Snowmobile Polaris Two Stroke (2007 year). Manual - part 53

8.15

FRONT SUSPENSION & STEERING

8

4.

Replace snap ring (22).

5.

Install spindle.

6.

Install the ski(s).

UPPER / LOWER CONTROL ARM REMOVAL

1.

Remove the spindle(s) and shock(s).

2.

Remove the upper and lower control arm(s) bulk head bolts
(1,6).

3.

Remove the upper or lower control arm (10,20) and remove
all pivot bushings (5,9), and all pivot shafts (3, 7).

Upper / Lower Control Arm Installation

1.

Replace the upper or lower control arm bushings (5,9) and
pivot shafts (3, 7) in the control arm(s).

2.

Replace the upper or lower control arm(s) into the
bulkhead.

3.

Replace the upper or lower control arm bolts (1,6). Torque
to 40 ft-lb (54 N-m).

NOTE:  A spacer washer (2) is located on the lower
rearward mounting area, and should be located at
the bolt head.

STEERING

INSPECTION

Prior to performing steering alignment, inspect all steering and
suspension components for wear or damage and replace parts as
necessary. Refer to steering assembly exploded views in this
chapter for identification of components and torque values of
fasteners. While disassembling, make notes of what direction a
bolt goes through a part, what type of nut is used in an
application, in which direction do the steering arms go on - weld
up or weld down, etc.

Some of the fasteners used in the IFS are special and cannot be
purchased at a hardware store. Always use genuine Polaris parts
and hardware when replacing front end components. Review
steering adjustment guidelines before making adjustments.

The following components must be inspected at this time.

• Tie rods and tie rod ends

• Control arms and control arm ends

• Torsion bar and bushings / linkage (where applicable)

• Handlebars and steering post assembly

• Spindles and bushings

• Skis and skags

• Pitman arms / Idler arms

• Steering arms

• A-arms and bushings

• Shock absorbers, shock mounts, springs

• All related fasteners - check torque. Refer to steering 

exploded views at the beginning of this section.

• Grease all fittings.

 Always follow rod end engagement guidelines. Maximum
setup width must be checked whenever front suspension
components are adjusted or replaced.

Alignment Bar Specifications

• DIAMETER: .623”-.625” (15.824-15.875mm)

• LENGTH: 45” (114.3cm)

• MATERIAL: C-1018

Camber Definition

The following definitions of camber use automotive
terminology to describe positive and negative positions.

• 0 = Neutral camber. The spindle is 90° (perpendicular) 

to the ground.

• + = Positive camber. The bottom of the spindle is 

canted inward toward the chassis.

• - = Negative camber. Spindle bottom is canted outward 

from the chassis.

+

-

0

-

0

+

8.16

FRONT SUSPENSION & STEERING

Rod End

Rod ends must be parallel to their respective mounting surface
after tightening jam nut. Hold the rod end and tighten jam nut.
If possible, support the edge of the rod end to keep it from
rotating out of position until jam nut is tight. When rod ends are
properly tightened, the rod should rotate freely approximately 1/
8 turn.

Rod End Engagement

Rod ends must engage the rod a minimum of 2x the thread
diameter when adjustment is complete.

Example: .4375” (11mm) rod end (A) X 2 = minimum thread
engagement (B) .875” (22mm).

FRONT SUSPENSION MEASURING

Maximum width and camber measurements are to be taken with
the front end elevated and shocks at full extension.

Maximum Width

Width is measured from the center of the spindles.

Toe Alignment

Toe alignment is measured at ride height. This means that the
machine is on the ground and resting at normal ride height, not
full rebound. Measure at a point 10” (2.54cm) forward of the ski
mount bolt and 10” (2.54cm) behind the ski mount bolt,
preferably on the center line of the carbide skags.

Camber

Camber measurement is taken from the top of the alignment bar
to the top of the ski mount hole in the spindle with the bushing
removed.

ALIGNMENT ADJUSTMENTS

Alignment adjustments should be preformed in this order.

Edge/Edge LX/Edge RMK Set Up Width

Prior to performing steering alignment, the suspension should
be inspected for damage or wear and replacement parts installed
as required.

IMPORTANT: 

Camber, width are dimensions that

depend on each other. If any adjustments have been

made, each one should be checked.

1.

Make sure that the track is properly aligned. Track
alignment is critical because this will be used as a
reference point for final toe out measurement. See
“TRACK ALIGNMENT” on page 3.20.

2.

Support the front of the machine is at ride height.

3.

Remove the skis and ski pivot bushings.

4.

Disconnect the torsion bar.

5.

Measure spindle to chassis centering and record the
measurement.

6.

The spindle centering and set up width is controlled by
adjusting the radius rod lengths, and must not exceed the
maximum set up width listed. 

NOTE: Both spindle centers should be an equal
distance ± 1/8” (3mm) from the center of the chassis.

A

B

WARNING

A maximum set up width is listed in “Front Suspension 

Torque & Specifications” on page 8.3. Maximum set 

up width is the maximum allowable distance between 

ski spindle centers at ride height. The Maximum Set 

Up Width specifications are maximum width 

measurements, and are critical to ensure adequate 

torsion bar engagement with the Trailing/Control 

Arms. If the suspension is set too wide, the torsion bar 
may disengage from trailing arm. Do not attempt to set 
the suspension wider than the specified maximum set 

up width.

Center to center distance

8.17

FRONT SUSPENSION & STEERING

8

Edge/Edge LX/Edge RMK Camber 

Adjustment

1.

Raise the front of the machine so that the skis are off the
floor 3” (7.62cm). The shocks should be at full extension.

2.

Remove the skis.

3.

Determine which spindle requires the greatest amount of
correction by installing the alignment bar through one
spindle to the other spindle. Measure the distance (2) from
the top of the alignment bar to the top of the ski mount hole
with the bushing(s) removed. Record measurement.

4.

Remove the alignment bar and install it to the opposite side.
Measure the distance (2) from the top of the alignment bar
to the top of the ski mount hole with the bushing(s)
removed. Record measurement 

5.

To adjust the camber, change the lower radius rod (1) length
until alignment bar measurement is within the specified
range for each spindle.

6.

Once the specification is achieved, tighten all jam nut(s)
and torque them to 8-14 ft-lb (11-19 N-m).

7.

Re-check the set up width and compare to specification.

IQ/IQ LX/Switchback Camber Adjustment

1.

Raise the front of the machine so that the skis are off the
floor 3” (7.62cm). The shocks should be at full extension

2.

Remove the skis.

3.

Determine which spindle requires the greatest amount of
correction by installing the alignment bar through one
spindle to the other spindle. Measure the distance (1) from
the top of the alignment bar to the top of the ski mount hole
with the bushing(s) removed. Record measurement.

4.

Remove the alignment bar and install it to measure the
opposite side. Measure the distance (1) from the top of the
alignment bar to the top of the ski mount hole with the
bushing(s) removed. Record measurement 

5.

To adjust the camber, unlock the jam nut (2) and adjust the
camber with the adjuster nut (3) until alignment bar
measurement is within the specified range for each spindle.

6.

Once the specification is achieved, torque the upper rod end
jam nut (2) to specification.

7.

Re-check the toe alignment after changing the camber
settings.

WARNING

After camber adjustment is complete, be sure to 

measure set up width outlined in this chapter and 

compare to model specifications listed. Do not 

attempt to set suspension wider than the specified 

maximum set up width. If set up width exceeds 

maximum, adjust upper and lower radius rods 

equally to maintain camber adjustment. 

1

2

= T 

Rod End Jam Nut Torque: 45 ft-lb (61 N-m)

2

1

3

8.18

FRONT SUSPENSION & STEERING

Handlebar Centering

1.

Raise the front of the machine off the floor so that the
spindles are off the floor 3”(7.62cm).

2.

Insert the alignment bar through both ski bolt holes in each
spindles.

3.

Adjust the Toe as outlined below, until handlebar is
centered.

Toe Adjustment

Toe is adjusted with the shocks and skis installed. Track
alignment must be correct before starting this process. See
“TRACK ALIGNMENT” on page 3.20.

Toe alignment is measured at ride height.

1.

Lift front of the machine off the floor rock the front end up
and down and then set it down gently. This will set the unit
at ride height.

2.

Measure and make a mark 10” (2.54cm) forward of the ski
mount bolt and 10” (2.54cm) behind the ski mount bolt,
preferably on the center line of the carbide skags.

3.

Place a straight edge along the one side of the track. Make
sure that the straight edge is touching along the length of
the track.

4.

Record the measurements from the edge of the straight edge
to the forward ski mark and the rearward ski mark.

5.

Adjust the tie rod so that the toe is set per the specifications.
See “Front Suspension Torque & Specifications” on
page 8.3.

6.

Place the straight edge on the opposite side of the track and
measure the opposite ski marks.

7.

Adjust the tie rod so that the toe is set per the specifications.
See “Front Suspension Torque & Specifications” on
page 8.3.

8.

Verify that the ski center distances are within specification
from the forward marks and the rearward marks.

SKI STANCE

Adjustment (IQ RMK Only)

WIDE SKI STANCE

For maximum stability, install both of the spacers
to the outside of the spindle

NARROW SKI STANCE

For maximum maneuvering, install both of the

spacers to the inside of the spindle.