Polaris RMK & Switchback Installation

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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 extensionRMK 1RMK 2
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.RMK 3 RMK 4
  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:RMK 5
  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.RMK 6                                                    Install studs into our plate as shown below:RMK 7
  4. 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.RMK 8
  5. 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.                                                                       RMK 9
  6. 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):RMK 10
  7. 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.RMK 11
  8. 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 placeRMK 12