how to add a belly pan protector

So, you think your sled is a bad boy. You think you're a bad boy. Tough on the snow, is ya? Well, how 'bout that rock or stump? Is your $7,000 investment stronger than it? Mmmm. What about that little mound of snow that is tempting you? Is it a hidden landmine, sort of speaking? Or is it an old horse drawn plow? Whack. Crunch. "I didn't know it was there." Have you been there before?

Cheap insurance. We all want it. Well, you can find it - cheap insurance that is - in a belly pan protector for your sled. The $75 to $100 spent on this tough hunk of plastic is worth the cash, even in good looks for your sled.

AmSnow's '02 Polaris RMK Vertical Edge received such an insurance policy from Tri-City Polaris who, without discussion, installed an official Polaris belly pan protector on our PR sled. Tracy Seegmiller, walked us through the installation. This may seem trivial to some. But to some, installing a protector in a do-it-yourself fashion can be a little taxing, especially when you know that holes are about to be bored out in that new sled. Here for your information, are a few hints and stories for your pocket of knowledge.

Ensure the belly pan protector is indeed, built for your brand and model. This may sound stupid, but at times people may confuse model years that are similar, for example, a 2001 Gen II belly pan protector will not fit an Edge chassis RMK for '02.

Tools you will need are a drill electric, cordless or pneumatic; applicable sized sockets; a rivet gun and rivets, screwdrivers, and closed or open end wrenches.

Read the instructions to have a good mental view of what the process is about.

Lift the hood and ensure no wires or hoses are in the way of the soon-to-be-drilled holes. If so, move them out of the way, or tape the hose or wires away from the target holes.

If at all possible, place the sled's nose high up on a jackstand, and brace the sled's rear to prevent it from rolling back, or engage the brake lock.

If a stand is not available, lay down some thick carpet on the ground, and roll the sled over on its side onto the carpet. Before such, take time to lift the hood and close off the fuel valve to the motor - no use in filling the crankcase and carbs with raw fuel. Also, make sure the fuel filler cap is on tight. If not, fuel will leak out onto the ground.

Set the belly pan protector up the sled's belly pan and make sure the fit is snug and proper - checking for warping; hopefully there is none.

With the protector up to the belly pan, insert a felt-tip pen or magic marker through the protector's pre-drilled holes and mark. If the sled's belly pan is black, consider using white-out or a dab of fluorescent paint. Solicit, if possible, the help of a pal. This way, a second pair of hands can hold the protector in place while you mark and drill.

Double check the alignment and each hole's placement.

Starting at the back, near the track drivers, slowly drill the first marked hole, with a 1/4-inch drill bit, and verify the drill did not puncture a hose, tear a wire or hit any vital engine or chassis part. It never hurts to do the double check. Try to avoid wobbling the drill as this will elongate the hole and make the mounting bolt less secure.

Install the mounting bolt or rivet.

Move to the front, near the front bumper, and drill out the next marked hole. It is best to move to the opposite side from the rear-mounted drilled hole. In other words, if the rear hole was drilled on the right side, then drill out the front hole on the left side. This cross-mounting allows the installer to install the protector "square."

Install the mounting bolt or rivet.
Proceed back to the rear, drill and mount with bolt and nut, or a rivet.

Move to the front, drill and mount with bolt and nut, or a rivet.
Complete drilling through the marked holes and placing mounting the bolts through the protector.

Wallah, you are done.

After this, lower your snowmobile, or roll back over to its skis, lift the hood and open up the fuel valve.

Many thanks to Tri-City Polaris, service manager Tracy Seegmiller for assistance.