aerocharger catalog
Transcription
aerocharger catalog
2013 2014 R BOOST. IMPROVED. We’re turbomachinery engineers. It’s what we do. Aerocharger is in a unique position in the industry - not only do we produce the world’s most advanced turbocharger, we also use our expertise to create application-specific turbo systems. We know the Aerocharger inside and out. We know how to make it work right and do what we need it to do, because we’re the same people who build it. The advantage for the performance enthusiast is huge. Historically, forced induction systems were hard to tune, potentially damaging to engines, and very costly. For these reasons, aftermarket turbocharger modification represented a nearly impossible undertaking for the average gearhead. But now, Aerocharger’s nextlevel engineering is bringing forced induction out into the mainstream. Our comprehensive knowledge of fueling, bearing technology, thermal management and flow dynamics have ramped up engine performance without sacrificing efficiency on numerous applications. And our focus on the end-user installation experience has finally put success in reach of the typical owner. The 2013-2014 season is shaping up to be a strong one, with new platforms, new partners, and more racing. And we’re proud to be the makers of the Aerocharger: the turbo that will not only get you out there, but also get you back home again. - Aerocharger, August 2014 Club BRP 2014, Dallas TX In February, BRP invited Aerocharger to participate again in their annual corporate dealer conference, marking the third year in a row in which Aerocharger was the only aftermarket performance vendor in attendance at Club BRP. Aerocharger values it’s close cooperative relationship with BRP and Rotax - technical input from BRP Racing was instrumental in the development of the Aerocharger Ski-Doo system, and valuable R&D was shared back and forth. These ties represent the best possible support for Aerocharger dealers, and the most effective and reliable technology in the industry. Race Day R&D This year’s out-of-the-box system was last year’s secret weapon on the hill. All of Aerocharger’s prototypes have to survive the competitive gauntlet, where innovation is rewarded with performance and everything else goes back to the drawing board. Aerocharger Racing 2013 Aerocharger’s hillclimb Top Left: Carl Kuster launches his Summit SP off the starting line at efforts have been the catalyst for offerings such Jackson Hole. Bottom Left: Aerocharger’s race fleet lined up at the trailer. as vent kits and ultra-lightweight system options. Middle: Calvin Felker waiting for the signal at Jackson. Top Right: Calvin RMSHA Hillclimbs also inspired the development Felker and Chris Shover work on a Race Summit. Opposite page: Calvin of the Snow-To-Air Intercooler, the most effective Felker tears towards the top at White Pine. intercooler in the snowmobile world. The Competitive Edge After building sleds with Calvin Felker #405 in Colorado, it was off to Jackson Hole WY, where legendary SnoCross champion and Ski-Doo product consultant Carl Kuster #47C was waiting for us. The Aerocharger Racing crew loaded up the trailer and drove through the snow to the Bridger-Teton National Forest to practice. We found the perfect area: several treed hills with good climbs, sharp turns and obstacles, all within view of the trailers where sleds were being tuned. Raysha Nielsen of Renegade Powersports, the Crockett brothers with their Aerocharged RMKs, and Chase Johnston’s crew all came out to practice with us here. Aerocharger was well-represented on the hill on race day, with Aerocharged Polaris, Ski-Doo, and Arctic Cat sleds taking top places. Engineer Cory Ellis provided support to Team Ski-Doo’s mod sleds, which all get boost from Aerochargers. X-Games star Heath Frisby came on board for a run on one of our Ski-Doo Summits. Jay Mentaberry joined us as well in the Dash for Cash on “Black Betty,” Team Aerocharger’s 2011 Ski-Doo turbo rocket. His performance wowed the crowd with the horsepower on display. The hill beat many riders this year, as sled after sled got caught in trenches and highmarked out. But Aerocharger Racing proved to be crowd favorites, with Carl Kuster’s agile riding style and Calvin Felker’s aggressive gate charging. Anything can happen on the hill, and Aerocharger Racing looks forward to returning in Spring 2014. Aerocharger Anatomy In 1976, an engineer had a dream. He drew up his vision of an innovative new turbocharger, one that employed an ingenious vane assembly to focus and optimize exhaust energy. That was the variable geometry turbo that became the Aerocharger. Some three and a half decades later, his brainchild remains on the forefront of innovation, being fitted for use on new applications for which conventional turbochargers are inadequate. The Aerocharger ranks as one of the most efficient turbochargers available for any application, and this means horsepower-boosting energy savings for your engine. 01 Variable Vane 02 Internal Oil Supply 03 Thermal Management The Variable Area Turbine Nozzle (VATN) system is an adjustable vane assembly that focuses the exhaust gas flow towards an exhaust wheel, while altering it’s formation as the engine load changes. This allows boost to be generated immediately, without the delay in power that every conventional turbo has. The Aerocharger’s integrated boost controller allows boost response to be mechanically adjusted, and this is the only turbo in the world to have this option. What does lag free boost mean? It means no dangerous surges or jolts when control is critical. It means a smooth power band when properly fueled and clutched. It means massive horsepower and torque, dropped right on top of your engine’s stock power band. Aerocharger is highly regarded in the engineering world for utilizing a self-contained oil supply. Conventional automotive turbos require oil lines to be tapped and fitted. This aversely affects the vehicle’s stock system, adding large amounts of heat to the oil supply and creating extra load for the oil pump. The Aerocharger lubricates from an internal oil reservoir contained within the housing of the turbo. An oil wicking system draws oil from the reservoir. Internal forces then work to force the oil into a mist, sending a fine cloud of lubrication over internal components. This system is so effective that a relatively small amount of oil can last for several years, will never require changing, and reduces the overall weight of the turbocharger system while radically improving speed and efficiency. It has been rigorously tested and proven, exceeding a 30,000 hour operation test conducted by the U.S. Military. Journal bearings are the typical bearing for conventional turbochargers. These bearings sit in a bath of super heated engine oil, and have to fight against excessive thermal resistance and engine contaminants. The Aerocharger’s oil mist system allows the bearings to operate at a significantly higher RPM, causing the turbo to spool faster with less backpressure. The backwall of the Aerocharger is reinforced with layers of high-tech insulation. This keeps thermal energy where it belongs on the exhaust side, and away from the compressor side where the air charge is generated. Self-Contained Integrated Boost Controller Advanced Turbine Balancing The turbo that we manufacture has industry-exclusive self-contained lubrication. This reduces weight, complexity, and eliminates fail-prone parts from your turbo system. The integrated boost controller allows for the boost amount to be set. Boost response can be mechanically adjusted here, making it the only turbo in the world with this feature. Aerocharger turbines are balanced to tolerances up to ten times more precise than standard turbos. This exactitude ensures performance that surpasses the competition. Integrated Turbine Inlet By reducing the flange when application-appropriate, we maintain a laminar flow to correctly carry energy to the turbine wheel. This is an industry-exclusive feature, and is another advantage made possible by producing our own turbo. Turbine Heat Shield A stainless, ceramic-coated Turbine Heat Shield reduces under-hood temperatures, while containing thermal energy so it can generate boost. Ceramic Ball Bearings Variable Turbine The most modern bearing technology available. The Aerocharger’s ball bearings exceeded a 30,000 hour operation test by the US Military that’s 3.4 years at full boost. An Aerocharger uses 100% of exhaust gases, eliminating energy-sapping waste gates. The result is faster, more efficient boost. Similar technology is now used on luxury cars and modern diesel trucks. D5S NiResist Alloy Compressor Wheel The Aerocharger’s turbine housing is constructed from an exotic D5S NiResist alloy. This premium aircraft-grade metal contains up to 38% nickel, and has advanced corrosionresisting properties superior to stainless steel. Building our own turbo gives us the data and knowledge to precisely match the compressor wheel to each application’s flow requirements - a concept generally misunderstood by other turbo kit builders. www.AEROCHARGER.com +1-913-829-3400 [email protected] 402 NEW CENTURY PARKWAY. NEW CENTURY KS 66031 AEROCHARGER SNOWMOBILE SYSTEMS Innovate O2 Gauge Ski-Doo E-TEC The best 02 Gauge on the market. Features multi-color LED indicators for quick & easy reading when hurtling through trees. Fuel Controller Boost Gauge Pre-tuned fuel controller comes loaded with the maps your sled needs to run right, the first time and every time. Automatically compensates for elevation and has fine-tune adjustability features. A rugged external 3-Bar M.A.P. sensor is a standard feature for all Aerocharger snowmobile fuel controllers this season. Riders told us that they wanted their gauges mounted directly to the dash plastics for a cleaner look. To make this work, we produced a custom boost gauge with an Aerochargerspec size and PSI range. Silicone Charge Tube This custom molded Silicone Charge Tube is lightweight and flexible for a simple install, yet extremely durable to carry the pressurized air charge. First on the Snow Aerocharger co-developed the Ski-Doo E-TEC turbo system with BRP Racing starting in 2009 for RMSHA, and the Aerocharger was the first working kit available at the E-TECs release in 2011. BRP Racing dyno’d the Aerocharger system and registered 240hp at only 7psi, and this system can be set to produce a range of 200-300hp. This system was designed in close collaboration with BRP Racing, who contributed design criteria and system specifications to ensure that a properly designed aftermarket turbo kit would be available for the E-TEC snowmobiles. The Aerocharger’s technology creates a lowbackpressure operating environment, which makes it the most ideal turbo for use with Rotax 2-stroke engines. The Aerocharger E-TEC system was built to prioritize horsepower-generating efficiency, and this equals an ultra-responsive, ridable system that excels at high altitude and on technical terrain. For all Ski-Doo/Lynx 600 & 800 e-tec models 2011 and up. ELEVATION OPERATING SPECS BOOST FUELING 0 - 5000 Feet 5psi 100 Octane 0 - 1524 Meters 7psi 104 Octane 5000 - 8000 Feet 5psi 93 Octane 1524 - 2438 Meters 7psi 100 Octane 8000+ Feet 5psi 91 Octane 2438+ Meters 7psi 96 Octane Blow-Off Valve Industry exclusive BOV. 2-Strokes produce very little vacuum compared to automotive engines, leading us to develop our own BOV in-house. Different spring pre-loads match the factory vacuum levels for improved performance. Turbo Reeds Developed by BRP Racing based on use with sleds modded with Aerochargers. These reeds feature increased durability and have longer life than standard reeds under turbocharged conditions. Turbo Cradle This lightweight stainless steel/ ceramic coated assembly locates the Aerocharger exactly where it needs for easy installation and perfect fitment. Turbo Airbox Your turbo E-TEC needs an airbox, and don’t let anybody tell you otherwise. This durable pressurized airbox puts a large air charge volume as close to the intake as possible. This is where your 2-stroke needs it the most for the snappiest throttle response. The shape additionally mimics the stock airbox to maintain the factory’s acoustic tuning advantage. Exhaust Stainless steel construction offers the longest service life and reduces under-hood temperatures. The exhaust assembly is then ceramiccoated for further heat management, giving it a clean, OEM appearance. Snow Silks Critical for proper operation, yet often overlooked by other kit builders. Aerocharger’s custom Snow Silks are made in-house and will deliver the venting that your sled requires to beat the competition. Snow-to-Air Intercooler The most effective intercooler for a snowmobile, period. This intercooled airbox assembly installs into the tunnel, taking advantage of a high-pressure area created by track speed. Water, snow and ice are forced through the core for a consistent & efficient charge-temp drop that won’t tax the stock coolant system. Innovate O2 Gauge AEROCHARGER SNOWMOBILE SYSTEMS The best 02 Gauge on the market. Features multi-color LED indicators for quick & easy reading when charging up the hills. Polaris Pro RMK Boost Gauge Fuel Controller Riders told us that they wanted their gauges mounted directly to the dash plastics for a cleaner look. To make this work, we produced a custom boost gauge with an Aerochargerspec size and PSI range. Pre-tuned fuel controller comes loaded with the maps your RMK needs to run right, the first time and every time. Automatically compensates for elevation and has fine-tune adjustability features. A rugged external 3-Bar M.A.P. sensor is a standard feature for all Aerocharger snowmobile fuel controllers this season. Silicone Charge Tube This custom molded Silicone Charge Tube is lightweight and flexible for a simple install, yet extremely durable to carry the pressurized air charge. The Ultimate pro Aerocharger has been the preferred turbocharger for Polaris snowmobile tuners since 1985, and this system has been available and tested constantly since 2011. Elite snowmobile techs and racers needed fast-spooling variable vane performance for backcountry and hillclimb riding, and realized that the Aerocharger was the best available for turbocharger technology. The Aerocharger RMK is tuned and tested, and runs hard and strong with zero bogs or hiccups and absolutely no lag. for all 600 & 800 rmk/pro-rmk models 2010 and up. ELEVATION 0 Feet and up OPERATING SPECS* BOOST FUELING 5psi 91 Octane 7psi 100 Octane 7+psi 91 Octane 0 Meters and up 0 - 5000 Feet Exhaust Stainless steel construction offers the longest service life and reduces under-hood temperatures. The exhaust assembly is then ceramic-coated for further heat management, giving it a clean, OEM appearance. Blow-Off Valve Industry exclusive BOV. 2-Strokes produce very little manifold pressure compared to automotive engines, leading us to develop our own BOV inhouse. Different spring pre-loads match the factory vacuum levels for improved performance. 1524+ Meters *with Polaris Timing Key This Intercooler assembly upgrade provides a consistent heat drop for the charge air. It is available in an openloop version, or a new standalone closed-loop version that includes a tunnel heat-exchanger assembly. The assembly is ceramic-coated for durability and appearance. Aerocharger Turbo Airboxes feature a tuned backwall. The acoustic properties of a 2 stroke engine requires proper geometry on the intake side as well as the exhaust, and this airbox closely mimics the design of the stock airbox for full performance advantage. www.AEROCHARGER.com Critical for proper operation, yet often overlooked by other kit builders. Aerocharger’s custom Snow Silks are made in-house and will deliver the venting that your sled requires to beat the competition. Air-to-Water Intercooler Turbo Airbox 0 - 1524 Meters 5000+ Feet Snow Silks +1-913-829-3400 [email protected] Turbo Timing Key An Aerocharger Timing Key upgrade alters ignition timing in order to permit higher boost levels while using lower octane fuels. 402 NEW CENTURY PARKWAY. NEW CENTURY KS 66031 b l ack betty 2011 Ski-Doo XP 800 turbo Race Sled AKA Black Betty. Estimated 300 Hp. 154” Track Length. Weighs 485 lbs wet. Timbersled Skid, Z-Bros Front End. S.L.P. Skis. Fly Handlebars. Custom seat from a KTM 525. 66 Series Aerocharger with Dual Exhaust. 1st Gen Aerocharger Air/Snow Intercooler. Tuned by Felker Motorsports. Notable Riders: Heath Frisby, Calvin Felker, Carl Kuster, Jay Mentaberry. Innovate O2 Gauge AEROCHARGER UTV SYSTEMS Blow-Off Valve The best 02 Gauge on the market. Features multi-color LED indicators for quick & easy reference while speeding down the trail. Polaris RZR Industry exclusive BOV built in-house at Aerocharger. Different spring pre-loads match the factory vacuum levels for improved performance. Exhaust Boost Gauge A flow-through design provides exhaust output with the least possible backpressure, and remains noise-compliant with U.S.A. Forest Service noise regulations. Because 100% of exhaust gases pass through the Aerocharger, no spark arrestor is required on this muffler. Both gauges mount directly to the RZR’s dash plastics for the most stock appearance. The Engineer-Built Difference Donaldson Air Filter Aerocharger was tired of seeing the aftermarket flooded with poorly designed and crudely built turbo kits, so our engineers produced a one-off turbo system in 2008 to be a demo on the correct way to turbo a RZR. It featured elegant flow, tucked-away fitment, and was so efficient it could make more horsepower with less boost than any other system. Word got out as Polaris RZR owners discovered it was vastly superior to what the competition was producing, and the Aerocharger RZR prototype quickly became a best selling turbo system package. The Aerocharger’s lag-free boost is apparent, either when drag racing in the desert or rock crawling at high elevation: zero lag boost means instant power for your engine, right on top of your stock power band. for all rzr 800, rzr s 800, & rzr xp 900 models 2008 and up. OPERATING SPECS BOOST FUELING 5.5 psi 91 Octane 7-9 psi 100 Octane 8 psi E85 10 psi 110 Octane The Aerocharger is fed by a heavy-duty Donaldson Air Filter. This is the same filter used in mining and industrial machinery, and is integrated into the Aerocharger system to provide full-volume air flow even in extremely dusty environments. Coolant System A secondary radiator system provides coolant for the intercooler. A custom radiator sits next to the stock radiator at the front of the vehicle. Coolant is circulated by a provided automotive-grade Bosch water pump. Fuel Controller Custom Headers Pre-tuned fuel controller comes loaded with the maps your RZR needs to run right, the first time and every time. Automatically compensates for elevation and has fine-tune adjustability features. Headers are durable TIG welded stainless steel, which is then heat wrapped to help maintain thermal energy and lower engine compartment temperatures. Race Clutching The entire system fits under the stock paneling for the stealthiest and cleanest appearance. Intercooled Turbo Airbox A Custom Race Helix and Primary Spring creates smoother shifting and less aggressive engine breaking during backshift, resulting in a much smoother ride. www.AEROCHARGER.com Full Under-Bed Install The robust design of the Airbox allows for the best air flow from the turbo, and includes an integrated Airto-Water Intercooler for a cool, dense air charge. +1-913-829-3400 [email protected] E85 Conversion Setup E85 Fuel is commonly available at many gas stations, and will permit higher boost levels in your Aerocharged RZR. An E85 setup consists of larger fuel injectors and an alternate fuel map. 402 NEW CENTURY PARKWAY. NEW CENTURY KS 66031 Donaldson Air Filter AEROCHARGER UTV SYSTEMS Can-Am Maverick The Aerocharger is fed by a heavy-duty Donaldson Air Filter. This is the same filter used in mining and industrial machinery, and is integrated into the Aerocharger system to provide fullvolume air flow even in extremely dusty environments. Fuel Controller Pre-tuned fuel controller comes loaded with the maps your Maverick needs to run right, the first time and every time. Automatically compensates for elevation and has fine-tune adjustability features. Our cooperative relationship with BRP and Rotax continues with the production of the new Can-Am Aerocharger turbo system. Aerocharger’s leading presence in the UTV/Side-by-Side performance market has made us the obvious choice for new Maverick owners who are looking for the most effective turbo system available. The best 02 Gauge on the market. Features multi-color LED indicators for quick & easy reference while speeding down the trail. Boost Gauge Blow-Off Valve Both gauges mount directly to the RZR’s dash plastics for the most-stock appearance. Industry exclusive BOV made in-house at Aerocharger. Different spring preloads match the factory vacuum levels for improved performance. Hood Scoop A custom molded Hood Scoop installs into the stock hood plastic to force air through the intercooler core. Installs easily with provided templates. Exhaust Pushing the boundaries Innovate O2 Gauge A flow-through design provides exhaust output with the least possible backpressure, and remains noise-compliant with U.S.A. Forest Service noise regulations. Because 100% of exhaust gases pass through the Aerocharger, no spark arrestor is required on this muffler. Custom Headers Headers are durable TIG welded stainless steel, which is then heat wrapped to help maintain thermal energy and lower engine compartment temperatures. Clutching Air-to-Air Intercooler A clutch weight setup is provided for best operation under turbocharged conditions, and includes Aerocharger recommendations for your configuration based on boost and altitude. www.AEROCHARGER.com +1-913-829-3400 Durable intercooler assembly features a cast intake for the most efficient flow with low pressure drop. Works with a provided hood scoop, which forces air through the intercooler core for a cooler air charge. [email protected] 402 NEW CENTURY PARKWAY. NEW CENTURY KS 66031 AEROCHARGER MOTORCYCLE SYSTEMS HarleyDavidson Blow-Off Valve Fuel Controller Industry exclusive BOV made in-house at Aerocharger. Different spring pre-loads match the factory vacuum levels for improved performance. Innovate O2 Gauge Pre-tuned fuel controller comes loaded with the maps your Harley needs to run right, the first time and every time. Automatically compensates for elevation and has fine-tune adjustability features. The best 02 Gauge on the market. Features multi-color LED indicators for quick & easy reference while speeding down the road. Boost Gauge Both gauges can be mounted to the handlebars or directly to the fairing dashboard for the most-stock appearance. 100% H-D PEDIGREE Aerocharger has a legendary history with Harley-Davidson. From 1994 to 2001, the best-selling turbo for Harley-Davidson motorcycles was the Aerocharger. Because of the advanced technology and uncomplicated install, it became a massively popular system for riders that wanted more power from their large EVO engines. Harley-Davidson made an attempt to partner with Aerocharger as the officially selected turbo for a factory turbo motorcycle. Unfortunately the deal was not able to be completed and the project never saw the light of day. But now due to popular request, Aerocharger has returned to the Harley-Davidson performance industry as an aftermarket manufacturer. Featuring the updated 53 series Aerocharger and refined tuning for modern EFI Big Twin engines, the turbo system intended for Harley is finally available. FOR ALL FL-SERIES TOURING MODELS 2008 AND UP. OPERATING SPECS BOOST FUELING 7 psi 91 Octane 8 psi 93 Octane Header Pipes Custom header pipes are designed to perfectly replace your stock headers, and are heat wrapped to transfer full thermal energy to the Aerocharger. Exhaust Exhaust provides an authentic exhaust note. Exhaust upgrade options are available, including the optional 4” exhaust pictured here. Customizability DIY Install Tons of chrome? Murdered out? We’ve got a full line of finish options, so no matter what, the Aerocharger H-D turbo system will look right on your bike. Rear Fitment Turbo Airbox The Aerocharger is mounted at the rear of the bike. This location was selected to create a superior flow path, which translates to a lower pressure drop and additional horsepower. This placement also gives the system a covert appearance and leaves the passenger plenty of room to ride comfortably. www.AEROCHARGER.com We know how Harley riders operate - this kit was designed so it could be installed in an alley or backyard, in just a few hours, with ordinary garage tools. Billet CNC-machined Turbo Airbox follows the lines of the motorcycle for a clean OEM appearance. It is ceramic coated for additional resilience, and features a customizable badge for logos,club insignias or other graphics. +1-913-829-3400 [email protected] Air-to-Air Intercooler An Air-to-Air Intercooler upgrade is available for a consistent air charge temperature drop. This intercooler is highly effective for its small size, and is tucked out of the way near the left passenger rider peg. 402 NEW CENTURY PARKWAY. NEW CENTURY KS 66031 AEROCHARGER SNOWMOBILE SYSTEMS AEROCHARGER MOTORCYCLE SYSTEMS Arctic Cat M8 & F8 Can-Am Spyder RS Models The Aerocharger was a perfect fit for Can-Am Spyder applications. Where the Spyder lacks in power, the Aerocharger creates huge performance gains and provides lag-free boost with minimal modification and zero engine mods. With the Aerocharger Spyder turbo system, Spyder riders can reliably expect 140 hp at the wheel, with an improved torque curve and an abundance of top-end power for all riding styles. Can-Am Spyder For Spyder RS Models 2008-2012 Aerocharger turbo systems are available for all Arctic Cat ProClimb 2-stroke snowmobiles 2012 and up, and include an optional Air-to-Water Intercooler for a consistent charge temperature drop. Aerochargers have been very popular options for Arctic Cat racing setups. Many top riders have ran Aerocharged Cats on the RMSHA circuit, including Nate Zollinger with ZBroz/ Exit Suspension out of Logan, UT. Let Aerocharger help you get to the top faster with an Arctic Cat ProClimb turbo system this season. For Arctic Cat M800 & F800 Models 2012 and up. Arctic Cat ProClimb PARTS & SERVICE Aerocharger has replacement parts and components for past and present turbo systems. We also have a full range of products such as boost springs, turbo oil, shims and clips, and other consumable parts that might require replacing. Contact us for availability. Aerochargers are extremely well built and durable. Repairs are rare because of this, but occasionally they become necessary. Aerocharger offers a 50% off discount from retail pricing for all service to the Aerocharger unit, if originally purchased from Aerocharger as part of a complete kit package. The warranty discount is valid for 3 years from date of purchase. Visit www.AEROCHARGER.com for repair pricing and service information. ACCESSORIES Aerocharger has stuff for sale with the famous red turbine logo on it, and everyone knows that an Aerocharger t-shirt is good for a few extra HP. Pick up some official Aerocharger branded gear and let the world know how you’re beating the competition. Check www.AEROCHARGER.com for the full list. We’ve got for sale: • T-Shirts • Hats & Beanies • Garage Banners • Stickers • Tunnel Wraps • and MORE! www.AEROCHARGER.com +1-913-829-3400 [email protected] 402 NEW CENTURY PARKWAY. NEW CENTURY KS 66031 R 402 New Century Parkway New Century, KS 66031 www.AEROCHARGER.com +1-913-829-3400
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