Snowmobile World banner

1 - 7 of 7 Posts

·
Registered
Joined
·
19 Posts
Discussion Starter #1
Hi guys i am new to Polaris sleds. I bought 1 last March and it ran perfect. I got to ride for about a week and then came the stump. Bent the hell out of my tunnel. i now need to get a tunnel for it. My question is what tunnel will work for all the stuff i have with the least amount of rigging. My sled is a 98 xc700. Everything seems to be OK just the tunnel is bent at the front of the track so i think the tunnel is trash. i have pulled the sled down and junked the tunnel .I was thinking of getting rid of the parts but maybe if not to big of a deal i will just rebuild it. Thank you for your time guys!
 

·
Registered
Joined
·
1,352 Posts
It's a lot of work to change out a tunnel, any insurance company will total a sled that needs that kind of work. It will be easy to sell the engine and front and rear suspensions, the xtra-10 stuff is pretty sought after, as is the engine. I would disassemble and start parting things out.
 

·
Registered
Joined
·
19 Posts
Discussion Starter #3
Well i decided to rebuild. Was thinking about strip and sell but if i rebuild i know what i have and don't have to worry about all the mess of another used sled and the hassle of trying not to get screwed. I have gone trough a bunch of stuff in my area. I think the people here would screw there own mothers just to sell there sleds.
So to start i went to the snowmobile salvage yard near me. I found a tunnel with the heat ex-changers and front end pretty much intact. The part i am thinking about now is the old tunnel has heat ex-changers in the center of the tunnel. The new tunnel has the ex-changers in the center of the tunnel and another under each running board. I'm thinking more heat ex-changers more cooling. The thermostat should keep the engine temp up where it needs to be and the extra Ex-changers should be great for keeping it cool under shall we say heavy loads.
I have also ordered new bushings for the front end so all will be nice and tight.
Any input on this build would be more than welcome.
 

·
Registered
Joined
·
1,352 Posts
The job isn't complicated, but it's very time consuming, especially if you have to remove a lot of rivets. If you do, replace with stainless, they will take more abuse than regular steel or aluminum.

The heat exchangers under the running board are supposed to help keep the running board free of snow. They don't work that well at doing that, but if you do start overheating, you can pile some snow on the top of the running boards and that helps cool the exchangers from the top side.

Take lots of pics as you go, especially as you disassemble the broke sled. It's amazing how quickly you forget how things go together. A picture or 10 can save you tons of grief!
 

·
Registered
Joined
·
19 Posts
Discussion Starter #5
Great advice on taking lots of pictures ( I love my smartphone). As far as the rivets go I hope not to be doing many of them the replacement tunnel I am using has the bulkhead still on it and in good condition.
I was very lucky at the salvage yard as they had 3 tunnels to choose from. I hope to have this done before the heavy snow comes but may not be done until after the new year.
I am a over the road driver so sometimes projects drag out.
I do have everything I need so I am hoping for a unbolt and replace on new tunnel.
I did find a rust hole on the LH foot rest inside the tunnel. Not sure if I will cut it out and weld in a new section or drill and rivet in a new section. When I do this I will want it to last for a few years so I want it done rite and while it is striped down is the best time to do a repair like this.
I will be checking back in when I get home and keep you guys posted on my progress.
 

·
Registered
Joined
·
1,352 Posts
Snowmobiles vibrate so much, I would be concerned about a weld holding over time. Rivets may get a bit loose over the years, but won't fall out.

If it were me, it would be a no-brainer.. my welding sucks ;)
 

·
Registered
Joined
·
19 Posts
Discussion Starter #7
The rivets will be a bit more work as far as removing the old and replacing the new part but I have more time now. I just bought another sled so I can take my time with this 1.
 
1 - 7 of 7 Posts
Top