Stock Surge Tank Coolant Re Route DDM-16-51

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Clement Moody
5 years ago
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Stock Surge Tank Coolant Re Route DDM-16-51 The DDMWorks Slingshot Coolant Re Route fixes a problem with the flow of coolant through the engine.

1 Stock Surge Tank Coolant Re Route DDM The DDMWorks Slingshot Coolant Re Route fixes a problem with the flow of coolant through the engine. This helps keep coolant circulating properly and your engine safer from over heating. Please note the differences in the instructions regarding model years. If you are pretty handy with tools the Coolant Re Route can be installed in one hour or less, however we suggest that you schedule at least a few hours for the installation. If you have any questions during the installation you can call or text (864) or us at Tech@ddmworks.com. Pliers or channel locks Flat head screw driver Drill, 11/32 drill bit. 1/8 NPT Tap TOOLS NEEDED QTY PART DESCRIPTION 1 3/8" 90 degree fitting 1 3/8" Barb fitting straight 1 1/8 NPT Fitting to 3/8" tube SS #4 Hose Clamp 1 Silicone Hose 2 Zip ties 119-A Hwy 183 Piedmont, SC Tech Support (864) (call or text) Tech@DDMWorks.com Make sure that the engine is cool to the touch. You will be working with the cooling system so it is best if the slingshot has not been ran for a few hours or better let sit over night. Page 1

Make sure that the engine is cool to the touch.

You will spill a little coolant so have some towels handy to clean up.

The engine is designed to sit at a 10 degree angle and the steam line that comes off of the head follows this 10 degree downward angle.

2 Make sure that the engine is cool to the touch. You will be working with the cooling system so it is best if the slingshot has not been ran for a few hours, or better, let sit over night. You will spill a little coolant so have some towels handy to clean up. Stock Configuration Shown here is the Stock Polaris Coolant configuration. The engine is designed to sit at a 10 degree angle and the steam line that comes off of the head follows this 10 degree downward angle. This causes steam to build up and block the flow of coolant. This Kit will Re Route the steam line and correct the problem. Stock Configuration 1. Disconnect the two clamps holding the line to the front of the valve cover. Then remove the 3 lines from the T fitting. If you have a or newer your lines will not have a T but will have 2 lines joined by a 90 degree elbow. Page 2

3 If you have a or newer remove the steam line completely and cap off your surge tank with the provided cap. Then skip to the next page. Replace the T fitting with the new Straight Fitting included in your kit. This will join the line coming from the top of the radiator to the line that runs up to the surge tank. Use the clamps included in the kit to secure the new straight fitting. Page 3

Remove the Steam line that was running across the front of the engine.

This will help the breather line coming out of the valve cover clear the steam line.

4 Remove the Steam line that was running across the front of the engine. You will need to trim 1/2 of an inch off of the bottom of the elbow that connects to the fitting on the engine. This will help the breather line coming out of the valve cover clear the steam line. With that 1/2 inch trimmed put the line back on the fitting with a clamp and direct the line along the valve cover and fuel rail towards the rear of the engine. Included in your Kit there is a 90 degree elbow that needs to be inserted and clamped into the steam line at the back of the engine. This will join with the New line included in your kit. Insert the other end of the 90 degree elbow into the straight end of the new hose. The opposite end with the bend in it will meet up with your stock surge tank that we will now add a fitting to. Page 4

With the new 90 degree elbow and hose clamped together and in their general location you can see about where the new

You will be drilling a hole in the neck of your stock surge tank using an 11/32 drill bit.

The hole should be at a slight angle towards the drivers side and about 1/2 inch under the threads for the cap.

5 With the new 90 degree elbow and hose clamped together and in their general location you can see about where the new fitting will be placed into your stock surge tank. Included in your kit you have a 1/8th NPT fitting. You will be drilling a hole in the neck of your stock surge tank using an 11/32 drill bit. Then using an 1/8th NPT tap, tap the hole so it will accept the new fitting. The hole should be at a slight angle towards the drivers side and about 1/2 inch under the threads for the cap. Use some thread sealer when inserting the fitting into the tank. Then connect the bent end of the hose securing it with a clamp. Fill the surge tank back up if you lost some coolant. And the Re Route is complete. 1/8th NPT Fitting Page 5

With the lines and fittings Re Routed make sure all the clamps are

You can add a zip tie or two to make sure the steam line does not

You have successfully installed your new Coolant Re Route.

6 With the lines and fittings Re Routed make sure all the clamps are tight and there are no leaks. You can add a zip tie or two to make sure the steam line does not move around. Zip Tie Congratulations! You have successfully installed your new Coolant Re Route. This product is Buddy the Turbo Dog Approved! 119-A Hwy 183 Piedmont, SC Tech Support (864) (call or text) Tech@DDMWorks.com Page 6

DDMWorks Windshield Mount DDM-16-31

DDMWorks Windshield Mount DDM-16-31 The DDMWorks windshield mount is designed to work with the Polaris Slingshot and offer some more mounting options than the stock windshield mount along with a way to