Complete post season check

[lords_605]

Hi guys, last year I got a boondockers pump gas turbo on my 09G8. Could some of you please post anything that i need to check up on or things that i need to replace on this sled/kit. is there anything specal I need to order?
Any help is appreciated, and thank you.

 

[SLDHVN]

rubber boots between the reeds and throttle bodies, look for cracks etc, replace if necessary

 

[Jkinzer]

how many miles did you put on the sled with the turbo? and what boost levels do you run?

 

[lords_605]

I ran it about 600 miles at 11 lbs

 

[Jkinzer]

with that little of miles i'd just pop the head off and take a look at the pistons, make sure there wasnt any sever deto, pull the throttle bodies and replace the throttle body boot and reeds while your there (the reeds at 10+psi only hold up for 6-800 miles) might as well do it now rather than mid season. other than that give everything the once over, make sure everything is tight and all boost lines have good fittings.

 

[lords_605]

That much I can do, and ya 600 miles lets just say it wasnt a very good snow year.
So thanks guys for the help.
ps one more question what kind of oil are you guys runnin in your turbo?

 

[Jkinzer]

i have just over 5000 miles on my turbo w/ zero issues, have ran polaris ps4 plus atv oil since day one, its a full synthetic 2w50

 

[TEC800]

rubber boots between the reeds and throttle bodies, look for cracks etc, replace if necessary

Would that make your sled idle high? mine wont drop below 2400 even at start up. Started doing it one day and has done it since. Found my primary clutch spring was snapped in half , but fixed that and it didn't help

 

[Jkinzer]

yeah it makes your sled idle high, the more it tears the higher it will idle

 

[SNOMAN1174]

Would that make your sled idle high? mine wont drop below 2400 even at start up. Started doing it one day and has done it since. Found my primary clutch spring was snapped in half , but fixed that and it didn't help

I snapped two primary springs last season. Turbos seem to eat them

 

[EricW]

If you find yourself going in far enough to inspect/replace the intake boot you might consider adding the brace that several have available now days.

Once your in that far you might want to check your TPS settings on the throttle bodies. There is great info about building your own TPS tool and the proper peramiters in the "Increasing Your IQ" thread

You might also consider installing some better grounding wires from your electronics mounting plate (the plate over your clutches) to the chassis and to the motor mounts. Several have suspected poor grounding to be a contributor to fried ECU's, Regs, etc. I used a 8ga tinned marine grade wire with expoxy heat shrinks for coneectors. Doesn't take much to do and could save some $$$ and trouble on the hill.

Another issue to watch for is a broken front PTO side motor mount bolt. If this bolt breaks it can cause some alignment problems as well as possible delamination of the rubber mount. You will know right away with a pry bar and your eye ball. You could replace this OEM bolt (notice the cut threads all the way up) with an ARP bolt (Rolled threads and shouldered where it passes through the mount) from Summit Racing and have no worries.

If you have access to the Polaris OEM tool you could check primary/secondary alignment. There is a lot of talk on here about proper alignment and the use of tools other than the OEM Polaris tool. Do a little searching on this one or shoot me a PM.

You might look for any hoses that are rubbing in areas like the charge tube, pull rope, brake/shaft, etc. If you see any issues these wear pieces work great and can be found at any hyd. or hose supply place. They attach with zip ties.

Good luck. EW

 

[SNOW JW]

Justin you have the boot plate on your kit already but good idea to check it out anyway as far as reeds with the intercooler they don't seem to be an issue if you are pushing the boost without an intercooler the high temps can but allot of stress on them. I would do an oil change in the turbo tank BD has a new turbo oil they have developed so with you being so close to them you could easy pick some up hot oil temp is not an issue on these systems it's when the oil is cold that can cause wear..

Check the clutching and keep a close eye on that main spring may want to get an extra to keep in the trailer or shop for this season.

EW posted a good post there were some Team alignment bars that were out of spec last year SLP had some good ones you can use.

Also sent you a PM

 

[lightening800]

i found the throttle body plates that are offered are only a bandaid, if you want no more problems with this issue, and if you run higher boost without any worries, check out twisted turbos billet throttle bodies, no more poor excuse for a throttle body boot just buy the ones from shain and you will not ever blow out those ever again. ran up to 15psi and no issues, will blow the boots even with the plates at higher boost levels. i like to do things once, and there is no time in the riding season for problems like this. just my .02

 

[lords_605]

wow looks like theres plenty to keep me busy, and thanks for all the help.

 

[SNOW JW]

i found the throttle body plates that are offered are only a bandaid, if you want no more problems with this issue, and if you run higher boost without any worries, check out twisted turbos billet throttle bodies, no more poor excuse for a throttle body boot just buy the ones from shain and you will not ever blow out those ever again. ran up to 15psi and no issues, will blow the boots even with the plates at higher boost levels. i like to do things once, and there is no time in the riding season for problems like this. just my .02

I would not recommend any solid unit even Boysen has some prototype AL stuff out there that still needs some more work. Just my 2cents.

 

[Jkinzer]

i havent gotten my hands on one of shain's billet intake boots or gotten to see one in person yet, but my take is there has to be somewhere for things to flex with out causing more severe damage. we all know the motor doesnt sit perfectly still, especially under a lot of boost pressure, the motor torques back and forth. with BD's billet boot adapter plate like in EricW's post above i went 1800-2000 miles last year on the same throttle body boot and am running the same one again this year. i'm curious to see more on shain's new set up, but the last i heard his piece was over $200, that will buy a guy 4 sets of intake boots, so at least 8 years of riding for the average joe...

 

[TEC800]

got to tear it apart and the boot was torn pretty good, it is torn the same on the top, too. Right around where the plate seats on the boot. Ill probably try to soften the inside edge of the boot plate this time, see if that helps.

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Here is a pic of the mag side piston where the tear was, and then a pic of the pto side. Anyone with more turbo experience that would like to give me an assessment of the wash would be greatly appreciated,(supposing it was shut down properly and read in the field) maybe could help out some other less experienced turbo owners as well. Cylinder walls looked brand new. 9-12000 ft, 8-10lbs of boost, about 50/50 93 non-oxyenated and Av gas (which i now know is overkill)

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[buckshot]

It's a real tough job getting at the top bolts on the boots as the fuel rail seems to be too low. Do you guys pull the fuel rail to get at the bolts easier?

 

[TEC800]

yeah i did, just be careful when you pull the injectors to keep track of the little green o rings and make sure they get back in on reinstall

 

[skibreeze]

yeah i did, just be careful when you pull the injectors to keep track of the little green o rings and make sure they get back in on reinstall

There are 2 o rings on each injector to keep track of and it is easy to damage the injector end if not careful.