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How I put a Polaris skid in my 1980 Invader

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freak_in_cage:
This is how I put a Polaris skid into my 1980 invader. My factory skid was in need of major repair/replacement. I received some great info from members on this site and was able to make it happen. This is what worked for me and is only meant to be used as a guideline for you.

Supplies needed:

- 1990's Polaris skid. Mine was from a 1993 Indy Trail
- Kawasaki skid for parts
- 7' of 2" wide flat metal, the same thickness as the Kawasaki tunnel braces
- Nuts, bolts and washers or rivets
- Basic tools (drill, wrenches, etc.)

The steps:

1. Remove the gas tank, seat and skid. You will have to drill out the factory rivets to remove the gas tank.

2. Drill new cross shaft holes in the tunnel. This should go without saying, but make them the same size as the factory ones. I drilled my holes in 2 stages. First stage was just through the tunnel with no new braces in place, so I could test fit the new skid. The second stage was after the new tunnel braces were in place. My new skid was from a 1993 Polaris Trail. The center to center of the cross shafts was 26 5/8". I Drilled the new rear hole 3 3/16" forward and in line with the factory one. The new front hole was 2 3/8" back and 3/4" down from the factory one.

3. Make 2 new tunnel braces with the 2" wide flat metal. I bent mine into shape using a vice and a hammer.


4. Bolt (or rivet) the new tunnel braces into place and drill the new cross shaft holes through them. I used 1/4" carriage bolts. I didn't have lock nuts on hand so I used regular nuts with blue locktight.  You will also have to remove the front factory brace at the top of the tunnel. Mine was broken anyway and there was only a small piece of it left.



5. Reinstall the gas tank.  Sorry no picture, it's self explanatory.

6. Prep the new skid. Use the aluminum Kawasaki cross shafts in the Polaris skid. They are longer than the Polaris by about 2" so cut spacers from the Kawasaki skid. You will need 4 about 1" long. Take the measurements from your sled. The idea is to have the new skid centered in the tunnel.





7. Clean and grease the cross shafts with a grease that is rated for at least -30.

8. Install the Polaris skid in its new location with the bolts from the Kawasaki skid.


I hope this helps some people and thanks for reading.

rminier:
 Wow,...very well done, and excellent pictures and post. 8)

Doug in NY:
great job on your project! just enough details.

freak_in_cage:
Thanks guys.

Lloyd (ljm):


Great Job!!

 Thanks for posting such a good description of your switch!

 It will save many people from going through the research you had to do.

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