Snowmobile Polaris 2006 - 2007 FS / FST. Manual - part 58

10.33

Rear Suspension

10

Rev. 1 07/2006

6.

Install the new, well lubricated, o-rings into the bearing
housing. Correct placement of the shaft seal o-ring is in the
groove next to the DU bushing. Check to make sure the
seals are properly seated, and are not twisted. If a tool is
required to aid in proper seating of o-ring, use the non-
writing end of a pen, or a similar soft, blunt object, to push
it in.

7.

Install the new U-cup seal into bearing. U-cup should be
installed so the cupped end is facing the DU bushing inside
of bearing. Check to make sure seal is properly seated. If a
tool is required to aid in proper seating of U-cup seal, use
the non-writing end of a pen, or a similar soft, blunt object,
to push it in. 

8.

Install FIST bearing into housing. Check for proper
orientation of the FIST bearing. The stepped side of the
FIST bearing should be visible.

9.

Using a small pair of snap-ring pliers, install the snap-ring
into the bearing housing. Check for proper orientation of
the snap ring. The flat side of the snap-ring should be
visible. Check to make sure the snap-ring is properly
seated.

10. Install the new, well greased o-ring onto the IFP.

11. Install the new, well greased o-ring on the IFP bleed screw.

10.34

Rear Suspension

Rev. 1 07/2006

M-10 ACE SYSTEM

Assembly Illustration

Assembly Notes

• Install potentiometer with pin aligned with recess in 

mounting plate. Tighten lock nut to 25 In. Lbs.

• Turn ram and screw shaft assembly so the ram is fully-

retracted into the housing before setting potentiometer 
and installing gears.

• Turn potentiometer shaft so the resistance between the 

BLACK and WHITE wires is 107 Ohms.

• Apply Loctite 480 to the ID of the potentiometer gear, 

then carefully install without moving the potentiometer.

• Once installed, verify the resistance has not changed 

from 107 Ohms.

NOTE: Never re-use a potentiometer gear if it has
slipped on the shaft during use as the ID will be too
large for the Loctite to hold securely.

ELECTRIC MOTOR / GEAR BOX

MOTOR COVER

COVER SEAL

COVER SEAL

SMALL / LARGE BEVEL GEARS

PIN

THRUST WASHER
(STEEL SIDE FACES HOUSING)

HARNESS
(5.25 IN LENGTH)

THRUST WASHERS

BEARING

SPUR GEARS

SHAFT SCREW

RAM

POTENTIOMETER

SET SCREW

A
LOCTITE 262

A
LOCTITE 262

A (All Cover Screws)

A

B

A

C

APPLY GREASE TO THREADS

APPLY LOCTITE 480 TO
INSIDE DIAMETER OF BOTH GEARS
ALLOW 24 HOURS FOR CURING

= T 

A = 15 In.Lb. (1.7Nm)

B = 4 Ft.Lb. (5.5Nm)

C = 25 In.Lb. (2.8Nm)

10.35

Rear Suspension

10

Rev. 1 07/2006

TROUBLESHOOTING

Rear Suspension

PROBLEM

SOLUTION

Rear Suspension Bottoms Too Easily 

IQ 121 / Switchback: Adjust torsion spring preload to achieve 
proper static sag. Change torsion spring to a stiffer optional 
spring. Re-valve the rear track shock.
M-10: Increase FRA position. Install appropriate optional 
center retainer on rear track shock. Increase front track shock 
coil spring preload by adding washers. Re-valve the rear track 
shock. Check the track tension.

Rear Suspension Too Stiff

IQ 121 / Switchback: Adjust torsion spring preload to achieve 
proper static sag. Change torsion spring to a softer optional 
spring. Re-valve the rear track shock. Lubricate pivot points. 
Move limiter straps to lower holes. Check track tension.
M-10: Decrease FRA position. Install appropriate option 
center retainer on rear track shock. Decrease front track shock 
coil spring preload by removing washers. Re-valve the rear 
track shock. Check track tension.

Deep Snow Operation

IQ Switchback: Change worn rail slides. Move limiter straps 
to lower holes (lengthen). Always adjust torsion spring 
preload to achieve proper static sag setting. Install stiffer front 
track spring to remove ski pressure.

NOTES

Rear Suspension

10.36

Rev. 1 07/2006