Warrior Troubles

[Mackinback]

Well let me start off by saying what a crap winter! Haha..
I went on my 1st trip to the UP 2 weeks ago and snow wasn't so good..
So I have a 04 Warrior which has had work done on by Simons CPR.. I purchased this off my buddy who basically had Simons build him a lake racer which is trailable.
I purchased this sled June 09 with 800miles. And only been on 2 trips with it.
My 1st trip I had a big heat problem in which the main harness/boost controllers melted through. Lost my boost/fuel and AF gauges.
Well I had Simons do some work on it (it was originally thought there might be a cracked header).. But it turned out everything was fine, no leaks, no cracks, just needed some re-wiring and wrapping..
Took it out this season and having the same problems.. Now the trails were not horrible, but around town we were scraping pavement here and there, warmer temps (high 20's, low 30's). I had to keep a close eye on where my skis were and I could manage somewhat normal temps.
I'm running out of ideas.. I'm going to see if the header is wrapped, and if not wrap it.. And I was considering adding a radiator to it.. My buddy has a 08 Nytro and I see there is a radiator w/ fan behind the brake on the right side.. Looking at my sled there seems to be a decent bit of room there.

Any suggestions? I'm running premium and a max 6-7psi (though I do want to crank it up sometime).. Coolant's holding..
Normal riding temp is 190 and the sleds gotten up to 210 (temp light on) a few times this last trip.
It seems mocking up a radiator is the best bet.

Thanks for any help

 

[Mackinback]

Wow quess I need to look at these sticky's..
Looks like I shall be doing this.. And hopefully this will take care of my overheating.
Any other suggestions though? There's a hell of a lot of heat under the hood after riding.. I'm almost thinking a small exhaust fan mounted in the hood or something w/ a timer.. Beats propping the hood open after a ride..

 

[DennisTheMenace]

You could also add the large rear cooler if you do not already have it. The Apex rad and fan works good too.

 

[Mackinback]

Well how about an update-

My last trip was disastrous.. The motor blew (hearing a lot of bad rap on Simons CPR)...
When I got back home I started the process of looking for the problem... Cylinder leak test showed #2 and #4 low pressure.. Drained the coolant - oil in coolant! Doh!... Continued dis-assembly. Header has a big crack in it - appears to be poorly designed, getting that fixed. Head came off - no visible signs of a blown head gasket. Hmmm
And currently the sled sits in pieces since March.. I am going to have the motor rebuilt. The only thing I can think of is the head may be warped... I found a guy (if I can find the link) south of Chicago who specializes in the RX-1 motor. So when money is available, I'm bringing the whole motor to him for work.

Now I am starting to figure out what extra I need to do... I was thinking about adding the extra radiator & fan and possibly the rear exchanger. I for some reason (maybe the long week) can't find the how-to links for these mods. Can anybody help me out?

Also because of my overheating, my wire harness got fried again.. Upon putting the sled back together, I plan to wrap the header & turbo. And I think that's about it. Defiantly not what I wanted to do in the off season. Mods would have been the more obvious choice. But hey, it is what it is, right?
My goal for this up coming season is to run high boost & race fuel on Lake Gogebic. With all the head-aches this sled has given me (and only 1,700 miles on it), I need to see what she's got!

MacK

P.S. all input is welcome

 

[Indy]

rear exchanger

you really dont need any instructions to put in a rear exchanger, this picture is all you really need.