Disassembly, Stock parts removal list.
1. Side panels
2. Hood
3. Clutches
4. Muffler
5. Air box
6. Throttle Body Boots
7. Steering linkage
8. Coolant bottle hose ( 5/16th hose from bottle to throttle bodies.)
9. Remove the sensor from the stock airbox.( plug the sensor back into the harness and zip tie it too the wiring harness so it doesn’t rub and contact any sharp or abrasive objects.
Turbo Kit Installation
Billet Throttle Body Boot
1. Install the billet boot onto the engine, Posistion the oil linkage rod, between the boot and the fuel rail. Be sure the linkage pivots towards the Mag side of the engine. Also connect the injector plugs from the fuel controller on the injectors in the billet boot.
2. Bolt the boot to the engine using the supplied 6mm Socket head bolts
Install the throttle bodies.
1. Remove some material off the throttle cable bracket, so it doesn’t interfere with the air box when opening the throttle.
2. Spread grease around the o rings in the boot and around the throttle bodies.
3. Insert the throttle bodies into the billet boot, be sure to connect the oil linkage rod and make sure its pivoting towards the Mag side of the engine.
Fuel Lines
1. Run the fuel lines between the two large coolant lines, This will keep it from flopping around and rubbing on the bulk head. Use some Zip ties to hold it in place.
2. Remove to return fuel line from the fuel pump assembly on the gas tank.
3. Connect the return line into the new fuel line from the billet boot. ( This has the quick connect fitting.
4. Connect the other perpendicular line from the tee back to fuel pump assembly on the gas tank. Wrap the hose so it will rest against the gas tank and not rub on any sharp or abrasive parts
Airbox Installation.
1. Install the oring fitted airbox onto the throttle bodies. Install the supplied 1/4x5” bolts into the outside tabs and place the supplied spacers over the bolts.
2. Use plenty of grease on the o rings to ease the installation.
3. Once the box is fitted to the throttle bodies. Insert the ¼” bolts through the tabs on the billet boot. Be sure the spacers are installed between the air box and boot. Use the supplied rubber grommets and washers on the throttle body boot side of the bolt. Use the supplied Lock nuts and tighten the bolts do not over tighten the bolt. Tighten the nuts so it slightly puts pressure on the o rings. (Over tightening can cause bolts to break).
6. Remove the left steering post bolt and bolt the air box mounting tab to this bolt. You may have to slightly bend the bracket to ensure a good fit.
Blow off valve
1. The blow off valve is mounted on top of the airbox
2. Connect the hoses coming off the valve, onto the preinstalled 3/16th fittings on the billet boot.
3. Clamp them to the fittings using some small Zip ties.
Turbo/ Oil tank Assembly
1. Un spring the stock pipe to make room for the turbo assembly process, You don’t have to fully remove the pipe.
2. Use the supplied cushion clamp to zip tie this radiator hose towards the airbox
3. Install the turbo assembly onto the existing muffler bracket. Using the stock rubber cushion from the OEM muffler. Install the coldair intake tube and charge tube onto the turbocharger before installing the turbo assembly.
4. Once in place bolt the down pipe onto the muffler bracket using the supplied 5/16th bolts
5. Re spring the stock pipe while locating it into the new turbo stinger flange
6. Spring the turbo onto the stock pipe using the 2 5/8th exhaust springs.
7. Double the springs on your Y pipe to pipe coupler, to ensure a leak free joint.
Oil pump/tank
1. The oil pump is preinstalled onto the oil tank. Install the oil pump on the the bulk head, use the supplied bolt.
3. Connect the oil line from the top of the pump onto the fitting on the turbocharger
4. Run the oil pump wiring towards the front of the bulk head, and zip tie it along the tri spar chassis, that runs up towards the handle bars
5. Use Zip ties to hold it in place.
6. The wiring plug will plug into the existing accessory plug located in the hood of the snowmobile. Use Zip ties when connecting this plug to ensure it cannot come apart.
7. Locate the 2 amp fuse, and replace it with a 10amp.
Coolant lines
1. The coolant line facing the rear side of the engine connects to the existing coolant bottle.
2. Use the existing clamp on the hose.
3. The coolant line facing the front side of the snowmobile connect to the fitting located on the throttle bodies.
4. Use the existing clamp on the hose.
5. Also route this hose so it doesn’t rub on any sharp or abrasive objects. Use zip ties to hold it in place.
Charge Tube
1. Install the preassembled charge tube.
2. The 2” side coupler connects onto the turbo charger.
3. The other side connects into the air box.
4. Be sure to check all the t clamps to ensure they are tight.
5. Reinstall the steering linkage and check fitment. Use the supplied aluminum washer, and flip the steering linkage towards the top. You may have to adjust the couplers and pipe to make clearance of the linkage.(Use thread locker the nut.)
Air intake
1. Install the air intake and filter cage onto the turbo charger.
2. Position the elbow to it doesn’t rub on the exhaust or side panel.
3. Use the supplied worm gear clamp to fasten it to the turbocharger.
4. Install the supplied pre filter over the stainless filter cage.
Control Box.
1. Velcro the control box on the consol of the snowmobile using the supplied Velcro.
We suggest mounting it right above the gas cap.
2. Connect the plug in connectors into the oem injector harness, located right in front of the throttle bodies.
3. Connect the ground wire to the ground stud located in the front left of the bulk head.
4. Connect the two extra injectors into these plugs from the control box.
5. Velcro the 3 way seloniod onto the ECM located on the back side of the oil tank.
6. Connect the power wire from the seloniod into the wiring adapter plug that will be connected to the accessory plug on the hood.
7. Connect the boost hose from the control box, into the selonoid ( the side with only one port).
8. Connect boost hose from the other side of the soleniod into the fitting on the PTO side of the throttle body boot.
9. Use a small dap of super glue to secure the boost hose onto the control box, do not get any glue on the inside of the fitting or hose.
10. Be sure none of the hoses or wiring in routed to it will rub, and pull when reassembly, or operation of the snowmobile.
Gauges
1. Mount the gauge bracket onto the riser block of the handle bars.
2. Install the Wideband gauge and boost gauge into the bracket.
3. Put some silicone on the back side of the threaded mounting studs of the gauges to ensure the nuts wont back off.
4. Install the 1/8 npt fitting onto the back side of the boost gauge.
5. Use the supplied 1/8 nylon hose and connect the boost gauge into the fitting located on the MAG side of the billet boot.
6. Connect the wideband gauge, you can get power from the remaining accessory plug outlet where the oil pump and control box solenoid is wired to.
7. Install the oxygen sensor into the down pipe off the turbocharger.
8. Route all hoses and wiring and hold in place with zip ties.
Clutching
1. Install the secondary spring into the secondary clutch.
2. Install the new helix using the 44/48 ramp.
3. Install the new clutch weights. Be sure the check your belt to sheave clearance. And shim to .015 - .020
4. When loading the clutch weights with bolts and washers, be sure to only install the one small steel bolt and small washer in the hole closest to the pin ( heel of the weight).
5. Install the supplied primary spring.
6. Install the clutches back onto the snowmobile, be sure to torque the primary clutch to spec.
Turbo oil
1. Fill the oil tank ¾ full with 5w30 fully synthetic oil.
2. Be sure to check the oil level periodically throughout the day.
3. Prime the oil pump using a 12v battery. Do not hook the pump up back wards.
4. Let the pump run, and remove the oil line from the top of the turbo to check for oil flow.
5. Reinstall the oil line. Be sure to check the hoses for any kinks.
Reassemble
1. Top the sled off with coolant, be sure to bleed to system to remove any air bubbles.
2. Install the hood. Be sure to connect the power a wire, which powers the oil pump and gauges.
3. We suggest not using the plastic filler on the hood, that is located next to the steering post. This will allow all the new wiring and boost hose to fit freely between the hood.
Start up.
1. Check the make sure all the gauges are working properly.
2. Check the control box to make sure its powering up and go through the modes.
3. Pull the oil line from the turbo and check for oil flow. (Do not let the sled run long without the oil line connected, 2 seconds is more than enough.)
4. Let the sled completely warm up. Before riding.
5. Check all bolts, fittings and clamps after first ride to ensure they are tight.
Tuning tips and settings
Boost controller, one full turn on the boost controller is equal to one psi of boost pressure.
Never operate at boost levels above 15psi.
Spark Plugs
1. Be sure to gap you spark plugs down to .020 or less. The extra cylinder pressure will blow the spark out of the cylinder and cause a misfire.
2. BR9EIX is a better turbo application plug. We suggest running these.
Tuning Tips
1. Sled falling on its face at WOT, usally is cause by too rich of a fuel mixture. Remove fuel using the green/blue mode, or solid red mode on the fuel control box.
2. Det light, is caused from over boosting or too low of octane.
3. Clutch you sled to run 8250 RPM at WOT.
4. Run the 115 polaris belts.
Control box adjustments.
1. Green Mode- Cruise fuel adjustment.
2. Yellow Mode- Accel pump, lower the number adds less fuel on throttle stabs.
3. Red Mode- High speed cruise and WOT fuel adjustment.
4. Green Blue Mode- Amount of fuel per pound of boost adjustment. Lower the number= less fuel.
5. Yellow Blue Mode- Upper RPM that yellow modes turns off at.
6. Red Blue Mode- What rpm solid red modes turns on at. Lower the number the lower the RPM.
Default Control box #’s:
G- 4.5
Y-4.5
R-4
GB-4
YB-4.5
RB-4
