Seen on another site some talk of the tunnel protectors from Polaris for the IQ sleds (2008-'09).
Seems they are coming out with a new set-up? Anyone know how it differs from the previous/current protectors?
Posted were 2 part numbers for the "old" version: 2876563 (long black section) & 2877231(short white section)
Seems the above numbers above are now replaced with # 2877687. Anyone care to comment on what the difference is with the old and new tunnel protectors?
I had bought the p/n 2876563 kit for my '08 Shift but curious if it should be used or should the new kit be used instead as it seems Polaris recommends the new kit for the '08-'09 sleds.
Another question if I could still safely use the 2876563 kit, what is the purpose of the 2877231 strips?
Full Version: IQ Chassis Tunnel Protectors
First of all, the newer tunnel protectors are only needed for the MY09 600 & 800 sleds with the 121" or the 136/Switchback chassis. No concern for FSTs or Touring. RMK's and Assaults don't have the mounting extrusions for tunnel protectors to begin with, so they are not involved.
The affected sleds have a new smaller front bulkhead cooler: part number 1240263 and it does not keep the tunnel protector from being pushed forward if the track hits the protector hard enough. The new kits and the fix to allow the old kits to be used on the affected sleds, involves putting a bolt and nut in the correct spot to act as a stop within the protector so the end of the aluminum mounting extrusion prevents the tunnel protector from going forward.
The 2877231 strips came out in February of 2008 and they or the equivalent in the soon to be available 2877687 kit are REQUIRED when studding the outside bands of the track on sleds with the RAW 121 / 136 chassis. Polaris Team Tip S-08-01-02 explained this. The 2877231 WIDE kit is used in addition to the 2876563 kit. The new 2877687 kit combines both prior kits. It can be also be used on MY08 sleds.
P.S.
This information did not come from another site.
The affected sleds have a new smaller front bulkhead cooler: part number 1240263 and it does not keep the tunnel protector from being pushed forward if the track hits the protector hard enough. The new kits and the fix to allow the old kits to be used on the affected sleds, involves putting a bolt and nut in the correct spot to act as a stop within the protector so the end of the aluminum mounting extrusion prevents the tunnel protector from going forward.
The 2877231 strips came out in February of 2008 and they or the equivalent in the soon to be available 2877687 kit are REQUIRED when studding the outside bands of the track on sleds with the RAW 121 / 136 chassis. Polaris Team Tip S-08-01-02 explained this. The 2877231 WIDE kit is used in addition to the 2876563 kit. The new 2877687 kit combines both prior kits. It can be also be used on MY08 sleds.
P.S.
This information did not come from another site.
Thanks for the information ExcursionPSD.
Where can one access the Team Tips if possible?
For my application, studding just down the center of the track on an '08 Shift 121", I can still use the 2876563 w/o the 2877231 kit?
Is there a specific place I would need to drill and put a bolt through the extrusion and protectors, or just towards the rear of the tunnel?
Does Polaris have an updated install instruction page for this?
Where can one access the Team Tips if possible?
For my application, studding just down the center of the track on an '08 Shift 121", I can still use the 2876563 w/o the 2877231 kit?
Is there a specific place I would need to drill and put a bolt through the extrusion and protectors, or just towards the rear of the tunnel?
Does Polaris have an updated install instruction page for this?
QUOTE(xcsp @ Nov 1 2008, 08:47 PM) 
Thanks for the information ExcursionPSD.
Where can one access the Team Tips if possible?
For my application, studding just down the center of the track on an '08 Shift 121", I can still use the 2876563 w/o the 2877231 kit?
Is there a specific place I would need to drill and put a bolt through the extrusion and protectors, or just towards the rear of the tunnel?
Does Polaris have an updated install instruction page for this?
Where can one access the Team Tips if possible?
For my application, studding just down the center of the track on an '08 Shift 121", I can still use the 2876563 w/o the 2877231 kit?
Is there a specific place I would need to drill and put a bolt through the extrusion and protectors, or just towards the rear of the tunnel?
Does Polaris have an updated install instruction page for this?
Become a dealer technician and you will have access to the Team Tips. This is only to help dealers properly answer the questions of their customers.
The 2877231 strips came out in February of 2008 and they or the equivalent in the soon to be available 2877687 kit are REQUIRED when studding the outside bands of the track ... If you don't stud the outside of the track, you don't need the 2877231 kit.
First of all, the newer tunnel protectors are only needed for the MY09 600 & 800 sleds with the 121" or the 136/Switchback chassis... Your sled is MY08. You don't need to worry.
You can put a bolt thru the extrusion anywhere you want, you just will have to deal with losing coolant thru the hole after you do.
The new kits will come with updated instruction sheets.
Installed the tunnel protection kits, 2876563 (long black section) & 2877231(white rear sections) on my '08 Shift, a straight-forward install only that the instructions mention to cut the black sections at 42" for use with the white kit.
I cut the black protectors off at 44.25" and on my sled they fit perfect with the rear close-off panel in place.
One thing to mention to anyone adding the tunnel protectors is to replace the two rear bolts for the bumper with 1" long, 1/4"-20 stainless hex-head bolts in case you would ever need to remove the rear bumper
Once the protectors are in all the way to the clos-off panel, accessing the stock Torx-head bolts will not be easy.
I cut the black protectors off at 44.25" and on my sled they fit perfect with the rear close-off panel in place.
One thing to mention to anyone adding the tunnel protectors is to replace the two rear bolts for the bumper with 1" long, 1/4"-20 stainless hex-head bolts in case you would ever need to remove the rear bumper
Once the protectors are in all the way to the clos-off panel, accessing the stock Torx-head bolts will not be easy.
Still waiting for mine. I ordered them on October 11th and was told 12-2. Then it was 11-21,11-28 back to 12-2 and now I'm told they MAY ship 12-11 because I got my order in so early. I will not be riding the years first ride up at camp this weekend due to this blunder,way to go Polaris.
QUOTE(Stewy @ Dec 9 2008, 03:05 PM)
Still waiting for mine. I ordered them on October 11th and was told 12-2. Then it was 11-21,11-28 back to 12-2 and now I'm told they MAY ship 12-11 because I got my order in so early. I will not be riding the years first ride up at camp this weekend due to this blunder,way to go Polaris.
Tell us what sled you have got, maybe you could get some help.
I hope you are not waiting for turnnel protectors for a MY06 600 HO
I have the 09' 800 dragon 121. I had the dealer stud it 144 middle and they were attempting to put the protector kit on. They then called a poo tech who informed them of the new part number for my model. This was in October. I am still waiting and not real happy about it. I know many have drilled bolts in to make the old style work but my service rep told me the poo rep said not to do that. My third Polaris and my first new sled so I'm very anxious. Definetly a downer.
Please read this very carefully, the problem and the solutions have several variations.
First, this new problem with tunnel protector installation, only applies to some MY08 and MY09 Polaris 121" and Switchback sleds with 'RAW' style tunnels, which have two full length cooling extrusions running the length of the tunnel. These cooler extrusions have an upside down T-rail as part of them, and the Tunnel Protectors are installed onto this T-rail, similar to how you install hifax on the sliderail.
If you don't have this type of tunnel, this post doesn't apply to you.
If you or your dealer doesn't have some fabricating skills, don't attempt this either.
For MY09 2 stroke sleds, the front bulkhead heat exchanger was made smaller. It no longer will reliably stop the tunnel protectors from getting pushed forward and past the heat exchanger and down in front of the track. This is a bad thing, but it only occurs with: MY09 2 stroke sleds.
The Polaris part numbers that were intended to be used for tunnel protection on the RAW tunnel sleds are now all superceding to part 2877687 which at this time is not available until Dec. 16, 2008 or later.
Take a look at: Nov 08 Inner/Outer studding Wear Strip 2877687 instructions and then print them out.
Basically follow the instructions on the sheet from Polaris, after reviewing these fabrication additons. My additions basically replace step 4 of the Polaris instructions. You will need the dart clips and rivets to put the closeoff and taillight together after installing these tunnel protectors. You will also need some nuts and bolts.
I will now break this into several sections:
1. Tunnel Protector Length
Get 2 pieces of THICK hifax (5521632 or 55216333), same as factory usage on your sliderails. You will have one end cut at a 90 degree angle, and the other cut at a 45 degree angle. This will face against your tailflap, remember it will be channel up when you install it, so angle appropriately.
If you have a 121" sled, cut the piece to 52" overall length
For a 136" Switchback, cut the piece to 62" overall length, (61" will be okay, if you have short hifax)
2. Stopping the Tunnel Protector
If you DON'T have a MY09 2 stroke, skip to Section 3.
If you Do have a MY09 2 stroke, or you just want to, use a grade 5 button head torx drive 1/4-20 that is 1 1/2 to 1 3/4" long. Drill a hole crossways 3 inches in from the angled end of the tunnel protector/hifax. This bolt will be a stop in the mounting channel, so that when you install the tunnel protector the crossways bolt will hit the back end of the T-rail in the heat exchanger, and prevent the tunnel protector from going further forward. This is shown in the instructions. Use a mechanical/crimped flanged 1/4-20 locknut on this bolt, to keep it from falling out. Don't install the tunnel protector yet.
3. IF studding on the Outside bands of the track
As the instructions show, you will have to make the protector thicker at the tail end, to provide extra height. The instructions show the two bolts that make a sandwich of another piece of hifax below the long pieces you have already prepared.
You will have to fabricate a 'ripped lengthwise' section of tunnel protector (IQ Switchback Thick sliderail hyfax 5521632/ 5521633) to stack underneath the tunnel protector you already have. Black grade 5 Button head torx drive 1/4-20 1" long bolts are used with mechanical (not Nylok) locking flanged nuts to hold the stack together. They will need to be recessed or setin to the hifax on both the top and bottom pieces somewhat.
Your goal should be a total stacked depth top to bottom a minimum of 1 1/8" thick, 21 1/4" or more total length. Thicker is okay.
END of fabrication instructions.
Please notice that you do not drill new holes in ANY METAL. You are only fabricating slide on tunnel protectors, that are retained by the tailflap.
First, this new problem with tunnel protector installation, only applies to some MY08 and MY09 Polaris 121" and Switchback sleds with 'RAW' style tunnels, which have two full length cooling extrusions running the length of the tunnel. These cooler extrusions have an upside down T-rail as part of them, and the Tunnel Protectors are installed onto this T-rail, similar to how you install hifax on the sliderail.
If you don't have this type of tunnel, this post doesn't apply to you.
If you or your dealer doesn't have some fabricating skills, don't attempt this either.
For MY09 2 stroke sleds, the front bulkhead heat exchanger was made smaller. It no longer will reliably stop the tunnel protectors from getting pushed forward and past the heat exchanger and down in front of the track. This is a bad thing, but it only occurs with: MY09 2 stroke sleds.
The Polaris part numbers that were intended to be used for tunnel protection on the RAW tunnel sleds are now all superceding to part 2877687 which at this time is not available until Dec. 16, 2008 or later.
Take a look at: Nov 08 Inner/Outer studding Wear Strip 2877687 instructions and then print them out.
Basically follow the instructions on the sheet from Polaris, after reviewing these fabrication additons. My additions basically replace step 4 of the Polaris instructions. You will need the dart clips and rivets to put the closeoff and taillight together after installing these tunnel protectors. You will also need some nuts and bolts.
I will now break this into several sections:
1. Tunnel Protector Length
Get 2 pieces of THICK hifax (5521632 or 55216333), same as factory usage on your sliderails. You will have one end cut at a 90 degree angle, and the other cut at a 45 degree angle. This will face against your tailflap, remember it will be channel up when you install it, so angle appropriately.
If you have a 121" sled, cut the piece to 52" overall length
For a 136" Switchback, cut the piece to 62" overall length, (61" will be okay, if you have short hifax)
2. Stopping the Tunnel Protector
If you DON'T have a MY09 2 stroke, skip to Section 3.
If you Do have a MY09 2 stroke, or you just want to, use a grade 5 button head torx drive 1/4-20 that is 1 1/2 to 1 3/4" long. Drill a hole crossways 3 inches in from the angled end of the tunnel protector/hifax. This bolt will be a stop in the mounting channel, so that when you install the tunnel protector the crossways bolt will hit the back end of the T-rail in the heat exchanger, and prevent the tunnel protector from going further forward. This is shown in the instructions. Use a mechanical/crimped flanged 1/4-20 locknut on this bolt, to keep it from falling out. Don't install the tunnel protector yet.
3. IF studding on the Outside bands of the track
As the instructions show, you will have to make the protector thicker at the tail end, to provide extra height. The instructions show the two bolts that make a sandwich of another piece of hifax below the long pieces you have already prepared.
You will have to fabricate a 'ripped lengthwise' section of tunnel protector (IQ Switchback Thick sliderail hyfax 5521632/ 5521633) to stack underneath the tunnel protector you already have. Black grade 5 Button head torx drive 1/4-20 1" long bolts are used with mechanical (not Nylok) locking flanged nuts to hold the stack together. They will need to be recessed or setin to the hifax on both the top and bottom pieces somewhat.
Your goal should be a total stacked depth top to bottom a minimum of 1 1/8" thick, 21 1/4" or more total length. Thicker is okay.
END of fabrication instructions.
Please notice that you do not drill new holes in ANY METAL. You are only fabricating slide on tunnel protectors, that are retained by the tailflap.
QUOTE(ExcursionPSD @ Dec 10 2008, 11:26 AM)
Please read this very carefully, the problem and the solutions have several variations.
First, this new problem with tunnel protector installation, only applies to some MY08 and MY09 Polaris 121" and Switchback sleds with 'RAW' style tunnels, which have two full length cooling extrusions running the length of the tunnel. These cooler extrusions have an upside down T-rail as part of them, and the Tunnel Protectors are installed onto this T-rail, similar to how you install hifax on the sliderail.
If you don't have this type of tunnel, this post doesn't apply to you.
If you or your dealer doesn't have some fabricating skills, don't attempt this either.
For MY09 2 stroke sleds, the front bulkhead heat exchanger was made smaller. It no longer will reliably stop the tunnel protectors from getting pushed forward and past the heat exchanger and down in front of the track. This is a bad thing, but it only occurs with: MY09 2 stroke sleds.
The Polaris part numbers that were intended to be used for tunnel protection on the RAW tunnel sleds are now all superceding to part 2877687 which at this time is not available until Dec. 16, 2008 or later.
Take a look at: Nov 08 Inner/Outer studding Wear Strip 2877687 instructions and then print them out.
Basically follow the instructions on the sheet from Polaris, after reviewing these fabrication additons. My additions basically replace step 4 of the Polaris instructions. You will need the dart clips and rivets to put the closeoff and taillight together after installing these tunnel protectors. You will also need some nuts and bolts.
I will now break this into several sections:
1. Tunnel Protector Length
Get 2 pieces of THICK hifax (5521632 or 55216333), same as factory usage on your sliderails. You will have one end cut at a 90 degree angle, and the other cut at a 45 degree angle. This will face against your tailflap, remember it will be channel up when you install it, so angle appropriately.
If you have a 121" sled, cut the piece to 52" overall length
For a 136" Switchback, cut the piece to 62" overall length, (61" will be okay, if you have short hifax)
2. Stopping the Tunnel Protector
If you DON'T have a MY09 2 stroke, skip to Section 3.
If you Do have a MY09 2 stroke, or you just want to, use a grade 5 button head torx drive 1/4-20 that is 1 1/2 to 1 3/4" long. Drill a hole crossways 3 inches in from the angled end of the tunnel protector/hifax. This bolt will be a stop in the mounting channel, so that when you install the tunnel protector the crossways bolt will hit the back end of the T-rail in the heat exchanger, and prevent the tunnel protector from going further forward. This is shown in the instructions. Use a mechanical/crimped flanged 1/4-20 locknut on this bolt, to keep it from falling out. Don't install the tunnel protector yet.
3. IF studding on the Outside bands of the track
As the instructions show, you will have to make the protector thicker at the tail end, to provide extra height. The instructions show the two bolts that make a sandwich of another piece of hifax below the long pieces you have already prepared.
You will have to fabricate a 'ripped lengthwise' section of tunnel protector (IQ Switchback Thick sliderail hyfax 5521632/ 5521633) to stack underneath the tunnel protector you already have. Black grade 5 Button head torx drive 1/4-20 1" long bolts are used with mechanical (not Nylok) locking flanged nuts to hold the stack together. They will need to be recessed or setin to the hifax on both the top and bottom pieces somewhat.
Your goal should be a total stacked depth top to bottom a minimum of 1 1/8" thick, 21 1/4" or more total length. Thicker is okay.
END of fabrication instructions.
Please notice that you do not drill new holes in ANY METAL. You are only fabricating slide on tunnel protectors, that are retained by the tailflap.
First, this new problem with tunnel protector installation, only applies to some MY08 and MY09 Polaris 121" and Switchback sleds with 'RAW' style tunnels, which have two full length cooling extrusions running the length of the tunnel. These cooler extrusions have an upside down T-rail as part of them, and the Tunnel Protectors are installed onto this T-rail, similar to how you install hifax on the sliderail.
If you don't have this type of tunnel, this post doesn't apply to you.
If you or your dealer doesn't have some fabricating skills, don't attempt this either.
For MY09 2 stroke sleds, the front bulkhead heat exchanger was made smaller. It no longer will reliably stop the tunnel protectors from getting pushed forward and past the heat exchanger and down in front of the track. This is a bad thing, but it only occurs with: MY09 2 stroke sleds.
The Polaris part numbers that were intended to be used for tunnel protection on the RAW tunnel sleds are now all superceding to part 2877687 which at this time is not available until Dec. 16, 2008 or later.
Take a look at: Nov 08 Inner/Outer studding Wear Strip 2877687 instructions and then print them out.
Basically follow the instructions on the sheet from Polaris, after reviewing these fabrication additons. My additions basically replace step 4 of the Polaris instructions. You will need the dart clips and rivets to put the closeoff and taillight together after installing these tunnel protectors. You will also need some nuts and bolts.
I will now break this into several sections:
1. Tunnel Protector Length
Get 2 pieces of THICK hifax (5521632 or 55216333), same as factory usage on your sliderails. You will have one end cut at a 90 degree angle, and the other cut at a 45 degree angle. This will face against your tailflap, remember it will be channel up when you install it, so angle appropriately.
If you have a 121" sled, cut the piece to 52" overall length
For a 136" Switchback, cut the piece to 62" overall length, (61" will be okay, if you have short hifax)
2. Stopping the Tunnel Protector
If you DON'T have a MY09 2 stroke, skip to Section 3.
If you Do have a MY09 2 stroke, or you just want to, use a grade 5 button head torx drive 1/4-20 that is 1 1/2 to 1 3/4" long. Drill a hole crossways 3 inches in from the angled end of the tunnel protector/hifax. This bolt will be a stop in the mounting channel, so that when you install the tunnel protector the crossways bolt will hit the back end of the T-rail in the heat exchanger, and prevent the tunnel protector from going further forward. This is shown in the instructions. Use a mechanical/crimped flanged 1/4-20 locknut on this bolt, to keep it from falling out. Don't install the tunnel protector yet.
3. IF studding on the Outside bands of the track
As the instructions show, you will have to make the protector thicker at the tail end, to provide extra height. The instructions show the two bolts that make a sandwich of another piece of hifax below the long pieces you have already prepared.
You will have to fabricate a 'ripped lengthwise' section of tunnel protector (IQ Switchback Thick sliderail hyfax 5521632/ 5521633) to stack underneath the tunnel protector you already have. Black grade 5 Button head torx drive 1/4-20 1" long bolts are used with mechanical (not Nylok) locking flanged nuts to hold the stack together. They will need to be recessed or setin to the hifax on both the top and bottom pieces somewhat.
Your goal should be a total stacked depth top to bottom a minimum of 1 1/8" thick, 21 1/4" or more total length. Thicker is okay.
END of fabrication instructions.
Please notice that you do not drill new holes in ANY METAL. You are only fabricating slide on tunnel protectors, that are retained by the tailflap.
Thanks for the detailed info. If they do not ship Tomm. I will be doing this.
QUOTE(ExcursionPSD @ Dec 10 2008, 12:58 AM)
Tell us what sled you have got, maybe you could get some help.
I hope you are not waiting for turnnel protectors for a MY06 600 HO
I hope you are not waiting for turnnel protectors for a MY06 600 HO
ExcursionPSD- I have a 06 Fusion 600 HO I'm looking to put studs in. My manual says I need a wear strip kit (P/N: 2874687) which the Polaris website renders a bad number! With this post you're making me wonder what really is needed. Can you point me in the right direction please? Everything is stock on the sled front to rear. I was thinking 96 studs. It has 1" lugs.
Sorry for being so late to the party- but I'm glad I found this site.
QUOTE(Blue Fusion @ Nov 10 2009, 09:00 AM)
ExcursionPSD- I have a 06 Fusion 600 HO I'm looking to put studs in. My manual says I need a wear strip kit (P/N: 2874687) which the Polaris website renders a bad number! With this post you're making me wonder what really is needed. Can you point me in the right direction please? Everything is stock on the sled front to rear. I was thinking 96 studs. It has 1" lugs.
Sorry for being so late to the party- but I'm glad I found this site.
Sorry for being so late to the party- but I'm glad I found this site.
2874687 is available from Polaris $50US it is for the 121" sleds.
It is correct for your sled, if you have the 121" version MY06 600 Fusion.
What website did you look on?
QUOTE(ExcursionPSD @ Nov 10 2009, 01:51 PM)
2874687 is available from Polaris $50US it is for the 121" sleds.
It is correct for your sled, if you have the 121" version MY06 600 Fusion.
What website did you look on?
It is correct for your sled, if you have the 121" version MY06 600 Fusion.
What website did you look on?
I was on Polaris' site...
http://parts.polarisind.com/AdvancedSearch...ancedSearch.asp
It is a 121" and thanks for getting back to me. I'll go to see the dealer.
QUOTE(Blue Fusion @ Nov 10 2009, 02:32 PM)
I was on Polaris' site...
http://parts.polarisind.com/AdvancedSearch...ancedSearch.asp
It is a 121" and thanks for getting back to me. I'll go to see the dealer.
http://parts.polarisind.com/AdvancedSearch...ancedSearch.asp
It is a 121" and thanks for getting back to me. I'll go to see the dealer.
With the exception of service parts and sometimes spring options, the Polaris Online Parts Catalog, only shows parts used in production vehicles. No sled came with those protectors on, from the factory.
QUOTE(ExcursionPSD @ Nov 10 2009, 07:07 PM)
With the exception of service parts and sometimes spring options, the Polaris Online Parts Catalog, only shows parts used in production vehicles. No sled came with those protectors on, from the factory.
Thank you for all your help and insight. Receiving good, helpful information means a lot.
QUOTE(Blue Fusion @ Nov 10 2009, 11:59 PM)
Thank you for all your help and insight. Receiving good, helpful information means a lot.
Glad to help, you can bet a lot of people have helped me!
Guys I just ordered protectors for my 07 IQ600ho and I swear in the accessory book it said 2874687 for all IQ 121" models yet when I got it home here it is obviously not correct. In the instructions too it says for all 2005 IQ 121". I am running 144 down the middle and am wondering what part number I need. Thanks
here is a link too, look at the part number 2874687, it says 07 IQ 121" so maybe I do have the right one..
Here's a picture of the 2877687 tunnel protectors on my '10 Shift 121"
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