Warrior Heat Exchanger Question

[mikeb]

My warrior has two approx 1" square tubes that travel almost the full length of the tunnel. What are these and how do I get my cooler in over them?

The Yamaha instructions does not show them.

Mike

 

[SledderSteve]

I might be smoking something not commercially available but those look like tunnel protectors, installed by the factory to prevent user installed studs from tearing up the tunnel and other important components.

Your factory coolers (heat exchangers) are located under each running board. Are you looking to add an additional cooler?

 

[mikeb]

cooler

yes, i am installing the moutain cooler

Not sure of the best way to modify the tunnel protectors. The instructions from yamaha say nothing about them.

 

[impalapower]

I'd like to believe that the area where the exchanger goes that you would have to cut out the section of tunnel protection and replace it with the heat exchanger and then add heat exchanger protectors.

 

[SledderSteve]

If you're not running studs they're just dead weight and can be removed.

 

[impalapower]

And with what sledder stever said, then if you aren't running studs then you don't need the heat exchanger protectors either.

 

[mikeb]

Studs

Next project is adding 144 studs

 

[SledderSteve]

In that case we'll go back to April for LazyBastard's words of wisdom:

LazyBastard
RX1.Info God


Joined: 13 Apr 2003
Posts: 1370
Location: Somewhere in that frozen wasteland north of the border.
Posted: Tue Apr 20, 2004 3:44 am Post subject:

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EVERYONE who is adding rear heat exchanger to a WARRIOR:

If your track is studded, the studs will hit.

Solution: Drop down bracket needs to be extended by ~1 inch, add ~3/4 inch of tunnel protection over both existing tunnel protectors all the way, AND over the heat exchanger all the way to the back where the tunnel protectors need to be removed from to fit the heat exchanger.

You can use a nice thick piece of slider - some sleds (older enticers) had 1" x 3/4" sliders that would work great.

 

[impalapower]

Ok then, reverse what we just said. I'm suprised that the heat exchanger didn't have installation instructions. They might not have made it into the packaging in the manufacturing process. You might be able to go back to the dealer, have them open a new package and photocopy it. There should be a template.

 

[mikeb]

Manual

The cooler does have instructions. However they do not show the extended tunnel protectors.

Seams like others said this job was much easier.

Mike

 

[Mighty]

I have had mine for several months now and haven't installed yet for the same reasons as you :?

 

[impalapower]

If the tunnel protectors run a good length of the tunnel, you may want to be careful on cutting them. I don't know how well the heat exchanger seats in there, but if you leave some type of blunt edge heading towards the front, the track may catch when the suspension bottoms out and it could mess up the lugs of the track or even pull the protectors right out, maybe both. If for some reason the tunnel protectors do hang down, you may have to cut a taperd edge to them. Just a thought.

 

[mikeb]

Fit & Function

Maybe I'm doing something wrong but I made a cardboard model of the mountain cooler and taped it inside the tunnel. I then put some grease on me track and flexed the rear track as much as I could.

Even with that minor loading the track hit the dummy cooler. Like I said maybe I doing it wrong but I DONT think the mountain cooler will work on a warrior. It looks like it will hit the track

 

[low flying missile]

Heat exchanger

Mike, if you have the option of returning the Yamaha exchanger I would do it. The problem with Yamaha exchangers is that the nipples extend to the outside of the tunnel necessitating the making of large holes in the tunnel to get them in. You will then be left with large unsitely coolant hoses running outside the tunnel when you are done. This brings me to the second problem. The mountain kit puts the exchanger where it doesn't get hit with enough snow to do its job. It should be located at the very back of the tunnel. To do this job the best way possible I would replace the stock tunnel extension with one from MPI which flips up and gives much more clearance. You can then purchase a Polaris exchanger which fits completely inside the tunnel and connects to the running board exchangers by rubber hoses that run along the upper corner of the tunnel.You should then drop the stock tunnel exchangers down by riveting 1/4" flat aluminum bar stock along the entire lenghth and carrying right back over the new exchanger to the rear tunnel closure.

 

[mikeb]

Fit

The stock crossover tube is also outside the tunnel. The hoses fit ok ..

This issue is loss of clearance from the heat exchanger.

Yes, you do have to cut the sled opening up each side for the new heat exchanger.