2011 & Newer Polaris RMK & Switchback 144 / 155

2013 Polaris Indy 600

Tunnel Extension Installation

Tunnel Preparation:

1) Remove rear bumper, snow flap as well as tunnel end cap. Loosen tail light from tunnel

bracket and allow to hang out of the way.

2) You now have a blank rear tunnel ready to accept the tunnel extension.

Installation Procedure:

1) Begin by placing the tunnel extension inside of your existing tunnel. Push tunnel

extension as far ahead as possible until it comes in contact with two extrusions that are

found in the top of existing tunnel. You can drill and place the rivets in several holes to

assure alignment prior to actually attaching the extension with all rivets included.

2) We have found that on the RMK and Switchback models, there is aluminum along the sides

of the tunnel that is of varying widths depending upon how much is ground out during

snowmobile construction. You might need to do some filing or grinding of your own to get the

tunnel extension to fit properly. See photo below for reference:

3) On Indy 600 models, you will need to remove the studs from the light / bumper plate. They

are tapped into place. Place the aluminum bracket over a socket and drive them out.

Install studs into our plate as shown below:

3) Once aligned, clamp the tunnel extension in place and place a rivet in all the holes pre-

existing in the transition plate.

4) At this point, drill out the two holes on each side where the bumper used to be attached,

insert and lightly snug them at this point, once triangular gussets are installed in next step, then

fully tighten.

5) You will have received two triangular shaped pieces. These are to be placed between the

tunnel extension and the existing tunnel as shown below (photo taken from inside of tunnel):

6) With the top now riveted and secure and the two bolts starting to hold the sides in place,

drill out the holes on the side of the tunnel to place the rivets in. Drill from inside of the tunnel

facing out using existing holes in tunnel extension.

7) The snowflap can now be removed from the original mounting plate and reattached to the

tunnel extension. The bumper can also be installed into existing holes in tunnel extension with

bolts that originally held it in place.

Thank you!

Tracks USA

10340 67th Ave SE

Lake Lillian, MN 56253

(320) 382-6128

www.TRACKSUSA.com