Before you begin, gather the following tools:

• Snap ring pliers
  
• 6 mm Allen wrench
  
• 10 mm ratchet wrench
  
• 10 mm socket
  
• 13 mm wrench
  
• 13 mm socket
  
• 15 mm wrench
  
• 16 mm wrench
  
• 17 mm wrench
  
• Ratchet
  
• Socket extension
  
• Impact gun (optional, but recommended)

Your Tom's Snowmobile Suspension Kit includes:

• Front Fox air shock
  
• Rear Fox air shock
  
• (2) Suspension support rods (torsion spring delete rods)
  
• Rocker arm
  
• Suspension stop block
  
• Cast suspension arm

Raise the rear of the snowmobile until the track is suspended off the ground or work table. This provides enough clearance to remove and reinstall the suspension components safely.

Using a 6 mm Allen wrench and a 13 mm wrench, remove the torsion spring bracket.

While removing the bolt, support the torsion spring with two fingers to prevent it from scratching the suspension rail.

Once removed, pull the bracket away from the rail and allow it to rest out of the way.

Using a 10 mm socket and wrench, remove the rear suspension mounting bolt.

Note: There is a washer and nut located behind the bracket. Be careful not to lose these components.

Using snap ring pliers, remove the snap ring.

Tip: If the snap ring is difficult to remove, pull the mounting bracket against the snap ring while using the pliers. This prevents the snap ring from flying off during removal.

Remove the bogey wheels from both sides of the suspension.

Once the wheels are removed, remove the torsion springs.

Remove the upper bolt securing the rear suspension bracket.

Remove the 13 mm bolt securing the lower end of the rear shock.

Push the retaining sleeve out of the lower shock mount.

With the mounting hardware removed, lift the rear suspension assembly out of the skid.

This assembly will be replaced with the Tom's Snowmobile Suspension system, which eliminates the torsion springs, adds Fox air shocks, and includes a stronger suspension bracket.

Remove the upper mounting bolt from the factory suspension bracket.

Remove the brass sleeve from inside the mount.

Set both the bolt and brass sleeve aside—they will be reused with the Tom's suspension

Using a 16 mm wrench on the bolt head and a 15 mm wrench on the nut, remove the lower rocker arm mounting bolt.

Note: This bolt is installed very tightly.

As you remove the bolt, retain the shim located between the bracket and the suspension rail.

Insert the bolt you just removed into the end of the sleeve and use it to pull the sleeve out.

Remove the factory suspension bracket.

Install the new Tom's suspension bracket.

Reinstall the sleeve into the bracket.

Reinstall the factory shim between the bracket and the suspension rail.

Insert the mounting bolt, ensuring the shim remains properly positioned.

Verify the washer is installed correctly on the opposite side before tightening the bolt.

Install the following components onto the new suspension arm:

• Bogey wheel (dish side facing outward)
  
• Mounting block
  
• Metal retaining clip
  
• C-clip
  

Repeat this process on the opposite side.

Verify the sleeve remains installed inside the suspension arm.

Position the suspension arm back into the skid.

Install the rear mounting bolt, but leave all hardware loose until the entire suspension has been assembled.

Position the rear shock into the rocker arm.

Install the supplied bushing.

Install both suspension support rods (torsion spring delete rods).

Install the retaining nut without the washer.

Install the new lower shock bolt supplied with the kit.

Install the sleeve into the upper support rod mounting bracket.

Pivot the suspension rearward to align the mounting holes.

A second person can be helpful during this step to keep everything aligned while installing the bolt.

Install the retaining nut without reinstalling the washer.

Once all rear suspension components are installed and aligned, tighten all mounting hardware securely.

Lift the rear of the tunnel while pulling the suspension rearward to align the mounting brackets.

Pull down on the tunnel as needed until the mounting holes line up.

Install the 10 mm mounting bolt.

Reinstall the washer and 10 mm nut on the back side of the bolt.

Remove the lower limiter strap bolt.

Removing the limiter strap first allows the front suspension to move more freely, making shock removal and installation much easier.

Remove the upper front shock mounting bolt using:

• 17 mm wrench on the nut
• 16 mm wrench on the bolt head

Remove the 13 mm nut from the lower shock axle.

Remove the outer washer.

Carefully remove and retain the inner washers located between the axle and each suspension rail.

These washers will be reused during installation.

Remove the C-clip from the back of the bogey wheel.

Slide the bogey wheel off the bearing.

If necessary, tap the wheel gently with a rubber or dead-blow hammer.

Remove the bearing from the bogey wheel.

A bearing puller is recommended.

If you do not have a bearing puller, use an alternative bearing removal method.

Remove:

• Sleeve
  
• Retaining clip
  
• Factory shock
  

Install the new Fox air shock.

Reinstall, in order:

1. Sleeve
   
2. Retaining clip
   
3. Bearing
   

Press or tap the bearing back into place using an appropriate driver.

Slide the bogey wheel back onto the bearing.

Tap lightly with a hammer until fully seated.

Reinstall the C-clip.

Position the shock so the top mount is above the suspension bracket.

This prevents having to flex the shock around the upper mount during installation.

Install the lower axle.

Important: Ensure the factory washers are installed between the axle and each suspension rail.

A second person can make aligning both washers much easier.

Install and tighten the lower nut.

Install and tighten the upper front shock mounting bolt.

Place a block beneath the front of the suspension to compress it slightly.

Reinstall the limiter strap, washer, and retaining nut.

Compress the suspension.

Install the supplied plastic stop block.

Ensure the long side of the block faces the suspension.

Install and tighten the mounting bolt.

The stop block prevents the suspension from folding forward during operation.

Before riding:

• Verify all hardware has been tightened to specification.
  
• Confirm all C-clips and snap rings are fully seated.
  
• Ensure all washers and spacers are installed in their original locations.
  
• Check that both Fox shocks move freely through the suspension travel.
  
• Verify the stop block and support rods are installed correctly.

Your Tom's Snowmobile Suspension installation is now complete. Enjoy your ride!