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Apex powderlites install, tips? tricks?

Boostfreak

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My powderlites kit is supposed to be here tomorrow! Just checking to see what good tips and tricks you guys have for a first time installer. Any clutching options welcome aswell. I ride mainly 8000' to 10000' and got the kit with the 2860. I do have veedies alpine install vid for some help too. Thanks
 
Follow the video. Make sure to get your header bolts torqued properly......You clearly can't get a torque wrench in there eh???........ I laughed everytime I watched that part. You will need an assortment of short 10 mm wrenches, sockets etc. This is the only part I hate when assembling or disassembling the motor!!!!

If you are doing the head shim make sure you use the torque sequence on TY.

Use a good fuel type sealant on the tank fittings. Make sure that the O-rings on the fuel level gauge are proud of the aluminum spacer so that they seat nicely on the fuel tank. Put some caps on the fittings and filler up with fuel. lean it forward and leave it for a bit and make sure that it is not leaking!! These are only inches away from the header and would be a disaster if they leak!!!

"""""Make sure you have at least 1/4 inch of space between your heat sheilds and the bottom front corner of your fuel tank"""""":eek::eek:

Make sure you address anything/hoses that can rub. This is very important!!

Wrap your cables and wires going to the bars!! If you use wire loom and don't wrap them they will melt!

It is by no means an easy install. Take your time and take lots of pictures to help you know were things go.

There are lots of little things you can do along the way that will make your install clean and safe. Don't get in a hurry!

Grin large:D Your going to love it!!
 
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Checked on TY and I assume you mean the torque of 15-25-38, back off quarter turn and back to 38ftlbs? Got my kit and it looks good but was supprised to hear they have no install instructions other than the vid! The vid will be helpful but obviously leaves out lots of things. Any body else with pics or tips? Thanks for the help
 
let us know how ur kit worked. i've been lookin for a turbo kit for my apex and have was reccommend to go with a powderlites kit next to the mcx.
 
Well I too am shooting in the dark, bought a kit from dave and had a ton of questions, thanks SAP, and thanks dave for answering the phone. I just wish there was a close templet for the exit hole, and a set of instructions. I cant imagine his call volumn with selling kits with no instructions. I am starting with a sled that had a boondocker kit on there, so I have no heat shields and no air box stuff, anyone that doesnt have that video, needs some sort of order of sequence of events page & pictures. Is there nothing to get started with the RB3 , initial maps? Dave did say that the video was different that his kit and install some what. I get the principals of the install, its just the little things, like turning your spark plug caps around and leaving the bolt out, where to knotch the delta box for the header, where to mount the fuel pump, where the oil supply line goes, pulling the snap ring off the turbo snail so you can get the oil return tight, or get your spark plugs changed before you get the turbo installed, the washers needed to shorten up the throttle body clamps, how to glue the throttle body boots to to the motor and the throttle bodies with some rightstuff, whether to to wrap the header with header tape or not, or to wrap the down pipe with header wrap, and better block off plate for the tunnel holes/snow deflecter and what heat shields to leave in or out. I am going to sit down and put together a set of instructions for anyone that wants, with some medium size pics.

Jim
 
Would be awesome if you could shoot me a set of those directions when you get them done and have a chance. I am sure they would be very helpful.
Thanks

Tim
 
Well I too am shooting in the dark, bought a kit from dave and had a ton of questions, thanks SAP, and thanks dave for answering the phone. I just wish there was a close templet for the exit hole, and a set of instructions. I cant imagine his call volumn with selling kits with no instructions. I am starting with a sled that had a boondocker kit on there, so I have no heat shields and no air box stuff, anyone that doesnt have that video, needs some sort of order of sequence of events page & pictures. Is there nothing to get started with the RB3 , initial maps? Dave did say that the video was different that his kit and install some what. I get the principals of the install, its just the little things, like turning your spark plug caps around and leaving the bolt out, where to knotch the delta box for the header, where to mount the fuel pump, where the oil supply line goes, pulling the snap ring off the turbo snail so you can get the oil return tight, or get your spark plugs changed before you get the turbo installed, the washers needed to shorten up the throttle body clamps, how to glue the throttle body boots to to the motor and the throttle bodies with some rightstuff, whether to to wrap the header with header tape or not, or to wrap the down pipe with header wrap, and better block off plate for the tunnel holes/snow deflecter and what heat shields to leave in or out. I am going to sit down and put together a set of instructions for anyone that wants, with some medium size pics.

Jim


95% of what you mention above and we talked about is shown in the video. The last 5% is what you have to look for for a super clean install. I would take the video over written directions any day!! Just set it up on the work bench in a portable DVD and keep rewinding it. There are always going to be small tweaks to each kit that can be personal tastes. Dave answered all of my questions. As for maps Dave has a couple good ones up on TY for the Apex. I have made a few that I am experimenting with but it is pretty easy to take Daves maps and just modify them to your liking.

Sap
 
Checked on TY and I assume you mean the torque of 15-25-38, back off quarter turn and back to 38ftlbs? Got my kit and it looks good but was supprised to hear they have no install instructions other than the vid! The vid will be helpful but obviously leaves out lots of things. Any body else with pics or tips? Thanks for the help

That is what I would follow. Seams to be the most consistent for everyone. Make sure you oil the nuts and don't get any oil on the mating surfaces/gaskets!!!
 
I highly recommend you find some longer header bolts and use a full nordlock washer on all turbo and header bolts. I have had to helicoil every hole in the head. They will be way stronger now, and using nordlocks, they won't come loose because of heat cycles and rough trails.
 
Sap, I got the video ordered last week, just waiting on it. I wasnt bashing anyone, its just a bit over whelming all those parts on the bench, and I think I took the header off 3 times before I got all the little stuff worked out. I think I had the down pipe off and on about 20 times. drilling, using the die grinder with a carbide deburing tool, I think I finally got it. I would love a pic of someones heat shields and some one wrapped up steering column wires to show how protect them/ how far away theyneed to be from the header.
 
I watched the vid again today and maybe i missed it but I did not hear what the cam cap bolt torque is supposed to be. any idea what it is? I feel better about things after watching the vid again. gonna hopefully get the motor work goin tomorrow!
 
I watched the vid again today and maybe i missed it but I did not hear what the cam cap bolt torque is supposed to be. any idea what it is? I feel better about things after watching the vid again. gonna hopefully get the motor work goin tomorrow!

You should really get a manuel! It comes in handy for the torque #'s.

7.2 ft/lbs for the cam caps. Make sure you take them down evenly until they are seated and then torque from the center out. You will need the torque for the cam sprockets as well that is 17 ft/lbs. Use red loctite on the sprocket bolts.
:beer;:beer;

Sap
 
Hope these help!

Heatshieldsside.jpg


Heatsheilds.jpg


Fronttopviewofturbowithheatsheildsi.jpg


Heatshields3.jpg


Fuelpump2.jpg


Oilreturnfittings.jpg


Complete.jpg
 
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Thanks for all the pics! What kind of oil should I use on the head nuts? Thinkin I saw somewhere they said something with moly? Thanks
 
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