Studs & Tunnel Protectors

skutr

New member
Going to put 96 studs on my 2002 Polaris Indy 500 and was wondering if I need protection for the tunnel & front heat exchangers? Here's what it looks like:
 

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zimmbob

Member
I don't think that Polaris has a place for a front cooler protector. But you definitely need to put tunnel protectors on.
 

indy_500

Well-known member
no matter what you do this can still happen...
 

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zimmbob

Member
But don't let Indy's message scare you off. Studs make a HUGE difference in traction forward and stopping. You just need to take the right steps to safeguard your sled. Put them in right, use the tunnel protectors, be aware of them when you ride. Don't spin the track on the road or concrete. And trust me, you'll mark up your driveway or garage floor a few times......
 

stevis

New member
You do not need tunnel protectors of any kind. The cooling rails, that are shown in your picture, act as the protectors when studs are installed.
 

zimmbob

Member
No disrespect stevis, but I don't think those cooling lines are thick enough to keep the studs from ripping up the tunnel. I see what you are saying, but a proper stud should be 1/8 to a 1/4 longer than the lug height. And I'd bet when you jump or slam into a mogul, the lug would compress and the studs rip into the tunnel.....

Personally, I wouldn't take the chance.
 

xcr440

Well-known member
That depends on the lug height. I've seen 1.25" lug tracks with studs without tunnel protectors, where the tunnel coolers pictured kept the studs off the tunnel itself. Now if you have a longer track, you better protect the tunnel extension, or you will rip that up. I've seen that also.

Best to get a tape measure out, or press the track against the tunnel coolers to see just how much, if any, room you have for studs to stick above the lugs on the track.
 

stevis

New member
I own a 02 600 xcsp with a 1.25 track with studs. 10000 miles and not a scratch in the tunnel. I am sure you do not need any protectors.
 

stevis

New member
Indy,
Your damage happened because you either lost a stud and it went into your front cooler or your track tension was not adjusted correctly.
 

snow_monkey

New member
X'2 why take a chance. I carried a chuby friend out of the woods a few years ago after he crashed his sled and was rubbin the whole way home.
 

dan72499

New member
studs

I just like to say, no, you dont need tunnel protection.you have them and if you try and install anything over those coolers,you will have heating issues.IV,E RODE POLARIS AND WORKED ON POLARIS SLEDS FOR YEARS,AND I RAN WOODY STUDS 1175 IN A 1 INCH TRACK AND NEVER HAD ANY ISSUES.AND I RAN THE TRACK LOOSE FOR BETTER SPEED.THE 1175 RUNS ABOUT 7/16 OVER THE LUG TOO. SO HERES SOME INFO.POLARIS TRACK .92 YOU CAN RUN 1 INCH OR 1075.1 INCH TRACK,YOU CAN RUN 1075 OR 1175. NOW IF YOU HAVE A OLDER 3/4 TRACK.THEN YOU RUN 1 INCH STUD ONLY .BUT IF YOU HAD A .92 TRACK AND RAN 1 INCH STUDS ,YOUR NOT GOING TO GET A BITE HARDLY AT ALL. AGAIN YOUR FINE WITH THE TUNNEL.
 

dan72499

New member
Studs

Also i want to mention that to be safe , it's 3/8 of an inch over the lug.1/8 of an inch would be a waste of time and no traction and you would wear that off in a few hundred miles,lol.call mw if you need to 608-235-4786
 

meathead

New member
studsintrack

Indy 500, What did you end up doing ,about studs ? I have a 05 cat 600 EFI.Not too agresive rider but not afraid to take a few good bumps & pull the trigger on the throttle.Meathead
 

indy_500

Well-known member
Indy 500, What did you end up doing ,about studs ? I have a 05 cat 600 EFI.Not too agresive rider but not afraid to take a few good bumps & pull the trigger on the throttle.Meathead

got 2 new tracks for mine and my dads sled since the same thing happened to both sleds, and we welded the heat exchangers. i'll never drive a sled with studs anymore. Both didn't even happen on bumps or anything.
 

johnmaster

New member
Stevis is right, your 02 does not need any additional tunnel protection or exchanger protectors. The coolers on the tunnel on your sled contact the track in an area where studs simply can't be installed, over the windows. This means rubber on aluminum if the track were to hit and it can do that all day long without a problem. You have plenty of front exchanger clearance, enough to run a 1.5" unstudded track with no problem, and plenty of room to run that track you have there with 3/8" penetration studs without worry.

The damage Indy500 shows in his photos is of a stud that has torn out but hasn't completely left the track yet. It hangs on by a thread like a wrecking ball and whips the aluminum in its path usually popping the exchanger open until it finally tears off and leaves the track (hopefully before the motor blows). Not studding isn't the answer, you can't blame a brittle old track that has had old school studs sawing away at for years for finally giving up the ghost. Maintenance and a sharp eye is the only thing that can prevent it.

Studding that track should be just fine, you'll just want to do it properly, you may want to get our more forgiving nylon round backers and not go crazy on penetration. Let me know if you need any help figuring out the job.
John Preiser
www.johnmaster.net
 

skutr

New member
I went with a 96 stud pattern (.92 Woodys Gold Digger). I didn't think it would be a problem after I looked at it closer, but it's nice to hear from the "experts" (including Indy ;).

Now I just have to figure out if I want to go with dual carbides or stick with the 6 inch.
 
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