When I put my tunnel extension on, I never bent or removed the existing piece in the rear where the snowflap rivets on.

After riding last night, I see that after landing from a jump, the track caught on that peice and bent it. I would like to fix this before any further damage is done.

Should I be pulling the extension off and cutting that rear lip off? If so, what do I do with the coolant crossover hose? From factory it has a cover to protect it that rivets to that lip.

Can I simply bend that lip up as flush as possible to the extension? I'm trying to avoid drilling out the 15+ rivets I put in the extension to stiffen it up. lol

Any help would be appreciated. Pictures would be better!

Never had this problem on my XC and i dont remember what mine looks like. Plus im not at home to go look and take pics. If you post up pics of your I may be able to tell you what mine is in comparison. I do still have the aluminum cover over my coolant crossover hose, but i dont think its riveted to a lip.

When I put mine on , I bent the lip up and riveted it to the extension.

Usually, you must remove the old tunnel close off panel, then put the new one on.

I'll see how far up I can bend it tonight and take some pictures. I'd prefer not to damage my new track.

Ivar, I'm trying to avoid riveting it to the new extension because I'd prefer not to see any rivets behind the seat. If I can get in close enough with the air nibbler, I'll see how much of it I can cut off.

if you could lighty hit it with a cut off wheel, then bend it back and forth, it will snap off flush

There's an idea. I'll give it a shot. What are you guys doing for the crossover hose protector? Ideally it would be under the seat like most other sleds I see, but I don't have that luxury.

I cut took the seat and hose cover off, then chopped the sides of the old tail and had to come inside. I'll finish it off tomorrow. Here's how it stands now:




And before anyone asks, the new hose is wrapped in the old one after I drilled through it putting the extension on in the summer. LOL

I gave it my best shot, but the hose shield is now in a ditch somewhere after using a little of the suspension. I'm going to pull the coolers out tomorrow and have the hose nipples re-welded to go up through the trunk area like the newer model sleds and use some old hyfax in the tunnel to keep the track from tearing the coolers off.

What an ordeal. I really do like the 136" track though. Instead of sinking the ass end down when trying to track up a drift, it goes right up on top of it.

There are plenty of 02-06 coolers around for sale. Might be cheaper and easier to just replace yours with the newer ones.

i got coolers from my 03 pro x that should work in your case. $40+ shipping for em.

I cut the coolers and drilled new holes in the top, had them welded up for 20 bux. Works like a charm. Now where is that extra cooler? lol