APPENDIX - Aerocharger.com

37 | E-TEC 600 & 800 Turbo System Installation Manual
APPENDIX
Aerocharger Turbo Systems | 38
C. TURBO REEDS
A. FUELING
A set of Turbo Reeds are provided to replace the
stock outer reeds. The traditional “double-stack
method” can also be used for forced-induction.
By stacking reeds with the halved outer reeds, the
opening action is not slowed and throttle response
stays snappy. The extra reed layer will add stiffness
to the reeds as they open to the fullest extent,
preventing them from striking the case.
DOUBLE-STACK METHOD:
1. Remove the old set of reeds and cut off half the
length of the petals with a razor blade.
2. Install the half-reeds on the outside of the
outer reeds on your new reed cage/petals.
When troubleshooting, always check the reeds for
chipping and wear. Worn reeds can cause many
symptoms of poor performance.
D. AEROCHARGER MAINTENANCE
Aerocharger boost springs are used to set the
boost pressure. Every Aerocharger is shipped
with a green 5 PSI spring already installed.
Available springs include:
5 PSI
GREEN
8 PSI
BLUE
ORANGE
6 PSI
GREEN
BLUE
BLUE
9 PSI
ORANGE
7 PSI
11+ PSI
PN # 66325
PISTON
PN # 66322
PN # 66333
Specialized oil for ultra-high rpm machinery.
Only use genuine Aerocharger Turbo Oil.
The wrong oil can lead to bearing failure.
DIAPHRAGM
PN # 66321
ADD 1 BOTTLE
FOR 53 SERIES
Oil is full at 1”
height (2.5 cm.)
PISTON SHIM
PN # 66342
Use red thread lock fluid on the threads
when replacing the fill plug and tighten
down securely .
SPRING SHIMS
PN # 66338
BOOST SPRING
PN # 66341
DUST SHIELD
VISIT AEROCHARGER.COM
TO SEE A VIDEO TUTORIAL
ABOUT ADJUSTING THE
AEROCHARGER’S BOOST
CONTROLLER TO AFFECT
TURBO RESPONSE
PN # 66340
ADD 2 BOTTLES
FOR 66 SERIES
Housing
PN # 66326
CONTROL ROD
PN # 66078
NOTE: NEVER attempt to disassemble
the main Aerocharger housings.
The bearing and vane systems
require specialized tools to take it
apart without damaging it. Contact
Aerocharger for all service and
repairs.
Adjusting the CVT clutch is critical for the turbo
system to function with full power and reliability.
A clutch setup is included with this system, and
includes ramps, weights, primary spring, helix,
and gearing. Aerocharger’s recommended
settings are included to offer a baseline setup for
the snowmobile. Additional configuration may
be necessary to fine-tune clutch performance to
specific riding areas and boost setups.
INTEGRATED BOOST CONTROLLER
The Integrated boost controller on the Aerocharger is a simple
mechanical actuator where pressure in a chamber pushes against a spring
to move the vanes. It can be easily disassembled to adjust the boost by
changing springs and/or shims. Manual & electronic boost controllers are
compatible with Aerocharger systems, but are not recommended.
E. AFR GAUGE GUIDELINES
•
•
Specialized OEM tools are required to installation
and adjustment of the vehicle’s clutching. If you
do not have the proper tools or experience to
adjust the clutching on your E-TEC, take the
vehicle to a qualified performance shop or dealer.
(913) 829-3400
HORIZONTAL ORIENTATION
Oil should be added if the
level is lower
1” (2.5 cm)
1/2” (1.3 cm)
than .5” (1.3
cm.)
DIAPHRAGM SHIM
PN # 66323
AEROCHARGER OIL
CHECKING OIL LEVEL
Remove the fill plug and
use a zip tie as a dip stick
to measure the oil level.
R E TA I N I N G C L I P
PN # 66328
CONTROLLER TOP
X1
X2
B. CLUTCHING
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Shims can be added
to the springs to
increase the boost in
increments of about .5
to . 75 PSI.
ALWAYS pay attention to the engine’s
performance, and carefully listen for signs
of detonation which could be an indication
that higher octane fuel is required. Contact
Aerocharger for additional recommendations.
PN # 66335
PN # 66337
CONTROLLER BONNET
Many factors play a role in octane requirements,
such as elevation, air density, temperature, and
tolerances specific to the motor. This Octane
Chart is intended to offer a rough guideline for
the octane levels that an Aerocharged sled will
require based on typical circumstances.
Aerochargers consume oil throughout their use. The
amount of oil consumed is very small, and the oil
level must only be checked once a year or every
30,000 miles. Aerocharger oil never has to be
changed - only added. There is no benefit to
changing the oil unless it has been contaminated
with a foreign substance, such as if the vehicle has
been underwater for a long time.
BOOST FITTING
JAM NUT
BLACK
SPRING SHIMS
OIL LEVELS
The Aerocharger is a sophisticated and highly efficient variable
vane turbocharger. Unlike conventional turbos, it does not
require oil pumps or lines. The Aerocharger will not need more
maintenance than any other turbo - this graphic contains
information for adjusting the Aerocharger to ensure best
performance.
BOOST SPRINGS
•
•
[email protected]
AFR numbers are most important to monitor when the engine is
under heavy load, such as heavy acceleration or climbing a hill.
Monitor your air/fuel ratio to ensure that it stays below 12.8 when
the engine is under heavy load.
The AFR will spike to very lean levels when decelerating. This is
normal.
Sensors should be periodically recalibrated. Always completely
remove the sensor from the pipe to get an accurate reading.
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(913) 829-3400
[email protected]
39 | E-TEC 600 & 800 Turbo System Installation Manual
Aerocharger Turbo Systems | 40
G. INNOVATE MTX-L AFR GAUGE ERROR CODES
F. AEROCOMMANDER FUEL CONTROLLER
There are 6 adjustable modes that can be used to fine-tune this system for personal preference and to specific
engine variances. The controller is preset for typical conditions, and further adjustment is usually not
necessary. If major adjustments on the fuel controller are required to resolve performance issues, this might
indicate a problem elsewhere in the system - contact an Aerocharger tech to review the install and setup.
FUEL CONTROLLER ADJUSTMENTS
The following modes are programming modes, and
are valid only while the controller is being adjustedthe controller will display differently while the
snowmobile is being ridden. Press the mode button
to scroll through the programming modes.
The first 3 modes are for fine-tune adjustments.
1. Green Mode: This mode controls how
much fuel is being added under low RPM
conditions. (0-4900 RPM). For cruising at low
RPM or riding downhill.
2. Yellow Mode: Controls how much fuel is
being added in the mid RPM range of the
powerband. (4900-6500 RPM). For typical
trail riding.
3. Red Mode: Controls how much fuel is being
added at the top of the RPM range. (6500Max RPM). For high speed cruise to wide open
throttle.
When the Blue light turns on while riding, it
indicates that the Aerocharger is making boost. The
following modes control fuel delivery while boosting:
4. Green and Blue: This is the fuel added when
the blue light first turns on and boost is
initially produced. This mode rarely needs
adjustment.
5. Yellow and Blue: The maximum fuel added
while under full boost. Adjust this mode if the
sled is lean or rich while at wide open throttle,
or at high load conditions under boost. This
mode is also useful for large changes in
elevation.
6. Red and Blue: This determines which psi the
Blue light turns on, and extra fuel is first added
to compensate for boost. Adjusting this mode
up will delay the initial fuel increase under
boost. This mode can be adjusted for crisper
engine response. NOTE: Read the warning below.
FUELING TIPS AND TRICKS
Here are several techniques for tuning with the
2. The Red and Blue mode can be adjusted to
Aerocommander. The fuel controller can be
create snappier throttle response for climbing
adjusted to fine-tune performance if desired, but the
hills. Adjusting this mode to the right will
default settings can be left alone for everyday riding.
reduce fuel in the midrange throttle band and
improve throttle response. 1. The Yellow/Blue mode is the most frequentlyWARNING: Sustained cruising while this
adjusted mode - 90% of all tuning can be
mode is set lean can cause damage to your
completed here. This mode controls fueling
engine. Always make sure this mode is set to
at wide open throttle under boost. If the sled
the default for all trail-riding.
is lean at wide open throttle, move the lights
to the right in yellow/blue mode to add more
fuel. Adjust this mode for large changes in
elevation (5000’ or more) or when setting the
Aerocharger for higher boost.
www.AEROCHARGER.com
(913) 829-3400
[email protected]
www.AEROCHARGER.com
(913) 829-3400
[email protected]
41 | E-TEC 600 & 800 Turbo System Installation Manual
H. AEROCOMMANDER WIRING HARNESS
MAG Secondary
Injector Plug
Visit us online at
www.AEROCHARGER.com for more
technical resources, such as:
Footwell Ground
Fuse Box Plug
PTO Secondary
Injector Plug
AeroCommander
Power Plug
AFR Gauge
Power Plug
MAG Coil Plugs
Main Plug
AeroCommander
PTO Coil Plugs
AEROCOMMANDER
WIRING HARNESS
SKI-DOO E-TEC
MAP Sensor
MAP Sensor
Plug
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RAVE Power
Plugs
(913) 829-3400
[email protected]
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