Tired of that rooster tail of mud, water, and rocks plastering you, your passenger, and the inside of your cab every time you hit a puddle? You bought your Polaris General to conquer the trails, not to spend half your time cleaning grime out of every nook and cranny.
That constant barrage of debris isn’t just annoying; it’s actively chipping away at your machine’s paint and plastic. There’s a better way to ride, one that keeps you cleaner, protects your investment, and gives your General an aggressive, trail-ready stance.
The solution is a quality set of fender flares, and the good news is you can install them yourself. This guide is your complete roadmap to a successful polaris general fender flare installation, turning a potentially frustrating job into a satisfying weekend project.
Let’s get those tools out and get it done right.
Why Bother? The Real Benefits of Polaris General Fender Flare Installation
Before we turn a single wrench, let’s talk about why this upgrade is one of the most practical mods you can make. This isn’t just about looks; it’s about making your ride better in every way.
Superior Mud and Debris Protection
This is the number one reason riders install fender flares. Wider tires are great for traction, but they act like shovels, throwing everything the trail has to offer directly at you. A good set of flares extends the coverage of your fenders, catching the vast majority of that spray.
This means a cleaner cab, cleaner gear, and a much more enjoyable ride, especially on wet and muddy days. You’ll spend less time with the pressure washer and more time on the trail.
Protecting Your Machine’s Finish
Every rock, stick, and chunk of gravel your tires kick up acts like sandpaper against your General’s body panels. Over time, this leads to scratches, scuffs, and chips in the paint and plastic.
Fender flares act as a sacrificial barrier, taking the brunt of the impact. It’s far cheaper and easier to replace a damaged flare than it is to repair or replace an entire body panel.
Enhancing Safety for You and Your Passengers
It’s not just mud. Your tires can launch surprisingly large rocks at high speeds. A well-placed fender flare can prevent a stray rock from hitting you or your passenger, turning a potential injury into a non-event.
This added layer of protection is a small price to pay for peace of mind when you’re pushing your machine hard.
Achieving that Aggressive Off-Road Look
Let’s be honest—looks matter. Fender flares give your Polaris General a wider, more muscular, and aggressive stance. They signal that your machine is built for serious off-roading and perfectly complement a set of aftermarket wheels and tires.
Gearing Up: Tools and Parts You’ll Need
A successful job starts with having the right gear on hand. Scrambling to find a tool mid-install is frustrating. Gather everything you need before you start for a smooth process.
Essential Tools for the Job
Most fender flare kits come with hardware, but you’ll need your own tools to get them mounted. Here’s a typical list:
- Drill with a sharp set of drill bits: A cordless drill is your best friend here. The kit instructions will specify the bit size.
- Socket Set and Ratchet: For removing any factory bolts.
- Pop Rivet Gun: Many kits use pop rivets for a clean, secure fit.
- Trim Panel Removal Tool Kit: These plastic pry tools are essential for removing factory push-pins without scratching your plastic.
- Marker or Grease Pencil: For accurately marking your drill holes.
- Painter’s Tape: A pro tip for protecting your plastic and making your marks more visible.
- Safety Glasses: Non-negotiable. You’ll be drilling plastic and working close to the machine.
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Choosing Your Fender Flares
You have a few options here, primarily between OEM (Original Equipment Manufacturer) and aftermarket. OEM flares are guaranteed to fit perfectly but can be pricier. Aftermarket brands like MudBusters or Spike Powersports often offer more coverage (extra-wide options) and can be more budget-friendly.
Pay attention to the material. Most are made from High-Density Polyethylene (HDPE), which offers a great balance of flexibility and durability.
Pre-Installation Prep: The Most Important Step
Before you even think about drilling, clean your machine thoroughly. You want to be working on a surface free of dirt, mud, and grime. This ensures the flares sit flush against the body panels and prevents you from grinding dirt into your paint.
Lay out all the parts from your kit and compare them to the instruction manual’s parts list. Make sure you have everything you need before you start.
The Complete Polaris General Fender Flare Installation Guide
Alright, it’s time to get hands-on. This section is your step-by-step polaris general fender flare installation guide. We recommend doing one flare at a time to keep things organized.
Clean and Prepare the Mounting Surface
Even if you already washed your General, give the fender edges a final wipe-down with a clean cloth and some isopropyl alcohol. This removes any lingering oils or residue for a perfect fit.
Remove Existing Hardware/Flares
If you have small factory flares or mud guards, you’ll need to remove them. Use your trim panel removal tool to gently pop out the plastic push-pins. If there are any bolts, use your socket set to remove them. Keep this hardware in a safe place.
Test Fit the New Flares
This is the most critical step. Do not skip this. Hold the new fender flare in place against the body. Use clamps or have a friend help you. Check the alignment along all the contours and edges. It should sit flush and follow the body lines perfectly.
Mark Your Drill Holes
While holding the flare securely in its final position, use your marker or grease pencil to mark the center of each mounting hole directly onto your General’s plastic fender. Be as precise as possible. For even better results, use the blue tape trick mentioned in our tips section below.
Drilling the Holes (Measure Twice, Drill Once)
Remove the flare. Take a deep breath. Using the drill bit size specified in your kit’s instructions, drill a pilot hole at each mark you made. Keep your drill straight and apply steady, light pressure. Let the bit do the work to avoid cracking the plastic.
Installing the Hardware
Position the flare back onto the fender, aligning the holes in the flare with the holes you just drilled. Start by installing one or two fasteners by hand to hold it in place. Then, proceed to install the rest of the supplied hardware (push-pins, rivets, or bolts) in the remaining holes.
Final Tightening and Inspection
If your kit uses bolts and nuts, tighten them until they are snug. Be very careful not to over-tighten, as this can crack the plastic flare or your machine’s body panel. The flare should be secure with no movement or rattling. Give it a gentle tug to be sure.
Repeat this process for the remaining three flares, and you’re done!
Pro Tips and Best Practices for a Flawless Install
Following the instructions is one thing; knowing the little tricks of the trade is another. Here are some polaris general fender flare installation tips to make the job easier and the results better.
The “Blue Tape Trick” for Perfect Alignment
Before you test fit the flare, apply a strip of blue painter’s tape to your machine’s fender where the holes will be. When you mark the holes, you’ll be marking on the tape. This makes the marks easier to see and protects the plastic from slips while drilling.
Dealing with Stubborn Push-Pins
Factory push-pins can be a pain. If they’re full of mud, use a small pick or flathead screwdriver to clean out the head before trying to pop the center pin. The right trim removal tool makes a world of difference here.
Weather Considerations
Plastic is more brittle in the cold. We strongly recommend performing this installation in a garage or on a warm day (ideally above 60°F / 15°C). This makes the plastic less likely to crack during drilling and installation.
Avoiding Common Problems with Polaris General Fender Flare Installation
We’ve seen a few installs go sideways. Here are some common problems with polaris general fender flare installation and how you can avoid them.
Misaligned Flares and Gaps
This is almost always caused by skipping or rushing the test-fitting step. Take your time to ensure the flare is perfectly positioned before you mark and drill. A small error here will be very noticeable later.
Cracked Plastic from Over-Tightening
More is not better when it comes to tightening fasteners on plastic. Snug is all you need. If you’re using a power tool, set it to its lowest torque setting. The goal is to secure the flare, not crush it.
Vibrations and Rattling Post-Install
If you hear rattling on your first ride, it means a fastener has come loose. Go back and check every single rivet, bolt, or push-pin. Some owners add a small dab of blue (medium strength) thread-locker to bolts for extra security.
Post-Installation Care and Sustainable Practices
Your new flares are on, but the job isn’t quite over. A little care goes a long way. This is your quick polaris general fender flare installation care guide.
The Right Way to Clean Your New Flares
Avoid harsh chemical cleaners or abrasive brushes, which can dull the finish. A simple pressure wash or car soap and a soft cloth is all you need. For a deeper clean and some UV protection, use a plastic-specific protectant like 303 Aerospace Protectant.
Regular Hardware Checks
After your first couple of rides, give all the mounting hardware a quick check to make sure everything is still tight. Make this part of your regular pre-ride inspection routine.
Eco-Friendly and Sustainable Installation Practices
Thinking about a sustainable polaris general fender flare installation? It’s about being a responsible owner. If you removed old flares, check if the plastic is recyclable in your area. Use high-quality tools that will last for years, reducing waste. Finally, dispose of any packaging materials responsibly. An eco-friendly polaris general fender flare installation is about minimizing your footprint while you work on your machine.
Frequently Asked Questions About Polaris General Fender Flare Installation
How long does the installation usually take?
For a first-timer taking their time, plan for about 2-3 hours. An experienced DIYer can likely get it done in 1.5-2 hours. Don’t rush it—the key is precision, not speed.
Can I install fender flares without drilling?
Some specific models and kits may utilize existing factory mounting points, but the vast majority of aftermarket fender flare kits for the Polaris General will require you to drill new holes for a secure fit.
Will aftermarket flares void my Polaris warranty?
Generally, no. Adding accessories like fender flares should not void your vehicle’s warranty. However, if an issue arises that can be directly attributed to a faulty installation (e.g., you drilled into a wiring harness), that specific repair might not be covered. Always install with care.
What’s the difference between standard and extra-wide flares?
Standard or OEM-style flares offer a moderate increase in coverage. Extra-wide or “max coverage” flares can extend several more inches, offering the ultimate protection for machines with offset wheels or very wide tires.
You’ve done the research and you have the guide. The only thing left is to do the work. Installing your own fender flares is a hugely rewarding project that improves the look, function, and protection of your Polaris General.
Take your time, double-check your measurements, and enjoy the satisfaction of a job well done. Now get out there, stay clean, and tear up those trails!
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