Aftermarket rear heat exchanger instructions

If you have studs, which I highly recommend, follow Option 1 instructions:

Remove the black plastic heater hose cover by drilling out the rivets. Then remove the cross over hose and cover the open holes in the tunnel heat exchangers. Then proceed to one of the options below.
Option 1, with track studs
Place the new heat exchanger on the top of your tunnel with the hose mounts towards the rear and facing upwards. Line up the hose flanges directly between the two outlets from your current heat exchangers so they are all in a line and Mark it with the magic marker. Then you cut a hole in your tunnel the same size as the raised portion of the cooler which is normally 5 in wide and 10 in long only do not trace and cut the whole cooler section out.
After that you can cut the hoses down as low as you want and attach them one side of the hose will be about an inch longer than the other side. Then drill and put your rivets in.

Option 2, without track studs
If you're not running studs the cooler can be mounted from underneath and you only have to drill two holes in the tunnel so that you can connect the cooling hoses however you will need to buy longer rivets. Only do this if you are non-studded and do not plan on studying the sled later.

These pictures were taken while installing the original heat exchangers. The Aftermarket exchanger is a little smaller. All the fuel tanks will fit over these exchangers. This is Option 1.

lay some duct tape partially down as shown to catch shavings	drill out rivets on cover	set heat exchanger into place lining up all the outlets to mark placement with a marker but do not cut yet	Measure the raised section of the heat exchanger and mark in on the tunnel those same dimensions to cut.
Cut out the dimensions you measured. On the aftermarket exchanger we sell cut out 5"x10"	mark and cut from underneath if needed	Drill 3/16"  holes for rivets	Drill holes and rivet in place
Fill with coolant	Cut down and attach U hoses. One side will be longer on each.	Place cover in place and mark to cut.	Cut
Carefully drill the holes to remount the plastic	Your finished product should look like this

Back to the Polaris IQ parts and accessories page