1. - boondocker€¦ · remove the muffler and egt. remove the stock ... and install the power...

Revised 10/23/2015 of 10

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1.Remove the gauge, side panels, hood and headlight.

Remove the air box from the throttle bodies then

remove the seat and gas tank.

2.Carefully remove temp sensor from air box using

a small pick or screw driver. DO NOT THROW

AWAY; this will be used for later use in the install.

3.Remove the muffler and EGT. Remove the stock

rubber muffler isolators from the bottom of the

muffler. DO NOT THROW AWAY; these will be

used later in the install.

4.Remove hood from headlight assembly and flip

upside down. Break off the weld dots on the air box

assembly. Pull apart the air box assembly. Discard

the lower air box & white air box tube.

5.Cut the upper air box matching both sides on

the cut (as seen in picture).

6.Cut the upper hood/air box assembly as seen in

picture for clearance purposes. Cut remaining

weld dots off of the upper air box.

Revised 10/23/2015 of 10


7.Remove the throttle bodies & reed cages from

the machine.

8.Remove the stock reed pedals and replace

them with new turbo reeds. DO NOT mix them

up. Reinstall back in engine and install the

throttle bodies.

9.Install the power adapter cable into the open

fuse holder. Install supplied fuse.

10. Hook up the ground right below the fuse

holder on the foot rest with the stock bolt.

Tighten the bolt so wires are pointed to the top

of the chain case.

11. Remove fuse holders from stock location

and install the power harness on the end of the

power adapter cable. Make sure red wire goes to

red wire.

12. Hook up throttle position harness to throttle

body. Zip tie all wires so they don’t chaff or

break off.

Revised 10/23/2015 of 10


13. Route wiring down the stock harness to the

power adapter harness and throttle position hook

ups. Use zip ties accordingly.

14. Install the throttle body tab clamp on the

throttle body with the tightening screw at the top

of the assembly. Install the silicone hose and

twist clamp into position then tighten clamp.

15. Install silicone on the left side of the

aluminum Y. Tighten the hose clamp. Leave all

the other clamps loose for proper alignment and

fitting.

16. Install the rest of the air box. Make sure you

index the hose clamps so you can access them

for tightening after you install the gas tank.

Leave the hose clamps loose.

17. Install the injectors in the injector rails. Use

assembly lube so you don’t tear an o-ring.

18. Route the fuel line as shown in picture.

Don’t over tighten these bolts. Zip tie fuel lines

so they don’t kink then zip tie the wire harnesses

securely.

Revised 10/23/2015 of 10


19. Cut and splice into the return fuel line.

Install brass T into fuel line and tighten clamps.

Position for clearance, zip tie and secure as

shown.

20. Install the gas tank and tank support

member. The Y will touch gas tank slightly on

PTO side. There should be reasonable clearance

elsewhere.

21. Remove the clear line on rave valve solenoid

& Install check valve. Turn the blow off to down

position. Route and zip tie.

22. Remove pipe and apply silicone to exhaust

doughnut. Triple up springs on pipe and

reinstall.

23. Install intercooler using hose clamps on

cross bar. Install fan and route adapter harness.

24. Install the 3” charge tube. Do not tighten

hose clamps. Try to slide the charge tube closer

to the Y end for proper fit. Hook up the air temp

sensor to the control box. Zip tie into place.

Revised 10/23/2015 of 10


25. Install clutch cover then turn the Y on the

PTO side upwards until the clutch cover fits

properly.

26. Install stock temp sensor and zip tie. Hook

up the boost reference line to the push to connect

on the intercooler. Route so it does not chaff or

break.

27. CAREFULLY trim oil tank as shown using

sharp knife or cutters. DO NOT puncture oil

tank during this process.

28. Install heat tape on the chain case, hoses,

stock EGT cable, and oil tank. Newer models do

not require heat tape on chain case.

29. Drill the hole for the spring tab with a 3/16”

drill bit. This hole already exists so you only

will drill the plastic in the bell pan on the right

side.

30. Install the stock muffler rubber bumpers on

the turbo bracket using a flat blade screw driver.

Revised 10/23/2015 of 10


31.Install the turbo assembly then install the

spring supplied for turbo bracket tab to bulk

head spring tab.

32.Route the inside coolant line under the bulk

head bracket. Route up to the back side of

coolant bottle.

33.Remove the small coolant line from the back

of the coolant bottle. Then route to the coolant

hose you just removed. Make sure you secure

hose.

34.Route the outside turbo coolant hose under

the bulk head cross member to coolant bottle.

On standard turbo kits clean the belly pan, apply

heat to velcro, then install oil pump as shown.

35.Route & hook up power for oil pump to

power harness. Route coolant hose to coolant

bottle. Zip tie the hose & power harness away

from any hazard. Tighten coolant hose clamps.

36.Install the waste gate solenoid. Use the

Velcro supplied to mount the solenoid. Use heat

to activate the glue on the Velcro.

Revised 10/23/2015 of 10


37.TIAL ONLY. Install the waste gate on the

inlet. Plug the remaining holes in the Tial waste

gate. You will not use the coolant fitting option

on this waste gate.

38. Using an air saw, cut exhaust side plastic for

exhaust to fit through. This hole will be

approximately a 3 1/2” hole. If desired, install

heat tape to the lower inside side panel.

39. Test fit the head light assembly to the

intercooler mount bracket. Tighten all the hose

clamps into position making sure the head light

assembly and charge tubes fit correctly.

40. Check for clearance on the clutch cover and

the 3” charge tube. Tighten all air box and

charge tube hose clamps.

41.Install Tial muffler. When installing the

muffler rotate the top of muffler to the inside of

the snow machine for a equal clearance to both

the side panel, chain case and stock oil tank.

42. Install the factory EGT sensor into the turbo

muffler, then remove the stock heat tape and

insulation from the side panel then install the

heat tape as shown.

Revised 10/23/2015 of 10


43. Cut the shroud just enough to run control

box wiring and boost reference line through,

then zip tie wires as needed.

44. Turn handle bars all the way to the left and

install the cold air intake as shown in picture.

45. Install the hose from boost solenoid to the

intercooler.

46. Install the hose from ECM onto cold air

intake box. Install the hose clamp on the cold air

bracket. Test fit the head light then tighten the

hose clamp.

47. Install the silicone hose on the cold air intake

box tube. Install the hose clamps between the

cold air intake tube and turbo.

48. Install the head light assembly. Route the

control box as shown in picture. Clean the

console then install Velcro. Heat the glue on the

Velcro to activate.

Revised 10/23/2015 of 10


49. Remove primary clutch. Remove the old

ramps. Install roll pins in ramps, index roll pins

as seen in picture. Be sure to perform clutch

adjustments to Ski-Doo specifications.

50. Install the pins in the clutch. At the top of the

page is low elevation to 5,000ft clutching. At the

bottom is 5000 ft up clutching. Tighten the set

screws to cotter pins in both cases.

51. On Standard Turbo Kits fill the turbo oil

tank with12oz of TC2 Turbo oil. Remove the oil

feed line off of the turbo then start the snow

machine. Verify oil is flowing, then reinstall the

oil line and tighten.

1. - boondocker€¦ · remove the muffler and egt. remove the stock ... and install the power...

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