Originally posted by Sno-X-treme
[br]take a die grinder, or a file, and grind away a channel in that flange from the heat exchangers....I have no clue why Polaris has that there because it makes installing the front a HUGE pain the the butt! Otherwise you have to tilt and twist the whole skid to install it. Always do the front first, and remember to loosen up the track tension adjusters a lot
Dude, don't tell people to grind away parts.
You don't need to grind heat exchangers. You don't need to loosen track tension either. I have removed and installed Polaris suspensions many times. Lots with my Indy 440 anyway cuz I kept breaking rails. My XCR's weren't bad.
Do like this:
1: put front part of suspension, crooked so that it fits. Then wiggle it around until u can get it back in the track. It takes some work but it's not that big of a deal. Works best if you take off the rear springs and have the rear arm collapsed.
2: use a bar to lift the front of the suspension and move it around to get the bolts in.
3: put springs on the spring things so the suspension is in "up" position
4: lower back end of machine down
5: Struggle some more to get back bolts in. It takes some effort but not too much. If you do it right you shouldn't have to grind away your heat exchangers [V] or loosen off the track tension.