The Front Rack...

[BearCat]

After changing the plugs in the machine last night ended up messing with the front rack abit. First off that front compartment is anything but waterproof or even resistant(IPX standards My Ass LOL) After filling it with water on our last ride I think the culprit is the fit&finish of the rad cover plate. It is bad, real BAD! So I added a couple screws to hold it down in place. If you do try this make sure you move the screws as close to the edge of the plate as possible(these could have went closer to the edge)

The next pic is what I did to securely hold items and stop them from bouncing around the inside of the compartment and make use of all that space between the ribs in the "lid"...drill 1/4in holes and zip tie whatever fits.

BC.

[Mr. Miyagi]

Your right...... You'll also find the tool box in the back has the same problem. You'll need Silicone......

Apparently according to the Village Person wearing Camo (AKA:Chadd)..... They (Polaris) fixed the problem in the 06 model.

BTW - Don't feel bad, my front box is cracked underneath in two or three places from wheel well to wheel well.

[BearCat]

LOL Miyagi...I don't put anything in the back box for that reason,haven't got around to messin' with that yet.

Sorry to hear about the front rack on yours hate to see what the dealer wants for one of those...But you could always call these guys up...(Front Rack $110 bucks)...
http://www.ridgerunner.biz/parts.htm

BC.

[BearCat]

Hey I forgot to mention, when we were changing the plugs, the rubber hose that goes from the valve cover to the air box had a 1" slit in it near the cover. I dont see how it could of been done other than leaving the factory like that. (This might be a Chadd question) Does anyone think some type of damage could be done to the engine over time if I never saw that cut?
BC.

[Chadd]

That slit in the hose is SUPPOSED to be there... Every 700-800 has it. Polaris said that if the hose gets plugged on the air box side you will have issues. So they put a slit right where it comes out of the valve cover as a secondary vent...

[BearCat]

LMFAO!!!! I wish the f'n book would have mentioned that!!!
Thx Chadd I'll fix that back up....

Actually, now that I think about it I'm gonna leave it and open the hole in the air box a couple drill sizes. Everything else is has ductwork up to the top of the gastank. That hose is only going to let water in. Even if your just hosing the bike off, hit that cut with a stream of water it will drain towards/into the valve cover. I'll just keep checking the airbox and make sure its venting through there properly. It already looks as though there are a few beads of water in the airbox below the vent-line. So I wiped them out, if they no longer show up...who knows??

BC.

[MrPolaris]

That slit in the hose is SUPPOSED to be there... Every 700-800 has it. Polaris said that if the hose gets plugged on the air box side you will have issues. So they put a slit right where it comes out of the valve cover as a secondary vent...

When he says supposed to be there that is Polaris excuse for we f'ed up and do not want to spend any money on a recall to fix the tubes. . .

As for the waterproofing of hte box's, good luck, I thought they were water and dust proof, only to open it after a dusty ride and found that really nice thin layer of the silicon dust all over my stuff, was a bitch to clean afterwards

[Ken]

SILICON CHAULK...hello.

[MrPolaris]

that crap is so messy and I find I always put to much on. . .

[BearCat]

Ken, the hatch I put the screws in has foam tape around the edge. But the fit'n'finsh of that thing is so bad. Being a person who builds the tools for those parts I'm surprized polaris thought that would be ok. The screws pull the warp out and I know its not 100% but they should stop water from blowing that hatch out of its location leaving a 5x5 hole above the rad. You should have seen it the day it filled with water...It was FULL I had a sweatshirt and my ball-cap in there eeewww it was ugly. Then to add insult to injury...My honda lovin' friend couldn't stop laughing...all in good fun mind ya , but still!

BC.

[Chadd]

A tube of black silicon fixs all dust and water problems. I siliconed that hatch, all 4 bolts that hold the box on and the two upper strut covers. Worked perfect no more water or dust.

[Ken]

A tube of black silicon fixs all dust and water problems. I siliconed that hatch, all 4 bolts that hold the box on and the two upper strut covers. Worked perfect no more water or dust.

But it's SO MESSY!! (for a 5 year old)

[BearCat]

Fixed the rear storage compartment this week..Actually pulled the whole thing out, took it apart and siliconed all the seams. Removed the gasket from the door, siliconed behind it and replaced the gasket(it now sits flush with the top of that groove)....It wasn't bad at all Dusty!!

BC.

[Ken]

Definitely sounds like it's worth the trouble. Nothing worse that putting an extra shirt or whatever...and finding out it's wet later.

[Mr. Miyagi]

I had an easier solution..... Go to your local Polaris dealership and pickup a new 2006.