Rear Heat Exchanger Install

[Ski-Dog]

I have in hand a rear heat exchanger for my 04 Warrior. What I don't have are the installation instructions. Anything I need to know before starting into this? One question I do have is do I need to remove the seat to get at the rivets that hold the current crossover pipe and is also the front mount for the exchanger. I assume for the rear mount you simply drill six holes in the extension (after making a template) I also suspect some trimming around the tunnel where the pipes meet rubber hose. Are the rubber wigits on the end simply for protection until time to install. Any help / comments are appreciated. Thanks.

 

[marc]

would like to know what you payed for it and were do you get it, was thinking of getting one for my 03 RX1

 

[Mighty]

Simple install. Seat stays on, remove some of the metal in the tunnel to get the crossover pipe out but don't worry the plastic sides cover it up when done.
Yes, the rubber caps simply protect the exchanger during shipping.

 

[Sled Dog]

I made a template right off the cooler itself out of a thick paper. Then I drilled the two rivets where the black new ones go. Then I taped the template I made onto the sled center punched each place that needs to be drilled. It made it a lot easier. Make sure to center punch good or when you drill your drill could wonder then you may miss the hole by a bit.

 

[RedRX1]

It was an easy install, I do not recall any special needs. It was straight forward. The biggest pain is getting the air back out of the system.

 

[RXWON]

You will need to cut out a bit of the aluminimum to both, remove the old, and install the new, if I remember correctly you cut about 3 inches, but be sure to only cut the sheet aluminimum, not into the cast, also be sure you have a good rivit gun that will fit the steel rivits. You also will have to cut the 2 tunnel protector bars a bit to fit it in.

 

[NY_Nytro]

here is pics of the install pages. click on them to expand them and hopefully they can be read.

 

[marc]

Ski-Dog, still would love to know how much and is it dealer only also is it a big job ti install. alsl from ontario,canada.....

 

[Ski-Dog]

Everyone - Thanks very much for your assistance. Special thanks to Ny-Warrior for the actual install sheets. I have printed them out and they are certainly readable.

Marc - Heat exchanger is available from Yamaha dealer. Part numbers are as follows:
Warrior / Mountain - 8EP-RHECR-KT-00
Rx1 (121 inch track) - 8ET-RHECR-KT-00
Price for Warrior cost me about $140. The shorty version is cheaper. May be able to find a better price. Yamaha offers these with minimal mark up from dealer. I didn't shop around as this one was on the wall and available (no instructions) But I have them now.
If you wish after Market I believe they are available but don't think you will save any money.

 

[Chris Velardi]

Has anyone had problemes with Stud interference on these heat exchangers?

 

[NY_Nytro]

Here is one more sheet

 

[NY_Nytro]

Has anyone had problemes with Stud interference on these heat exchangers?

Studs will definitely hit the exchanger. You will need to fabricate some sort of protection.

Last year I used 3/4" leftover hixfax. I figured the studs extended 1/4" above the lugs then 3/4" should be fine. But on hard landings the studs still hit. They damaged only the fins but it was enough to make me nervous and change my riding in attempt to avoid any more hard hits.

This off season I put on 1" protectors and I pulled the rear shock so I could collapse the skid to get a better view of the track contact to the rear exchanger.

Two main things I noticed:
1). If you curve your protectors to follow the curve of the heat exchanger then only one row of lugs comes in contact with the protectors. This puts all the impact of a hit on one row of lugs, even under just static weight of the sled the Ripsaw lugs folded over slightly causing the studs to penetrate even closer the exchanger.

2). Even more critical is that every 3rd row on the Ripsaw there is basically no lug in that area (look at your track). So since only one row hits the protector and that row has no lug you have nearly full stud length penetration. So even with a 1" tall protector the stud is nearly touching the exchanger just under static weight of the sled.

Also you have to remember that we are losing suspension travel due to the protectors and heat exchanger.

 

[RedRX1]

I have not seen andy problems with studs hitting the rear exchanger.

 

[Mighty]

I have not seen andy problems with studs hitting the rear exchanger.

If you have both the rear exchanger and studs they will eventually meet. Mine did

 

[NY_Nytro]

I have not seen andy problems with studs hitting the rear exchanger.

If you have both the rear exchanger and studs they will eventually meet. Mine did

Agreed it seems unavoidable unless you never bottoming out or have huge protectors, say about 1.5" tall. But then you lose about 1.75" of travel. It's that open 3rd lug on the RipSaw that is the culprit.

I've taken a different route now. I installed a 1/4"x10"x12" alumimun shield to take the stud hits when bottoming does occur. I'll report later on it effectiveness once I get some riding in.