumper Removed

Measure IFP depth from flat of piston

as shown using the IFP depth tool (PN
2871351 ) or a dial caliper.

c IFP
Depth

c
Polaris Industries Inc. 7.43 8/98
SUSPENSION
REAR SUSPENSION SHOCKS Fox TM Shock Specifications
FRONTTRACK SHOCKS
Body Shaft Max. Max.
Shock PN IFP Depth (in) Shaft Part#
Length (in) Length (in) Length (in) Travel (in)
7041294 5.050 5.350 10.470 2.850 0.544 1500040
7041386 8.955 9.125 18.150 6.375 1.140 1500068
7041402 5.430 5.570 11 .070 3.070 0.586 1500153
704141 3 5.050 5.350 10.470 2.850 0.544 1500040
7041493 5.430 5.570 11.070 3.070 0.590 1500153
7041507 5.330 6.400 11 .060 3.150 4.570 1500076
7041 584 5.430 5.570 11.070 3.070 0.586 1500153
7041589 5.430 5.570 11.070 3.070 0.586 15001 53
7041641 5.330 5.570 10.970 3.070 0.600 15001 53
7041642 5.330 5.570 10.970 3.070 0.600 1500153
7041706 5.330 5.570 10.850 3.070 0.600 1500153
7041735 5.330 5.570 10.850 3.070 0.600 1500153
REAR TRACK SHOCKS
Body Shaft Max. Max.
Shock PN IFP Depth (in) Shaft Part #
Length (in) Length (in) Length (in) Travel (in)
7041293 7.440 7.450 14.523 4.700 0.835 1500152
7041345 7.440 7.450 14.523 4.700 0.835 1500152
7041 347 7.440 7.450 14.523 4.700 0.835 1500152
7041387 5.850 6.350 12.320 3.650 0.633 1500076
7041403 6.825 6.850 13.560 4.350 0.795 1500133
7041444 7.440 7.450 14.523 4.700 0.835 1500152
7041480 5.850 6.350 12.320 3.650 0.630 1500076
7041492 7.440 7.450 14.520 4.700 0.835 1500152
7041585 7.440 7.450 14.523 4.700 0.835 1500152
7041588 7.440 7.450 14.523 4.700 0.835 1500152
7041595 7.440 7.450 14.523 4.700 0.835 1500152
7041599 7.440 7.450 14.520 4.700 1.500 1500152
7041695 7.440 7.450 14.523 4.700 0.835 1500152
7041707 7.440 7.450 14.520 4.700 1.500 1500152
7041728 7.440 7.450 14.523 4.700 0.835 1500152
7041 751 7.440 7.450 14.523 4.700 0.835 1500152
7041779 5.330 5.570 10.850 3.070 0.600 1500153

* IFP depth for limited build 1996 440 XCR SP with handlebar shock adjuster=4.570"

8/98 7.44 Polaris Industries Inc.

 SUSPENSION
Typical Shock Valving Arrangement
Shown below is an example of how valving stacks are arranged . The tables on page 7.46 contain production
valving specifications and piston orifice sizes. Optional valving (by shock part number) is listed in the tables on
following pages.

Parts in box are an example of standard valving .

* Note direction of valve piston before disassembly. The side with the greater number of slots should face the
IFP (nut end of the shaft).

Standard Valving
Typical Valve Stack

Compression Stack
I
I
~
------- - ,
@ .800 X .010
Shaft End

:@ .900 X .010
Toward Shaft

i® 1.00 X .010 (Fewer slots)

: @) 1.100 X .010
Piston*

( i®
I
1.300 X .010
Orifice

I
I
I
@) 1.300x.012 Orifice must be drilled to required size on
replacement valve pistons.
I
I
I
I IFP Deoth Adiustment For Limited Travel Setuo
I Spacer Thickness IFP Depth Modifier

8
Rebound Stack : .25 .029 (Subtract)
.50 .058
I 1.250x.010
.75 .088
I 1.0 .117
I
I
I
@ 1.100 X .010
1.25
1.50
.146
.175 Spacer
1.75 .204 PN
II~
~ 1.000 X .010 2.00 .234 5431355
I 2.25 .263
I ~ .900x.010
2.50 .292
I ~ I 2.75
3.00
.321
.350
: @ .800x.010 I 3.25 .380
I ~ I 3.50 .409
~

:>
1 .?oox .o10 I 3.75 .438
L __ _ _ _ _ __ _ j
4.00 .467
4.25 .496
NutEnd
4.50 .526
4.75 .555
5.00 .584

Changing oil on Fox™ Shocks is recommended annually and should be included when performing end of season stor-
age preparation . For competition use, shocks should be disassembled, inspected and serviced more frequently.

Polaris Industries Inc. 7.45 8/98

SUSPENSION
1997-1999 Production Valving Listed By Shock Part Number

Shock PN 7041385 7041494 7041536 7041537 7041540 7041545 7041593 7041692 7041697
IFS IFS IFS IFS IFS IFS IFS IFS IFS
Compress. BC N/A N/A N/A N/A N/A N/A N/A 1.250x.01 0 1.250x.010
Stack 7C N/A N/A N/A N/A N/A N/A N/A .800x.008 .800x.008
6C 0.700X.008 1.250x.010 N/A .700x.008 N/A N/A 1.250x.010 .900x.010 .900x.010
5C 0.800X.008 .800x.01 0 .800x.008 .800x.008 .800x.008 .800x.008 .800x.010 1.000x.Q1 0 1.000x.008
4C 0.900X.008 .900x.01 0 .900x.008 .900x.008 .900x.008 .900x.008 .900x.010 1.100x.008 1.100x.008
3C 1.000X .008 1.000x.010 1.00x.008 1.000x.008 1.000x.010 1.000x.008 1.000x.010 1.300x.01 0 1.300x.008
2C 1.100X.008 1.00x.01 0 1.100x.008 1.100x.008 1.1 00x.008 1.100x.008 1.100x.010 1.000x.006 1.000x.006
1C 1.300X.008 1.300x.010 1.300x.010 1.300x.008 1.300x.01 0 1.300x.01 0 1.300x.010 1.300x.008 1.300x.008
Orifice 0.078 0.081 0.078 0.078 0.078 0.078 0.081 0.081 0.086
Rebound 1R 1.250X.008 1.250x.010 1.250x.01 0 1.250x.008 1.250x.015 1.250x.010 1.250x.010 1.250x.01 0 1.250x.01 0
Stack 2R
3R
1.100X.008
1.000X.008
1.1 00x.008
1.000x.008
1.1 00x.01 0
1.000x.01 0
1.1 00x.008
1.000x.008
1.1 00x.012
1.000x.010
1.1 00x.01 0
1.000x.010
1.100x.008
1.000x.008
1.100x.010
1.000x.008
1.100x.OO
1.000x.008
)
4R 0.900X.008 .900x.008 .900x.010 .900x.008 .900x.008 .900x.010 .900x.008 .900x.008 .900x.008
5R 0.800X.008 .800x.008 .800x.008 .800x.008 .800x.008 .800x.008 .800x.008 .800x .800 .800x.008
6R 0.700X.008 .700x.008 .700x.008 .700x.008 N/A .700x.008 .700x.008 .700x.008 .700x.008

Shock PN 7041507 7041584 7041589 7041641 7041642 7041706 7041779 7041735

Front Track Front Track Front Track Front Track Front Track Front Track Front Track Front Track
Compress. 8C N/A N/A N/A N/A N/A 1.250x.010 N/A 1.250x.01 0
Sta ck 7C N/A 1.250x.010 .700x.010 N/A .700x.010 .800x.01 0 .700x.010 .800x.012
6C 1.250x.010 .900x.01 0 .800x.010 1.250x.01 0 .800x.010 .900x.012 .800x.010 .900x.012
5C .800x.008 1.000x.012 .900x.010 .800x.008 .900x.010 1.000x.012 .900x.010 1.00x.010
4C .900x.012 1.1 00x.012 1.000x.01 0 .900x.012 1.000x.010 1.1 00x.01 0 1.000x.010 1.100x.010
3C 1.000x.012 1.300x.012 1.1 00x.01 0 1.000x.012 1.100x.010 1.300x.012 1.1 00x.01 0 1.300x.012
2C 1.100x.012 .900x.006 1.250x.012 1.100x.012 1.250x.012 1.000x.006 1.250x.012 .900x .008
)
1C 1.300x.012 1.300x.008 1.300x.012 1.300x.012 1.300x.012 1.300x.010 1.300x.012 1.300x.01 0
Orifice 0.075 0.075 0.075 0.075 0.075 0.075 0.076 0.076
Rebound 1R 1.250x.010 1.250x.01 0 1.250x.01 0 1.250x.010 1.250x.010 1.250x.010 1.250x.010 1.250x.012
Stack 2R 1.1 00x.01 0 1.100x.010 1.1 00x.01 0 1.100x.010 1.1 00x.01 0 1.1 00x.01 0 1.100x.010 1.100x.010
3R 1.000x.01 0 1.000x.010 1.000x.012 1.000x.010 1.000x.012 1.000x.010 1.000x.012 1.000x.010
4R .900x.010 .900x.010 .900x.010 .900x.010 .900x.010 .900x.010 .900x.010 .900x.010
5R .800x.010 .800x.010 .800x.01 0 .800x.010 .800x.010 .800x.010 .800x .010 .800x .010
6R .700x.010 .700x.010 .700x.010 .700x.010 .700x.010 .700x.010 .700x.010 .700x .010

Shock PN 7041480 7041492 7041585 7041588 704 1595 7041599 7041695 7041707 7041728
Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track
Compress. 8C N/A 1.250x.010 N/A N/A N/A 1.250x.010 1.250x.01 0 1.250x.010 N/A
Stack 7C N/A .900x.010 1.250x.010 .700x.008 1.250x.010 .900x.010 .900x.012 .900x.012 N/A
6C 0.700X.006 1.1 00x.012 .900x.010 .800x.008 .900x.010 1.000x.012 1.000x.008 1.000x.012 .900x.010
5C 0.800X.006 1.1 00x.015 1.000x.010 .900x.010 1.000x.012 1.1 00x.015 1.000x.012 1.100x.015 1.000x.01 0
4C 0.900X.006 1.250x.01 0 1.100x.015 1.000x.008 1.1 00x.015 1.250x.010 1.100x.015 1.250x.01 0 1.100x.01 0
3C 1.000X.006 1.300x.015 1.300x.015 1.1 00x.008 1.300x.015 1.300x.015 1.300x.015 1.300x.012 1.250x.012
2C 1.100X.006 1.000x.006 1.000x.006 1.250x.008 .900x.012 1.000x.006 .900x.012 1.000x.006 .900x.006
1C 1.300X.006 1.300x.012 1.300x.01 0 1.300x.008 1.300x.012 1.300x.012 1.300x.012 1.300x.012 1.300x.008
Orifice 0.067 0.072 0.086 0.078 0.086 0.072 0.086 0.072 0.063
Rebound 1R 1.250X.01 0 1.250x.010 1.250x.012 1.250x.012 1.250x.012 1.250x.01 0 1.250x.012 1.250x.01 0 1.250x.015
Stack 2R 1.100X.010 1.100x.012 1.100x.012 1.1 00x.012 1.1 00x.012 1.1 00x.012 1.1 00x.012 1.250x.01 0 1.250x.012
3R 1.000X.010 1.000x.012 1.000x.012 1.000x.012 1.100x.012 1.000x.012 1.100x.012 1.100x.012 1.100x.012
4R 0.900X.010 .900x.012 .900x.012 .900x.012 .900x.012 .900x.012 1.000x.012 1.000x.012 1.000x.01 0
5R 0.800X.010 .800x.012 .800x.012 .800x.012 .800x.012 .800x.012 .900x.012 .900x .012 .900x .010
6R 0.700X.010 .700x.012 .700x.012 .700x.012 .700x.012 .700x.012 .800x.012 .800x.012 .800x.010

N/A = Not Applicable

8/98 7.46 Polaris Industries Inc.
 SUSPENSION
1999 Optional Valving Listed By Shock Part Number
1999 500 XC SP /600 XC SP /700 XC SP

LIGHT HEAVY
Shock PN 7041697 7041735 7041728 7041697 7041735 7041 728
IFS X-10 Front Track Rear Track JFS X-10 Front Track Rear Track
CRC X 10 X10 CRC X 10 X10

Com pres- 8C N/A N/A N/A 0.8x.010 1.25x.010

sion Stack
7C 0.8x.008 0.8x.010 N/A 0.9x.012 0.8x.012

6C 0.9x.008 0.9x.01 0 N/A 1.0x.012 0.9x.015 LO

(j)

sc 1.0x.006 1.0x.008 N/A 1.1x.010 1.0x.012 N

N
1'--
4C 1.1x.008 1.1x.008 N/A 1.3x.01 0 1.1x.012 a:>
N

r 3C

2C
1.3x.008

1.0x.008
1.3x.008

0.9x.008
N/A
N/A
1.0x.006

1.25x.008
1.3x.012

0.9x.006
"-
Q)
.0

z
E
::J

1C 1.3x.008 1.3x.008 N/A 1.3x.008 1.3x.01 0 t

("()

N/A 0...
Orifice .086 .076 .086 .076 .......
~
Rebound 1R 1.25x.008 1.25x.01 0 N/A 1.25x.010 1.25x.012 Q)
Stack Q)
2R 1.1x.008 1.1x.010 N/A 1.1x.010 1.1x.012 (f)

3R 1.0x.008 1.0x.01 0 N/A 1.0x.008 1.0x.01 0

4R 0.9x.008 0.9x.010 N/A 0.9x.008 0.9x.010

SR 0.8x.008 0.8x.010 N/A 0.8x.008 0.8x.0 12

6R 0.7x.008 0.7x.01 0 N/A N/A 0.7x.010

1999 440 XCR

LIGHT HEAVY
Shock PN 7041 692 7041706 7041707 7041692 7041706 7041707
IFSX-10 Front Track Rear Track IFS X-10 Front Track Rear Track
CRC X 10 X10 CRC X 10 X 10

Compres- 8C 1.25X.008 1.25x.010 1.25x.010 1.25X.01 0 1.25x.01 0 1.25x.01 0

sion Stack
7C 0.8X.008 0.8x.010 0.8x.010 0.8X.010 0.8x.012 0.9x.012

6C 0.9X.010 0.9x.010 0.9x.012 0.9X.012 0.9x.015 1.0x.012

sc 1.0X.008 1.0x.012 1.0x.010 1.0X.010 1.0x.015 1.1x.015

4C 1.1X.008 1.1 x.008 1.1 x.010 1.1X.010 1.1 x.012 1.25x.012

c 3C

2C

1C
1.3X.008

1.0X.008

1.3X.008
1.3x.010

0.9x.008

1.3x.008
1.3x.01 0

1.0x.008

1.3x.008
1.3X.012

1.0X.006

1.3X.010
1.3x.012

1.0x.006

1.3x.01 0
1.3x.015

1.0x.006

1.3x.012

Orifice 0.081 .075 .072 0.081 .075 .072

Rebound 1R 1.25X.010 1.25x.010 1.25x.010 1.25X.010 1.25x.012 1.25x.012

Stack
2R 1.1X.008 1.1x.010 1.1x.012 1.1X.010 1.1x.012 1.25x.012

3R 1.0X.008 1.0x.008 1.0x.012 1.0X.008 1.0x.010 1.1 x.012

4R 0.9X.008 0.9x.008 0.9x.012 0.9X.008 0.9x.010 1.0x.01 2

SR 0.8X.008 0.8x.008 0.8x.012 0.8X.008 0.8x.010 0.9x.01 2

c 6R

7R
0.7X.008

N/A
0.7x.01 0

N/A
0.7x.012

N/A
0.7X.008

N/A
0.7x.010

N/A
0.8x.012

0.7x.012

Polaris Industries Inc. 7.47 8/98

SUSPENSION
1999 Optional Valving Listed By Shock Part Number
1999 700 XCR /800 XCR

LIGHT HEAVY
Shock PN 7041540 7041779 7041695 7041540 7041779 7041695
IFS X-10 Front Track Rear Track IFS X-10 Front Track Rear Track
X10 X 10 X 10 X10

Com pres- 8C N/A N/A N/A N/A N/A N/A

sion Stack
7C N/A 0.7x.010 1.25X.010 N/A 0.7x.010 1.25X.010

6C N/A 0.8x.008 0.9X.008 N/A 0.8x.012 0.9X.012

5C 0.8X.008 0.9x.008 1.0X.008 0.8X.010 0.9x.012 1.0X.010

4C 0.9X .008 1.0x.008 1.1X.010 0.9X.010 1.0x.012 1.1OX.015

3C 1.0X.008 1.1x.010 1.3X.012 1.0X.012 1.1x.015 1.3X.015

2C 1.1X.006 1.25x.01 0 0.9X.012 1.1X.012 1.25x.012 0.9X.008

)
1C 1.3X.008 1.3x.01 0 1.3X.010 1.3X.012 1.3x.012 1.3X.012

Orifice 0.078 .076 0.086 0.078 .076 0.086

Rebound 1R 1.25X.012 1.25x.01 0 1.25X.012 1.25X.015 1.25x.012 1.25X.012

Stack
2R 1.1X.012 1.1x.008 1.1X.010 1.1X.012 1.1x.012 1.1 OX .012

3R 1.0X.012 1.0x.01 0 1.0X.010 1.0X.012 1.0x.015 1.0X.01 2

4R 0.9X.010 0.9x.01 0 0.9X.010 0.9X .010 0.9x.012 0.9X.012

5R 0.8X.008 0.8x.010 0.8X.010 O.BX.OOB 0.8x.010 0.8X.012

6R 0.7X.008 0.7x.010 0.7X.010 0.7X.008 0.7x.010 0.7X.012

7R N/A N/A N/A N/A N/A N/A

)
Refer to the appropriate parts manual for a complete listing of Fox shock parts . Fox, Registered Trademark of
FOX Shox.
Shock Travel Limiting Spacer (1/4") - Part Number 5431355
Valve Washer Part Numbers
Part No. Description Part No. Description
1500052 1.300 X 0.006 1500046 ... 0.900 X 0 .010
1500050 1.250 X 0.006 1500047 . .. 0 .800 X 0.010
1500049 1.100x0.006 1500044 ... 0.700 X 0 .010
1500048 1.000 X 0.006 1500079 ... 1.300 X 0.012
1500053 .... 0.900 X 0.006 1500078 .. . 1.250 X 0 .012
1500054 .... 0.800 X 0.006 1500060 ... 1.1 00 X 0.012
1500055 .. .. 0.700 X 0.006 1500059 ... 1.000 X 0.012
1500030 1.300 X 0.008 1500058 ... 0. 900 X 0.012
1500051 1.250 X 0.008 1500057 ... 0.800 X 0.012
1500031 1.100 X 0.008 1500056 ... 0.700 X 0.012
1500032 1.000 X 0.008 1500087 ... 1.300 X 0.015
1500033 .... 0.900 X 0.008 1500086 ... 1.250 X 0.015
1500028 .. . . 0.800 X 0.008 1500085 ... 1.1 00 X 0.01 5
1500029 .... 0.700 X 0.008 1500084 . .. 1.000 X 0.015
1500062 1.300 X 0.010 1500083 . .. 0.900 X 0.015
1500026 1.250 X 0.010 1500082 .. . 0.800 X 0.01 5
1500027 1.100x0.010 1500081 . .. 0.700 X 0.01 5
1500045 1.000 X 0.010
Note: Subtract .029" from IFP depth for each 1/4 inch spacer added to the shock damper rod for limiting.
For example: If standard (full shock travel) IFP depth is .835", and 6 spacers are add ed to reduce shock travel by
1.5 inches, multiply .029 x 6 to calculate the amount to subtract from IFP depth .
.835- .174 = .661 (± .025") New IFP Depth

8/98 7.48 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

c Changing oil on Fox™ Shocks is recommended annually and should be included when performing end of season
storage preparation . This oil change is necessary to avoid any chance of corrosion which could be caused by
moisture contamination. For competition use, shocks should be disassembled, inspected and serviced more fre-
quently.

When performing maintenance on Fox™ Shocks, use Gas Shock Recharging Kit PN 2200421. It consists of the
necessary valves, pressure gauge, and fittings to deflate and pressurize the shocks. The Body Holder Tool, Inter-
nal Floating Piston (IFP), and Shock Rod Holding Tool are not included in the Recharging Kit and must be ordered
separately. Refer to your Victor Specialty Tool catalog for part numbers.

c PN 2200421

A WARNING

Extreme caution should be observed while handling and working with high pressure service equipment. Wear
a face shield , safety glasses, and ear protection during service of these shocks.

Care should be observed while handling th e inflater needle and pressure gauges. Maintain your equipment and
keep it in good condition. If injury should occur, consu lt a physician immediately.

Extreme cleanliness is of utmost importance during all disassembly and reassembly operations to prevent any
dirt or foreign particles from getting into the shocks.

Keep the parts in order as they are disassembled. Note the direction and position of all internal parts for reas-
sembly.
Bleed Screw 1

Ref.# Qty. Description Internal Floating 3

1 1 Pressure Valve Piston (IFP)
2 2 0-Ring
Shock Body
3 1 Retaining Ring

c 4
5
1
2
Spring Retainer Body
0-Ring
6 1 Piston Ring (Floating)
7 1 Piston Ring (Damping) 8
8 1 Spring Retainer, Slotted

Polaris Industries Inc. 7.49 8/98

SUSPENSION
Fox™ Shock Maintenance

Disassembly

1. Remove spring and bushings from shock eyes.

)
Thoroughly wash shocks in a parts washer or with
soap and water to remove dirt and other debris. Dry
thoroughly with compressed air. Position and clamp
body cap of shock in soft jaws (aluminum or brass) of
vise. Remove Allen screw from pressure valve.

2. With valve outlet pointed in a safe direction, insert red

tip of safety needle assembly into recess in shock
pressure valve. Depress safety pin on safety needle
and push gauge and needle assembly slowly toward
shock, inserting needle. Be sure to push needle
completely into shock valve. Release nitrogen in a
safe direction away from everyone by turning
T-handle clockwise (if equipped) or by depressing
Schrader valve pin.

CAUTION: I

It is possible for some residual pressure to remain in the

shock regardless of the gauge read ing. Always com-
pletely remove valve from body cap before further disas-
sembly of shock.

3. Remove valve and sealing 0-ring from body cap.

J
4. Extend shock shaft by pulling up on shock eyelet.
Using a 1" (25 mm) wrench, loosen shaft bearing cap.

8/98 7.50 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Disassembly, Cont.
5. If body of shock starts to unscrew from body, tighten
and try again. To keep body from turning, it may be
necessary to use Body Clamp Tool clamped lightly
around body in soft jaws of vise as shown.

NOTE : Position body clamp at least 1 1/2" below bearing

cap.

Shock Body Clamp Tool

PN 2871071

6. Pull shock rod and piston straight out to avoid seal or

valve damage. Be prepared to catch piston ring
when removing the damper rod/valve piston .

7. Remove shock from vise and dispose of used oil

properly in suitable container. Set shock body aside.

8. Mount damper rod in soft-jawed vise as shown.

Loosen valve nut and clean the valve piston and
valving washers with electrical contact cleaner. Dry
thorough ly with compressed air. Tighten nut and
torque to 12ft. lbs. (1 .66 kg-m).

Valve Nut Torque -

c
Polaris Industries Inc. 7.51 8/98
SUSPENSION
Fox™ Shock Maintenance

9. If bearing cap and/or seals are to be replaced,

remove nut, washer, and valve piston with valving
washers and set aside. Keep washers in order and
)
note orientation of slots in piston for proper
re -installation. The side with the greater number of
slots must face the damper rod nut (toward IFP).

Seal Replacement

1. Remove bearing cap from damper rod. Inspect

seals, o-ring, and bushing inside cap. Inspect cap
0 -ring and replace if torn or damaged.

2. Using a small screwdriver or scribe pry upper seal,

)
main seal, and 0-ring out of bearing cap. Use care to
avoid scratching the seal cavity.

_)
3. Clean seal cavity and inspect bushing for wear or
damage and replace bearing cap if necessary.

4. Lubricate new seals and 0-ring with Polaris shock oil

and install. Be sure the seals are seated completely
in the seal cavity.

5. Inspect jounce bumper (where applicable) and

replace if damaged.

6. Inspect damper rod for nicks, scratches or abrasion.

Install bearing cap and thick backing washer on
damper rod. Install compression valve washer stack
in same order as disassembly. Install valve piston
with greater number of slots facing damper rod nut
(toward IFP). Install rebound stack, washer, and a
new nut. Torque nut to 12ft. lbs.

Valve Nut Torque -

)
12ft. lbs. (1 .66 kg-m)

8/98 7.52 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Seal Replacement, Cont.

7. Inspect valve piston ring for wear. The outer surface

of the ring should be even in color. Set aside damper
rod assembly for reinstallation.

8. Position shock in vise with Body Clamp Tool

positioned as shown. Clean body clamp tool before
installing.

Shock Body Clamp Tool

PN 2871071

9. Using an open end or large adjustable wrench,

unscrew the body cap from the body.

10. Inspect 0 -ring in body cap for damage.

c 11. Note location of Allen screw in internal floating piston

(IFP) for reassembly in body tube. Remove IFP
through body cap end (external th readed end) using
IFP too l. Be prepared to catch piston ring and piston
as it comes out. Remove Allen screw from center of
piston. Inspect bleeder screw 0-ring and IFP sealing
0 -ring for wear or damage. Replace 0-rings upon
reassembly.

12. Carefully clean all parts thoroughly with electrical

c contact cleaner or solvent and dry with compressed

air. Inspect shock body for scratches or wear.

Polaris Industries Inc. 7.53 8/98

SUSPENSION
Fox™ Shock Maintenance
Reassembly
1. Install bleeder screw in IFP until 0 -ring is lightly )
seated.
NOTE: Bleeder screw must be positioned toward body
cap (externally threaded) end of shock body.

2. Compress flexible piston ring around valve piston

and install piston into shock body.

_)
3. Screw in bearing cap by hand until 0 -ring is fully
seated.

4. Invert shock and mount bearing cap flats lightly in

vise. Caution: Be sure damper rod is fully extended .

J
8/98 7.54 Polaris Industries Inc.
 SUSPENSION
Fox™ Shock Maintenance

( Reassembly, Cont.
5. Fill with shock fluid to approximately 1" (2.54cm) from
end of body.

6. Instal l body cap until 0-ring is lightly seated.

7. Mount shock in vi se by top eyelet as shown. Support

shock and strike body cap end 2-3 times with a soft
faced hammer to remove all ai r trapped inside the
valve piston. Allow shock to stand for 3-5 minutes.

c CAUTION: I
Do not over-tighten vi se or bearing cap may be damaged

8. Unscrew body cap and remove.

9. Remove IFP bleeder screw.

c
10. Set IFP tool to specified depth with a dial caliper as
shown.

IFP Tool PN 2871351

c
Polaris Industries Inc. 7 .55 8/98
SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.

11. Place a shop towel over the end of IFP tool and slowly
push IFP to specified depth.

)
12. With the IFP set and the bleeder screw removed,
slowly stroke shock to force air through piston
oriface. Move the shock body slowly to prevent
aeration of the oil. Allow all air to purge throught the
bleeder screw hole.

13. Install the bleeder screw with a new 0-ring and

)
tighten secure ly using the flats on the tool to prevent
the IFP from turning. Pour out excess oil. It is not
necessary to completely clean all oil from the
nitrogen chamber, a small amount of oil will lubricate
the IFP. Verify the proper IFP depth to within± .025"
(.63mm) with a dial caliper. Be sure to measure to the
flat portion of the IFP, not to the tapered outer edge.

14. Reinstall body cap with a new 0-ring and tighten by

hand . Mount shock with body cap end down in the
soft jaws of a vise. Torque bearing cap to 8-10 ft. lbs.
(1 .10-1.38 kg/m). Thi s will also tighten the body into \
the body cap. ....)

I' CAUTION: ' I

Do not over tighten or damage to the bearing may result.

Bearing Cap Torque -

8-10ft. lbs. (1.10-1.38 kg-m)

8/98 7.56 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.

15. Install pressurizing valve with new 0 -ring and tighten

securely.

16. Set the nitrogen tank pressure regulator to 200 - 205

PSI.

17. Insert the Fox™ Safety Needle and charg e with

nitrogen to 200 PSI. Pull the needle straight outward
and remove from the pressurizing valve while holding
th e pressure hose on the fitting . Do not insert the
nee dle again to check pressure as the volume inside
the gauge will reduce pressure in the shock.

(
18. As a final check, push the damper rod through a full
stro ke . The damper rod must bottom out at full travel,
and then slowly ri se to full extension. Shaft
movement must be smooth and consistent
throughout the entire compression and rebound
stroke, without binding or loss of damping.

c
Polaris Industries Inc. 7.57 8/98
SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.

19. To check for leaks, submerge the shock in water and

look for bubbles or oil seepage around the bearing
and body caps.

20. When reinstalling shocks on the machine, torque

only to required specifications. If the shock is over
tightened it will not pivot, possibly resulting in damage
to shaft and seals.

21. When installing IFS shocks, tighten top mount first.

Pivot shock body into lower mount and determine if
spacer washers are necessary to prevent twist or
side loading of shock. Suspension assemblies
should always be moved through entire travel without
springs to verify free movement and proper
alignment of all components.

Shock Eyelet Replacement

Top Shock Eyelet

If shock eyelet is removed for damper rod replacement, clean threads

of eyelet and damper rod thoroughly with Loctite Primer N.
TM

Apply LoctiteTM 262 to threads before assembly.

8/98 7.58 Polaris Industries Inc.

 SUSPENSION
Polaris Position Sensitive Shock (PSS)

COMPRESSION STROKE
INITIAL MID-COMPRESSION END-COMPRESSION
COMPRESSION STROKE STROKE
STROKE

BASIC No bypass
PRINCIPAL #1 available.
For piston travel
as shown, oil Increased
must get from compression
this side of damping for
piston to this anti-bottom-out.
side of piston.

BASIC
PRINCIPAL #2
Oil must either
go through
piston valving,
or into outer PISTON
chamber MOVEMENT PISTON
On initiation of (bypass). MOVEMENT
compression
stroke. all flow Maximum
occurs through bypass of oi I
the piston only. middle of
compression
No bypass flow stroke .
is available in
this travel range. PISTON Lowest
MOVEMENT compression
damping

Very plush ride.

Valves on this
side of piston
flex open to
regulate flow.

Polaris Industries Inc. 7.59 8/98

 SUSPENSION
Polaris Position Sensitive Shock (PSS)

REBOUND STROKE
INITIAL MID-REBOUND END-REBOUND
REBOUND STROKE STROKE
STROKE

Valves on this
side of piston
flex open to
regulate flow.

No bypass flow
is available in
this travel
range.
Rebound bypass
is limited to
these holes ~--n

Flow is restricted
on hole(s)
covered by one
way check valve.

Maximum
PISTON bypass of oil

t
MOVEMENT into outer
chamber at
this stage.

PISTON
MOVEMENT
PISTON No bypass
MOVEMENT available
into outer
chamber.

Increased
rebound
damping for
anti-top-out.

8/98 7.60 Polaris Industries Inc.

 SUSPENSION
Polaris Position Sensitive Shock {PSS)

SHOCK VALVING
COMPRESSION:
1. 1 .300 X . 008
2. .900 X .006
3. 1.250 X .012
4. 1.100x .010
5. 1.000 X .010
7.450" 6. .900 X .010

REBOUND:
1. 1.250 X .015
2. 1.250 X .012
3. 1.100 X .012
4. 1.000 X .010
5. .900 X .010
6. .800 X .010
/ /
// A PISTON ORIFICE: .063
B
//
/ /
/
/ /
c
D SHOCK DESIGN DETAILS:
E
Travel 4.70"
Extended Length 14.52"
Compressed Length 9.82"
IFP Depth .835"
Bearing 1.15"
Nitrogen Pressure 200 PSI

BY-PASS HOLE DETAILS:

LOCATION QUANTITY CHECK VALVE DIAMETER
A. 1.80 1 NO 0.0787"
B. 2.00 3 NO 0.0787"
C. 3.50 1 NO 0.0787"
D. 4.25 2 YES 0.0787"
E. 4.50 1 NO 0.0787"

Polaris Industries Inc. 7.61 8/98

SUSPENSION
Position Sensitive Shock Maintenance

Disassembly

1. Remove bushings from body cap. Thoroughly wash

shock in a parts washer or with soap and water to
remove dirt and other debris. Dry thoroughly with
compressed air. Position and clamp body cap of
shock in soft jaws (aluminum or brass) of vise, body
cap down (as shown).

2. Remove Allen screw from pressure valve.

3. With valve outlet pointed in a safe direction, insert red

tip of safety needle assembly into recess in shock
pressure valve. Depress safety pin on safety needle
and push gauge and needle assembly slowly toward
shock, inserting needle. Be sure to push needle
complete ly into shock valve. Release nitrogen in a
safe direction away from everyone by turning
T-handle clockwise (if equipped) or by depressing
Schrader valve pin .

. CAUTION: .I
It is possible for some residual pressure to remain in the
shock regardless of the gauge reading. Always com-
pletely remove valve from body cap before further disas-
sembly of shock.

4. Remove valve and sealing 0 -ring from body cap.

_)
5. Extend shock shaft by pulling up on shock eyelet.
Using a 1" (25 mm) wrench, loosen shaft bearing cap.

8/98 7.62 Polaris Industries Inc.

 SUSPENSION
Position Sensitive Shock Maintenance

Disassembly, Cont.
6. If bearing comes loose first, unscrew bearing from
body and remove the shaft assembly from the body.
Pull shock rod and piston straight out to avoid seal or
va lve damage. Be prepared to catch piston ring
when removing the damper rod/valve piston .

7. Remove shock from vise and dispose of used oil

properly in suitable container.

c 8. Clamp the exposed portion of the shock body in a

vice using shock body clamp tool, body cap up. DO
NOT clamp on bypass sleeve or damage to the shock
will occur.

Shock Body Clamp Tool

"'
PN 2871071

9. Remove the body cap

Polaris Industries Inc. 7.63 8/98

SUSPENSION
Position Sensitive Shock Maintenance

Disassembly, cont.

10. Remove IFP

J
11. Remove bypass Sleeve.

1. If body cap comes loose first, reclamp shock in vice,

gripping on bearing flats with th e body cap up.

2. Remove body cap.

NOTE: Make sure bypass sleeve remains in contact with
collar during this procedure. Oil will spill if bypass sleeve
separates from collar.

J
8/98 7.64 Polaris Industries Inc.
 SUSPENSION
Position Sensitive Shock Maintenance

Disassembly, Cont.

3. Remove IFP and dispose of shock oil properly.

4. Remove bypass sleeve and clamp shock body in vise

using body clamps.

5. Unscrew bearing from body and remove shaft

assembly from body. Be prepared to catch piston
ring.

6. Follow procedures in FoxTM shock maintenance

section for inspection, cleaning, and valving if
needed.

Polaris Industries Inc. 7.65 8/98

SUSPENSION
Position Sensitive Shock Maintenance

Assembly

1. Compress piston ring and insert shaft assembly into

shock body.

2. Inspect bypass sleeve for burrs, dents, or oth er

physical damage.

3. Lube collar 0 -ring and replace bypass sleeve over

body. Be sure of a snug fit - do not pinch or cut 0-ring .

)
--
4. Clamp eyelet of shock in the vise body up. Fill shock
and bypass sleeve through shock body. Oil should
cover all bypass holes. Fill to approximately one inch
(2.54cm) from end of body.

8/98 7.66 Polaris Industries Inc.

 SUSPENSION
Position Sensitive Shock Maintenance

Aassembly, Cont.

5. Cycle shock through the first couple inches of travel

to release trapped air. Take care not to spi ll oil over
the bypass sleeve or introduce air through bypass
holes.

6. Ensure that the shaft is fully extended and set the IFP
to the proper depth. Remove IFP bleeder screw to be
sure no air is trapped under the IFP. lnstaii iFP.

IFP Depth:

.835" (21.2mm)

r
7. Replace the IFP bleed screw with a new 0 -ring and
tighten securely. Hold shock fully extended and fill oil
in bypass sleeve to th e top.

(
8. Replace the body cap. Oil will drain over the edge of
the bypass sleeve until the 0 -ring seals.

Polaris Industries Inc. 7.67 8/98

SUSPENSION
Position Sensitive Shock Maintenance

9. Once the body cap 0-ring seals, re-position the

shock in the vice by clamping on the body cap with )
the shaft up.

10. Continue to tighten the body cap utilizing flats on the

)
bearing. Torque cap to 55 ft lbs. Install pressure
valve with new 0-ring and tighten securely.
Pressurize shock to 200 psi.

Body Cap Torque

55 ft. lbs.

_j

....,
)

8/98 7.68 Polaris Industries Inc.

 SUSPENSION
Suspension Troubleshooting - WideTrak Style
Problem Solution
( Rear suspension bottoms too easily -Increase torsion spring preload
-Increase rear shock compression valving by turning
screw clockwise (if equipped with optional Indy Select
shock)
-Install overload kit PN 2871042 for extreme use
Rides too stiff in rear -Check for binding suspension shafts and grease all pivot
points
-Decrease torsion spring preload adjustments
-Decrease rear shock compression valving by turning
screw counterclockwise (if equipped with optional Indy
Select shock)
-Check for proper track tension
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all steering components are
free turning
-Make sure skags are straight on skis
-Check hi-fax and replace if worn
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload if shims have
been added
•Reduce rear torsion spring preload
Front end pushes -Check for worn skags
-Check for binding suspension shafts and grease all pivot
r points
-Increase IFS spring preload by adding shims
Steering is heavy -Check ski alignment
-Check skags and skis for damage
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload if shims have
been added
•Reduce rear torsion spring preload
Setting up for deep snow operation -Change worn hi-fax
-Lower front and rear torque arms (see Performance sec-
tion at the back of this manual)

Polaris Industries Inc. 7 .69 8/98

SUSPENSION
Suspen sion Troubleshooting - XTRA Lite Style
Problem Solution
Rear suspension bottoms too easily -Increase torsion spring preload
-I ncrease rear shock compression valving by turning
screw clockwise (if equipped with optional Indy Select
shock)
Rides too stiff in rear -Check for binding suspension shafts and grease all pivot
points
-Decrease torsion spring preload adjustments
-Decrease rear shock compression valving by turning
screw counterclockwise (if equipped with optional Indy
Select shock)
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all stee ring components are
free turning
-Make sure skags are straight on skis
-Check hi-fax and replace if worn
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS sprin g preload if shi ms have
been added
•Reduce rear torsion spring preload
Front end pushes -Check for worn skags
-Check for binding suspension shafts and grease all pivot
points
-Increase IFS spring preload by adding shims
Steering is heavy -Check ski al ignment
-Check skags and skis for damage
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload if shims have
been added
•Reduce rear torsion spring prel oad
Setti ng up for deep snow operation -Change worn hi-fax
-Lower front and rear torque arms (see Performance sec-
tion at the back of this manual)

_)

8/98 7.70 Polaris Industries Inc.

 SUSPENSION
Suspension Troubleshooting - XTRA 10 Style
Problem Solution
Rear suspension bottoms too easily -Increase torsion spring preload
-Increase rear shock compression valving by turning
screw clockwise (if equipped with optional Indy Select
shock) or refer to optional valving on Suspension Wall-
chart for Fox equipped models
-Change RRSS to highest setting
Rides too stiff in rear -Check for binding suspension shafts and grease all pivot
points
-Decrease torsion spring preload adjustments
-Decrease rear shock compression valving by turning
screw counterclockwise (if equipped with optional Indy

r Select shock) or refer to optional valving on Suspension

Wallchart for Fox equipped models
-Set RRSS to lowest position or totally remove
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all steering components are
free turning
-Make sure skags are straight on skis
-Check hi-fax and replace if worn
-Reduce ski pressure:
•Increase front track spring preload
(requires shims)
•Reduce IFS spring preload by adjusting
cam

c Front end pushes

•Reduce rear torsion spring preload
•Lengthen front limiter strap
-Check for worn skags
-Check for binding suspension shafts and grease all pivot
points
-Increase IFS spring preload by adjusting cam or adding
washers
-Shorten front limiter strap
Steering is heavy -Check ski alignment
-Check skags and skis for damage
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload by adjusting
cam
•Reduce rear torsion spring preload
Setting up for deep snow operation -Change worn hi-fax
-Lower rear torque arms (see Performance section at the
back of this manual)
-Increase front limiter strap length
-Based on rider preference, RRSS may be removed to
increase weight transfer

Polaris Industries Inc. 7.71 8/98

SUSPENSION
Suspension Troubleshooting - XTRA 12 Style
Problem Solution
Rear suspension bottoms too easily -Check to be sure FRSS block is in highest position
-Adjust torsion spring blocks to highest position
-Adjust coil over spring on front track shock to
increase preload
-Change to .421 torsion springs (PN 7041405, 7041406)
-Change to next heavier coil spring (e .g. 75/125 #/in. to
90/150 #/in.
-Chang e to stiffer shock valving (refer to wallchart)
-Check charge in shocks on models equipped with Fox™
shocks
Rides too stiff in rear -Check for binding suspension shafts and grease all pivot
points
-Decrease spring preload adjustments
-Remove rear track shock spring or reduce rate of spring
_)
(refer to wallchart)
-Change front track shock to lighter spring
-Change to lighter shock valving on models equipped
with Fox™ or Indy Select shocks (refer to wallchart)
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all steering components are
free turning
-Make sure skags are straight on skis
Front end pushes -Check for worn skags
-Check for binding suspension shafts and grease all pivot
points
-I ncrease front IFS preload )
-Change FRSS to low setting or move to forwardmost
hole
Steering is heavy -Check ski alignment
-Check skags and skis for damage
-Change FRSS to high setting
-Decrease IFS spring preload
Setting up for deep snow operation -Rotate FRSS to lowest setting, depending upon rider
preference
-Decrease preload on front track spring
-Move FRSS to forwardmost hole
-Tighten limiter strap one hole

8/98 7.72 Polaris Industries Inc.