I have an 2006 800 Sportsman that I recently hit a rock. I didn't think it was that bad as I am sure I have hit worse! However, the location it struck the skid plate apparently couldn't have been worse. It struck the plate in the back near the right/rear motor mount bolt. Looking at the plate itself, it doesn't appear to be that bad. But as soon as I hit the rock, I noticed a horrible vibration coming from the right side. When I bent the skid plate, it pushed the motor up on that side enough that the aluminum housing is now making contact with the exhaust that is bent/routed over the same housing below it. I am guessing if I could stand the obnoxious noise, that it would eventually wear a hole in the exhaust.
I just can't get anything in there in the right spot to bend the plate back down. After some researching it appears as though Polaris didn't provide much clearance for that aluminum housing and exhaust in the first place. I am just thinking I can't be the first guy to do this and was looking for some ideas to bend it back. Dealer wants to replace the frame and won't go that route. I have ideas of cutting that portion of the skid plate out to reshape and then welding back (would consider a machine shop for this one), pulling the motor and beating the plate back from the top but wanted to see what was out there.