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Old 01-04-2012, 08:06 PM   #1 (permalink)
'93 Phazer and The Kid
 
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'05 RX1 Heat Exchanger Replacement

I tore up my front heat exchanger on a rock that stuck in the track, I believe. It looks like it's riveted in. On a scale of 1 - 10, how difficult is it to replace? 10 being, welll you know, bad...... Any advice? Anyone replace one before? Not me!

Thanks!
Phaze
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-04-2012, 08:12 PM   #2 (permalink)
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havent done one on that sled model yet, but based on the ones i have done you would swear thats the first part on the assembly line and everything was built around it. on your 1-10 scale based on the ones i have done i would give it a 10. not so much difficult as it is labor intensive. and labor intensive may be an understatement. you will understand if you choose to take this on yourself.
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Old 01-04-2012, 08:16 PM   #3 (permalink)
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Ok, can you give me a quick rundown what needs to be done? It does look like it's buried...... Labor intensive sounds really, really bad if I need to bring it in.....
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-04-2012, 08:38 PM   #4 (permalink)
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engine out, skid and track out, perhaps a few rivets securing the belly pan plastics as well as the rivets for the exchanger. your basically accessing the exchanger from the topside.

on a side note, yamaha uses some gnarly rivets.

as an option, depending on the severity of the hit, removing the track and skid and taking the sled to a good welder the exchanger can sometimes be repaired.

sorry for your luck, and i hate to be the bearer of bad news, (i hope for your sake that sleds different) your in for a fight. insurance?
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Old 01-04-2012, 08:52 PM   #5 (permalink)
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Engine out!!

Insurance? Yeah, liability only.

I had the wife pour coolant in the tank and it ran out the exchanger.

That's exactly what it was, bad luck. I've run over small rocks before, no big deal. I think this one got caught in the track because I could hear it smacking the exchanger........ This season could of just came to an end before it got started......

I'm speechless. Removing my '96 Ultra's 2 stroke wouldn't be a big deal. But this 4 cyl. 4 stroke appears to be a whole new ball game.....
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-04-2012, 09:17 PM   #6 (permalink)
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engine removal isnt as bad as it appears, but i know how intimidating it looks until you get both arms in there.

the exchangers are typically a flow through with the fins added for heat dissipation. any good aluminum welder should be able to fix you up from the underside. may not be pretty but functional is more important. i have opted for this route on several occasions with excellent luck. your under $100 if you remove the track and skid, even though thats an endeavor in itself.

its not over, its just beginning. get the thing welded, look for a replacement, and you will have something to do in the off season.

if i could do the icon thing i would show a thumbs up along with a smiley! shake it off and dig in! stupid rocks.
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Old 01-04-2012, 09:39 PM   #7 (permalink)
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I believe there is an aluminum shield that "protects" the exchanger. Not sure, but I'm assuming that's riveted too. Didn't look real close when I saw the gouge and the fluid flowing out. Figured I saw enough for the moment....

I've had a guy weld on a different skid before who is excellent with aluminum and only charged me $20.....

Thanks for the help... Anything else comes up, let me know...
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-05-2012, 10:49 AM   #8 (permalink)
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Just called Hauck's powersports. For $300 labor they'll swap it out with a used one from one of the race sleds they have. They weren't sure if mine could be fixed since it has a big tear. They'll look at it. Apparently they have a offsite "guy" that welds them. Maybe he can just weld it up. The motor doesn't have to come out. Skid and track does. Soooo, they'll replace the bearings too, I would just have to pay for parts. $300 to replace exchanger and driveshaft bearings plus parts. They can have it.......
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-05-2012, 05:25 PM   #9 (permalink)
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Well, it’s at Hauck’s. He dropped another $25 to $150 for the exchanger. It all helps. They’re going to do a compression test and leak down once it’s fixed to make sure the engine is fine. Which is good. I think. Not sure I want to know. Lol Told them to change the oil too since they have it. Another $60. I guess I can then go another 2 oil changes before the filter needs to be changed. W/O filter it drops to $29. That filter must be a pain to get at. Should be good for quite awhile, I hope……..

They have a full race shop. There were 3 drag sleds outside being worked on. Didn’t go in the shop. Drags are big around here.

I guess they’ll be done with it in a couple days………
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-05-2012, 06:53 PM   #10 (permalink)
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sounds like good news! i have done business with them in the past and they do know their yamahas. would like the opportunity to sometime shadow their doorstep.

and you thought you were done for the season. just a minor set back not to mention the hit to the wallet.
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Old 01-05-2012, 09:28 PM   #11 (permalink)
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Quote:
Originally Posted by yamadad4 View Post
sounds like good news! i have done business with them in the past and they do know their yamahas. would like the opportunity to sometime shadow their doorstep.

and you thought you were done for the season. just a minor set back not to mention the hit to the wallet.
The wallet hit is the biggest downer, but what do you do????? As long as the compression and leak down tests are fine, I'll be happy!
__________________
'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..


Last edited by Phaze; 01-05-2012 at 10:09 PM.
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Old 01-05-2012, 10:11 PM   #12 (permalink)
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Quote:
Originally Posted by yamadad4 View Post
sounds like good news! i have done business with them in the past and they do know their yamahas. would like the opportunity to sometime shadow their doorstep.

and you thought you were done for the season. just a minor set back not to mention the hit to the wallet.
They run a real good operation over there. Well worth the 1hr 20mins drive down. $300 labor to keep my sanity? Priceless.......
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-05-2012, 10:33 PM   #13 (permalink)
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Worth it. If you made it out for $500 you aren't too bad. It's easy to go through that much in gas for the truck/sleds. Not exactly the same, but I sure as heck wouldn't be caught trying to do that job myself.
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Old 01-06-2012, 10:40 AM   #14 (permalink)
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I just thought, I'll now have fresh gear oil in it too. "ALL" the fluids will be new. It's worth it, IMO. I agree 600racer.
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-10-2012, 12:37 PM   #15 (permalink)
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Update: Sounds like my sled is starting to be worked on. And it's getting more spendy. They found the cause of the heat exchanger getting ripped up. The track where a stud is ripped 6 - 8". So the stud was going round and round tearing up the exchanger. Needless to say, the track is shot. It's a Camoplast Ripsaw 121, 1.25" lugs. I measured them and the track was still like new. Not sure exactly how it ripped, or, whether the rock had anything to do with it. I wasn't on it or anything. Not sure if something happened before I bought it and it was patched(if that's even possible) and the patch cut loose. If you remember, I bought it late, late, late last winter and I've been easy on it.

I can get a new Ripsaw for $500, which isn't bad at all. And we're still at the $300 labor mark. I guess now's the time to find issues since I'm paying for parts and no additional labor. For once, parts will exceed labor which seems never to be the case in any shop. Although, my wallet is shedding a tear..... They haven't done a leakdown/compression test yet. It does have a safety shutoff if the motor was to overheat. So, those tests should be good................. I hope!
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-12-2012, 02:00 PM   #16 (permalink)
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You should be able to find a real nice used track for $250. Check the closeouts at Tracks USA too.

It's really hard to believe there wasn't a light on in the dash if you were low on coolant. But then again, this is the company that chose not to put a temp gauge of any kind on it either.
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Old 01-12-2012, 02:44 PM   #17 (permalink)
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Quote:
Originally Posted by RxSX View Post
You should be able to find a real nice used track for $250. Check the closeouts at Tracks USA too.

It's really hard to believe there wasn't a light on in the dash if you were low on coolant. But then again, this is the company that chose not to put a temp gauge of any kind on it either.
I'm going with the new one for $500 and be done with it. That's a good price for a Camoplast Ripsaw.

There is a light that was on. The gouge in the exchanger was big enough where it dumped the fluid right now. Everything happened real quick like....

Another update:

We're not done yet. The cable that goes from the dial on the tunnel to the suspension is messed up, replacing. Replacing a few bogey bearings. Although when I checked them I didn't see anything that needed replacing now. Couple had a little movement. Whatever. One of the carbs was dumping too much fuel and was ending up in the exhaust. Had the carbs gone thru, all needles were replaced. Gaskets are leaking that go between the exhaust and manifold. Those are being replaced. I thought it sounded a little loud up front.

The good news. Compression and leak down test are fine as well as the head gaket.....

Before they put the exhaust gaskets in, I have $1k just in parts.....
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-12-2012, 03:04 PM   #18 (permalink)
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I guess if you want to play you've got to pay.

I'll still never understand why there isn't a digital temp gauge. Imagine if they would have omitted it on their R1. Crazy.
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Old 01-12-2012, 03:21 PM   #19 (permalink)
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I hear ya on all points.

Everything was already put back together. They found out about the exhaust gaskets while they put 5 testing miles on.... Sounds like I'll get it back tomorrow.....

We did get 2" of fluff last night. Been getting of and on fluff all day. Just doesn't add up to anything...
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'05 Yamaha RX1 ER 1000
'93 Yamaha Phazer II LE 485
'96 Polaris Ultra SP 700 - SOLD!!

2013/2014 miles: 290
2012/2013 miles: 654
2011/2012 miles: 737
The sled is fixed... Now my wallet is broke..

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Old 01-12-2012, 09:49 PM   #20 (permalink)
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That's more on repairs than a lot of sleds are worth. But you should be good for years to come now. Plus you have piece of mind knowing all of that maintenance was done.

Now, try not to go out until there's a good base down.
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