installation manual

Transcription

installation manual

AEROCHARGER TURBO SYSTEM
INSTALLATION MANUAL
SKI-DOO/LYNX E-TEC 600 & 800
Version 2.4
R
INTRODUCTION
Congratulations on your purchase of an
Aerocharger Turbo system for Ski-Doo and Lynx
E-TEC Snowmobiles!
You now own the most powerful, reliable, and technologically
advanced turbo system in the world. With your new turbo system
installed, you will experience substantial performance gains. Our
unique system combines VATN technology with our frictionless,
non-flooded ceramic ball bearing system, which provides zero lag
performance.
This system is proudly made and assembled in the USA by Aerocharger LLC.
CONTENTS
Warnings and Disclaimers........................................................................................ i
I. Initial Disassembly..................................................................................................1
II. Air plenum RemovaL............................................................................................3
III. Gas Tank Removal...............................................................................................5
IV. Muffler Removal...................................................................................................7
V. Airbox Removal.....................................................................................................8
VI. Install Reed Petals................................................................................................9
VII. Install the Air Plenum..................................................................................... 12
IX. install the Air/Snow Intercooler...................................................................... 13
X. Aerocharger Stinger Kit..................................................................................... 15
XI. Aerocharger Installation................................................................................... 19
XII. Charge Tube Installation................................................................................. 22
XIII. Fuel Line Installation..................................................................................... 23
XIV. Electronics and Boost Lines.......................................................................... 24
XV. Aerocommander Installation.......................................................................... 25
XVI. Gauge Installation.......................................................................................... 27
XVII. Rave Valve Installation................................................................................. 30
XVIII. Reinstall the gas tank.................................................................................. 31
XIX. Reinstall Hood................................................................................................ 33
XX. Venting.............................................................................................................. 35
XXI. Calibrate the AFR Gauge............................................................................... 36
XXII. Completing the Install................................................................................. 36
Appendix.................................................................................................................. 37
A. Fueling...................................................................................................... 37
B. Clutching................................................................................................... 37
C. Turbo Reeds............................................................................................. 38
D. Aerocharger Maintenance ..................................................................... 38
E. AFR Gauge Guidelines............................................................................ 38
F. Aerocommander Fuel Controller........................................................... 39
G. Innovate MTX-L AFR Gauge Error Codes.......................................... 40
H. Aerocommander Wiring Harness......................................................... 41
i | E-TEC 600 & 800 Turbo System Installation Manual
WARNINGS AND DISCLAIMERS
Any aftermarket power-adding product can be dangerous to a vehicle if
not used as directed. Aerocharger Turbo Systems are properly engineered,
manufactured with high-quality components, and heavily tested to ensure best
possible reliability. However, many factors that are out of our control, such as
installation errors or misuse, can potentially cause damage. When properly
installed and configured, this system should outlast the life of the vehicle.
Please note the following warnings, carefully follow all instructions, and do not
hesitate to contact an Aerocharger tech if you are unclear about any guidelines
listed here.
INSTALLATION WARNING
If you are uncomfortable performing any installation procedure outlined
in this manual, please consult a trained professional at a qualified performance
shop. If you are performing the installation of this system yourself, we
recommend reading the entire manual before beginning the installation. We
also suggest that you review your progress after each section to ensure that
everything has been correctly installed.
MODIFICATION WARNING
This system is designed for use on a stock Ski-Doo/Lynx E-TEC with an
undamaged, well-maintained engine. If your snowmobile is modified, consult
with Aerocharger before proceeding.
Aerocharger is not responsible for ECU tuning and programming for
snowmobiles that have been previously modified before the installation
of this turbo system.
ENGINE BREAK-IN WARNING
Installing turbo systems on brand-new vehicles is not recommended.
New engines require a specific break-in procedure that does not factor in
extra stress from forced induction. If your vehicle is brand new, consult
your local dealership and owner’s manual to determine the proper break-in
procedure before continuing with this installation. Failure to do so can result
in significant engine damage.
Aerocharger Turbo Systems | ii
WARNINGS AND DISCLAIMERS, CONT’D
MINIMUM OCTANE WARNING:
For best performance and reliability, always use the minimum
acceptable octane for your riding elevation and boost setting. See Appendix
B for recommended octane. Always listen for signs of detonation. IF
DETONATION SHOULD OCCUR, OR IF YOU THINK YOU COULD
BE HEARING DETONATION, DECREASE THROTTLE IMMEDIATELY
and consult an Aerocharger technician. If the system is installed, configured,
and operated correctly, detonation will not be an issue. Please note that
inconsistencies on stock engines and parts are possible on any new vehicle
from an OEM.
INTERNATIONAL OCTANE: Fuels are described in this manual using the
AKI octane rating system commonly used in North America (RON+MON/2).
Fuels that are sold in Europe and other countries generally use the RON
rating system. If you are located outside of North America, be sure to use the
equivalent octane that is available in your region.
IMPORTANT NOTES
Read and understand all safety and technical precautions in this manual
before proceeding. Failure to comply with the instructions in this manual
could result in personal injury, property damage, voided warranties, and
inconsistent or poor performance from the turbocharger system. Contact
Aerocharger with any questions or concerns.
DO NOT hit the rev limiter. This will cause detonation and damage the
engine.
DO NOT let any debris (hard or soft) enter air intakes or exhaust ports during
installation of this turbo kit.
DO NOT use any silicone sealants except as directed in this manual. Silicone
sealants can result in Foreign Object Damage to the turbo. THIS WILL VOID
YOUR WARRANTY.
AEROCHARGER WILL NOT BE HELD RESPONSIBLE
FOR DAMAGE TO THE VEHICLE’S POWERTRAIN.
1 | E-TEC 600 & 800 Turbo System Installation Manual
Aerocharger Turbo Systems | 2
I. INITIAL DISASSEMBLY
1.1 Remove the seat and plastic body panels on the left and right sides.
1.5 Use a screwdriver to unclip the gauge
1.6 Disconnect the Air temperature sensor on
cluster from the hood. Disconnect the main
electrical plugs from the back of the gauge cluster.
the velocity tube.
1.8 Remove the bolts that hold the plastic gas
1.9 Unplug the handwarmer and tether
1.7 Remove the hood and set aside.
1.2 Unscrew 2 Torx bolts behind the gauge cluster, and 2 Torx bolts on both sides of the hood.
tank panel onto the gas tank.
1.3 Unstrap the Velcro that secures the hood to 1.4 Use a flathead screwdriver to loosen the
the chassis. (For 2013 and earlier models only)
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velocity tube on the clutch side that connects the
two plenums together.
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switches on the gas tank plastics.
1.10 Remove the gas cap
filler ring. Pull the plastic gas
tank panel off the sled.
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II. AIR PLENUM REMOVAL
2.5
2.6 Remove the screws under the snow
Detach the snow deflector from the
headlight assembly.
2.1 Remove the black plastic plate from
deflector. Unplug the electrical connectors,
then detach the gauge cluster from the headlight
assembly.
2.2
Unscrew the 2 bolts under each black
plastic plate.
the sides of the hood with a flathead screwdriver.
2.7
Remove the intake vents from the side of
the headlight assembly. There are 2 screws at the
bottom of each vent.
2.3
Remove the 2 bolts on the underside of the
hood, toward the front. Unplug the small flexible
tube from the ECM. The hood panel can now be
removed from the vehicle.
2.8 Remove the 2 bolts holding the headlights
2.4
The headlights, gauge cluster, and air
plenum will now separate from the hood plastic.
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on. The headlights and glovebox will now detach
from the stock air plenum.
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III. GAS TANK REMOVAL
3.1 Unbolt the gas tank. There are two 13mm
nuts on either side of the seat, two 10mm bolts at
the handle bars, and two 10mm bolts connecting
the support members.
Two 10mm bolts connect the frame members running along
the gas tank to the neck of the handlebars.
Two additional vertical support members are attached at the
neck of the handlebars with two 10mm bolts.
3.2 Disconnect the gas tank vent line.
3.3 Disconnect the fuel lines and electrical
connectors from the fuel pump assembly.
Loosen all four 10mm bolts to loosen the frame
members from the handlebar neck.
Halfway down on both
sides of the gas tank are
two 13mm nuts covered
by panels. Pull on the
panels to disconnect
them
Use a 13mm ratchet to remove nuts from the
support members on both sides of the gas tank.
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3.4 Slide the fuel tank away from the airbox.
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IV. MUFFLER REMOVAL
4.1 Disconnect the rear muffler spring
V. AIRBOX REMOVAL
4.2 Disconnect the two spring tabs connecting
the muffler to the exhaust pipe.
4.3
Unscrew the temperature sensor
with a 17mm wrench and tuck it out of the
way. Caution: Sensor is fragile.
5.1 Pry up the retainers with a flathead screwdriver, and remove the intake air
temperature sensor from the air box tube. Leave the wiring plugged in and set aside.
5.2 Loosen the two hose clamps holding the
airbox onto the throttle bodies with a flathead
screwdriver.
4.4 Disconnect the front muffler spring.
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5.3 Remove the airbox.
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VI. INSTALL REED PETALS
It is necessary to displace the secondary clutch/ jackshaft to access the reed cage, and at
this time it will be convenient to adjust the clutching on the snowmobile - refer to the
clutching section in Appendix B.
6.3
Use a long flathead screwdriver to loosen
the hose clamps holding the throttle bodies onto
the reed boots. Remove the throttle bodies, but
do not disconnect the throttle cable.
6.4
Use an 8mm socket to remove the 12 bolts
holding the reed cage boots in place. The bolt
behind the jackshaft bearing support arm can be
removed with an 8mm wrench.
6.1 Using the clutch tool provided with the sled, open the secondary clutch and
remove the belt. Then use a 13mm wrench to remove the nut from the retainer bearing,
and a 10mm wrench to remove the nut attached to the brake cable bracket.
6.5 Inspect the inner reeds for wear or damage, 6.6 With the stock outer reeds removed, install
and replace if needed. Remove the reed cage and
unscrew the stock outer reeds. The outer reeds are
on the case side of the reed cage, and are retained
by a solid metal bar.
6.2 Use a 16mm socket and remove the bolt holding the chain gear to the jack shaft. Be careful not to
drop the inner washer into the chain case. Carefully drive out the jack shaft.
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the new turbo reeds that are included in this
system. These reeds have a concave side and a
convex side, and will seal when properly installed.
Install them with the concave side in - the notched
corner will be aligned with the upper right part
of the reed cage. If the reeds are not installed
correctly, this will cause poor throttle response.
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VII. INSTALL THE AIR PLENUM
6.7 Replace the bar and screws to secure the reed to the cage. Make sure to
apply a low strength thread locking fluid to the threads, such as Loctite 641.
7.1
Remove the throttle body screws and the vacuum plugs, which are no longer needed. It may be
necessary to loosen all screws on the throttle body to install the air plenum easier. Make sure to retighten them after the air plenum is installed.
7.2 Lubricate the turbo airbox o-rings using
the provided packet of silicone lubrication
7.4 Using the included longer screws, secure
the airbox to the throttle bodies.
6.8 Reinstall the reeds and boots onto the
engine.
6.9 Reattach the throttle bodies and tighten the
hose clamps.
6.10 At this time, the secondary CVT can be
reinstalled.
The holes on the air plenum support will line up
with the screws you removed from the throttle
bodies. (Non-Intercooled airbox only)
7.3 Push the turbo airbox onto the throttle
bodies. It is a very tight fit and will take significant
force to install - if necessary, heat the airbox
collars with a heat gun to expand the metal for
easier installation.
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7.5 Install the retaining spring onto the bottom
of the airbox, then hook it onto the tab on the
clutch shield.
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IX. INSTALL THE AIR/SNOW INTERCOOLER
NOTE: This section is for installation of the optional Air/Snow Intercooler upgrade. The Air/Snow
Intercooler uses snow and air from the track to cool the boost charge. The intercooler and airbox are a single
integrated component. Cover & protect all intakes from metal debris when installing this intercooler.
9.6 Install a bolt in the intercooler bracket
9.1 Remove the gas tank pad from the tunnel. 9.2 Using a drill and reciprocating saw, follow
Use the included cut template to mark the area on
the tunnel where the intercooler will be installed.
The template will fit against the tunnel heat
exchanger for proper alignment.
that attaches to the heat exchanger. (NOTE: Use
the shorter bolt for T3 models. The factory heat
exchanger is located further back, and there will be
less clearance.)
9.7 Mark the final position of the bracket and
remove the intercooler. Drill holes in the tunnel
to rivet on the intercooler bracket.
the marked outline and carefully cut out the
opening for the intercooler. Cut the opening
as accurately as possible - if the hole is too
large, there will not be enough metal for the
reinforcement bracket to secure to.
9.3 Remove this rivet on the heat exchanger.
9.8
Use the included truss head screws to
attach the front of the bracket. Make sure the
bracket lines up with the fitting marks, and then
flex the bracket down and rivet the back side.
9.4 Test-fit the reinforcement bracket. File
down any high spots, and make any other
necessary modifications for the frame to fit.
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9.5
Test-fit the intercooler. Loosen and raise
the throttle bodies and line up the intercooler.
Wedge the back of the intercooler into its bracket,
then lever it by pressing down on the front. It will
pop into the frame and onto the throttle bodies.
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9.9
With the bracket riveted on, re-install the
intercooler using the same procedure in Step 9.5.
When the gas tank is reinstalled, it will lock the
intercooler assembly firmly in the bracket and on
the throttle bodies .
9.10
Carefully clean away all metal debris. Make sure that no metal fragments can work into any
intake or exhaust ports. Failure to do so can cause damage to the turbo and engine.
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X. AEROCHARGER STINGER KIT
This optional mod replaces the stock stinger on the snowmobile’s expansion pipe with Aerocharger’s custom
stinger. The diameter on the custom stinger is larger, which reduces backpressure and increases flow
efficiency. This modification was developed by Aerocharger’s race team as a simple way to enhance throttle
response and horsepower.
NOTE: The Aerocharger Stinger Kit is optional, and is not required for the turbo system to be installed and
operated. Do not install this kit if you are uncomfortable cutting and welding the stock pipe. Incorrectly
modifying the pipe can result in fitment issues or damage the engine and turbo.
10.4
Deburr around the cut edge, inside and out. Clean the surface of the pipe
1/2” around the cut, so the new stinger will weld cleanly on.
10.1 With the pipe removed from the vehicle, 10.2 Measure and mark both lines 5” from the
draw lines to align the new stinger. Use a square
to mark two lines on opposite sides of the pipe,
running perpendicular to the stock stinger.
seat of the exhaust gasket. These marks will be
used to locate the new exhaust gasket seat.
10.5 Drop the stinger into the pipe from the
engine side, narrow end first. Pass it through the
pipe, and it will emerge from the cut edge lined up
in place.
10.6 If the pipe is old or has surface
corrosion, it may be necessary to grind off some of
the flange on the new stinger to seat properly.
10.7 Pull the stinger tightly
through the cut end of the pipe.
Use the marks and a square to
line up the stinger the same way
the original stinger was aligned.
10.3 With the location of the new stinger marked on the pipe, use a reciprocating saw to cut off the
stock stinger directly behind the weld.
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10.8
Once the stinger is located
according to the reference marks, use
a TIG welder to weld the stinger in
place. Be sure to tack it around the
circumference first so that it will not
pull or move during welding. A MIG
welder can also be used, but be sure to
carefully clean the pipe afterwards to
ensure that no MIG wire sticks inside.
10.12 The excess weld inside the pipe will need to be ground off to improve performance
and prevent damage to the turbo. Remove all burrs or MIG wire, and make sure the inside
surface of the stinger is smooth.
10.9
Locate the gasket seat ring using the 5”
reference mark from the original seat. DO NOT
measure from the end of the tube - the new stinger
will have the excess cut off the end after all the
welding is complete.
10.10
Measure the stock stinger to determin
how far back the spring tabs should be welded.
Mark the distance and orientation on the new
stinger.
10.13
The new stinger will be longer than
necessary and must be cut to the correct size. Use
the gasket to determine how much length needs to
be cut off. Use a reciprocating saw to cut it to the
correct size, and deburr all edges.
10.11
10.14
Make a final check that all inside
welds are smooth and free of burrs, and that
there are no chips, weld slag, MIG wire, dust or
debris remaining in the pipe. Thoroughly blow all
debris out the pipe with an air compressor before
reinstalling the pipe into the vehicle.
Weld on the new gasket seat and
spring tabs. The gasket seat is only welded on the
back side, providing a clean surface for the gasket
to seal against. Tack all around before welding
the full bead to make sure the ring doesn’t move
during welding.
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XI. AEROCHARGER INSTALLATION
11.5 Place the turbo heat shield with exhaust wrap onto the turbine housing of the Aerocharger.
11.1 Use the provided cover and rivets to seal 11.2 Use the included pattern to mark the
the factory exhaust opening.
location of the new exhaust hole. The template
includes labeled markings for both XP and XM
models - only use the one that pertains to the
correct sled.
Mig wire from the factory was found in this stock
expansion pipe. It must be removed or it will get
caught in the turbo.
11.6 Loosely bolt the turbocharger onto the cradle. Then set the turbo and cradle assembly into
position on the vehicle.
11.7 Re-use the exhaust
11.3
Use a 2.5” hole saw to cut a new
exhaust opening according to the template. Use
a deburring tool or sand paper to clean up any
rough edges.
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springs to attach the turbo flange
brackets to the stinger on the
expansion pipe.
11.4
Inspect the inside of the expansion pipe
(stock or modified) for any welding debris, and
grind off any material that might come loose and
go through the turbo. Blow out any debris after
grinding with an air compressor.
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11.8 Loosely bolt the turbo cradle to the
frame. There are 8 holes, but only 4 are required
for XM and XP models.
11.9 Make sure the Aerocharger is positioned
so it does not touch the chain case or plastic side
panel, and the ball joints are as straight as possible.
11.12 Apply thread-locking fluid to the
11.13 After oil has been added to the turbo,
turbo oil-fill plug, and torque to 35 in-lbs.
press on and tighten the dome filter over the
compressor inlet on the turbo.
XII. CHARGE TUBE INSTALLATION
11.10 Carefully install the stock temperature
sensor and wideband o2 sensor into their bungs
on the turbo muffler. Be sure to apply anti-seize
fluid to the threads.
12.1
Route the silicone charge tube from the
turbocharger to the airbox.
12.2
Attach the end of the charge tube with
the Blow-Off Valve to the top of the turbo airbox.
11.11 Remove the brass pipe plug and fill
with 2 bottles of Aerocharger High-Speed Turbine
Oil.
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XIV. ELECTRONICS AND BOOST LINES
Refer to Appendix E for the Aerocommander Wiring Harness diagram.
14.1 The wiring harness uses the extra
fuse block on the oil tank to supply power to
Aerocharger electronics. Insert the power wire
into the vehicle’s open fuse block.
12.3 Route the charge tube around the vehicle behind the headlights and connect it to the
Aerocharger’s compressor outlet. Tighten the hose clamps.
14.2 Connect the ground to the factory
grounding bolt, located behind the mag-side
footwell.
NOTE: 2013 and newer Aerocommander units do
not need to connect to this harness for power, and
one of the female plugs will not be used.
XIII. FUEL LINE INSTALLATION
TO BLOW-OFF
VALVE
TO MANIFOLD
TO MANIFOLD
Left: Install the short legs of the fuel line between
the gas tank fuel line and the ECU.
Right: Screw the long leg of the fuel line onto the
fuel rail on the turbo airbox.
13.1 Route the fuel line directly in front of the ECU and behind the chassis members. Follow
14.3 Insert the provided fuse into the fuse
block, and route the wiring harness up to the
Aerocommander and AFR Gauge. Either plug will
work for both devices.
the most direct path possible, checking that the line will not rub anywhere and rupture. Connect as
shown above, and verify that all fittings are securely attached.
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14.4 Connect the pre-assembled solenoid
valve/pressure sensor line assembly to their labeled
locations: the fittings on the throttle bodies,
the AeroCommander, and the blow off valve.
Leave the exposed barb on the solenoid open to
atmospheric pressure. Secure the solenoid housing
and lines to the chassis away from any moving
parts, and avoid overtightening the lines.
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XV. AEROCOMMANDER INSTALLATION
Refer to Appendix E for the Aerocommander wiring Harness diagram. All connections are pre-labeled - run
the lines and install accordingly.
15.5 Connect the line labeled 12V POWER to 15.6 Attach the pressure sensor to the
15.1 Run the electrical harness through the
steering post and into the sled.
15.3 Connect the fuel injectors (MAG
INJECTOR and PTO INJECTOR) to their
matching plugs. Make sure each coil goes to the
correct cylinder - the MAG COIL to the MAG
cylinder, and PTO COIL to the PTO cylinder.
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15.2
Unplug the top ignition coil, and attach
the Aerocommander connector labeled MAG
COIL inline with this plug. Unplug the lower
ignition coil, then attach the Aerocommander
connector labeled PTO COIL inline.
the loose 3-pin plug located near the gauge cluster
connections. The female part of this pass-through
will plug into the sled, and the male end will be
your new accessory plug for factory options.
DO NOT plug this in-line with the similar 3-pin
plug that only has 2 wires connected to it.
connector labeled MAP.
15.7
Connect the AeroCommander to the
pressure sensor line attached to the solenoid
assembly labeled “Aerocommander”(16.5).
15.4 Follow the electrical harness from
the middle of the RAVE valves to the nearest
connector, which should be tied to the frame on
the PTO side. Disconnect this connector and
attach the Aerocommander connector labeled
RAVE POWER.
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XVI. GAUGE INSTALLATION
16.1
Remove the right hand side clip in the
panel that contains the DES key. Unscrew the DES
key switch.
16.4
Connect the boost line from the turbocharger to the boost gauge and install the boost gauge
into the panel. Then secure the gauges with the included U-Clamps to the plastic panel.
16.2
Use the provided template to cut holes in the stock panel for the new gauges. Clean up the
holes with a deburring tool or sandpaper. The holes might have to be filed slightly to improve clearance
on the gauge panel. Avoid cutting into the clip holes.
16.5 Remove the opposite panel to relocate the 16.6 Use a razor blade to cut a notch at the
DES switch. Use the included template to mark
where the hole will be located. Use a 7/8” drill bit
or hole saw to drill a hole in the panel.
16.3
Clip the panels back in and check to make sure the gauges fit in the sled. Then use the
included rivets to secure the panel in place.
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top so the switch will sit flush in the panel.
16.7
Screw the DES key
into the panel. Reinstall
the panel onto the sled.
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16.8 Connect the power plug on the AFR
Gauge to either of the open female power
receptacles on the Aerocharger wiring harness.
Both receptacles provide the same power output.
XVII. RAVE VALVE INSTALLATION
16.9 Connect the sensor plug on the AFR
Gauge to the sensor wire.
17.1 Cut the hose between the RAVE valves
and the factory RAVE solenoid, and install the
large barrel valve with attached t-fitting. Secure
with zip ties. DO NOT install the check valve
onto the new solenoid that is included with the
system.
17.2 Install the small disc shaped check
valve with attached t-fitting onto the line going
to the top of the factory RAVE solenoid. It will
be necessary to remove and cut roughly 1/2” off
of the spring. Use a clamp or zip tie to secure the
hose.
16.10 The two extra wires on the AFR Gauge 16.11 If not already installed, use a 7/8”
are for programming and data logging, and will
not be needed for a typical installation. Secure
these wires out of the way with zip ties.
NOTE: Refer to the Innovate MTX-L online user
manual for more information about this AFR
Gauge’s advanced features.
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wrench to install the AFR sensor into the bung
on the turbo muffler. Do not over-tighten, which
might damage the sensor. Connect the sensor to
the AFR gauge wire.
The sensor will need to be calibrated before
use - refer to Section 27 for this procedure after
completing the entire installation.
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XVIII. REINSTALL THE GAS TANK
18.1
Place the gas tank back on the sled. Connect the electrical and fuel lines at the front
of the gas tank.
The hose coming off the
front of the gas tank goes
back to the filter it was
originally connected to.
18.3 Reconnect the breather line at the top of
18.4 Reconnect the plug coming off the
the tank.
bottom of the tank.
18.5 Use a zip tie to reattach the wire at the
18.6 Slide the tank forward on the sled to get
Reconnect the electrical
connector on the fuel
pump housing.
bottom of the tank.
18.7
the chassis supports and gas tank over the studs on
both sides.
Line up the bolt holes at the neck, and
reinstall the bolts the same way they came off.
Torque to 124 in-lbs.
Use the factory hose clamp to reattach it
18.2 All fittings reconnect exactly like they were taken off.
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Press the quick disconnect fitting
onto the post coming out of the
front of the tank.
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18.8 Use the aluminum washer inserts that hold the plastic gs tank onto the frame stud. Torque the
bolts to 25 ft-lbs.
19.3 Attach the other included set of brackets 19.4 Place the hood panel on the sled. Attach
to the hood panels. Re-use hardware from the
stock Air Plenum to attach the brackets.
with 2 screws on each side. The attached brackets
will slip under the gas tank plastic mounting holes.
XIX. REINSTALL HOOD
19.5
Attach the headlight support adapter
to the headlight assembly using the included
Phillips- head screws.
19.1
Reassemble the headlights, gauge cluster,
and glove box. The glove box installs between
the gauge cluster and headlights, which hold it in
place. Screw the gauge cluster onto the headlight
assembly using the original bolts.
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19.2
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19.7
Place the headlight assembly back onto
the sled and attach the headlight support bracket
to the adapter on the headlight assembly. Reuse
the stock screws to attach it. Make sure that the
screws thread through the hood plastic supports
that are included in the turbo system.
Attach the vents onto the sides of the
headlight using the provided brackets. Snap the
vents into place and secure by reusing threaded
tabs and T27 screws.
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19.6
Zip-tie the headlight support bracket to
the chassis cross member..
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19.8
Adjust the headlight support
to ensure proper height. Tighten
the clamps and top screw when the
headlights are seated correctly.
XXI. CALIBRATE THE AFR GAUGE
21.1 The AFR gauge is connected and
XX. VENTING
A basic vent kit is included in this turbo system. Venting your snowmobile is strongly recommended in order
to lower engine compartment temperatures and keep out snow. It is not necessary to use all of the included
vents, but there must be sufficient venting to get air to the turbocharger. All Aerocharger vents include cutout patterns for the panels. These can be used with a hole saw set to quickly install the vents.
20.1 Use the provided template to drill
holes in the panel using standard hole saws.
The included template provides suggestions
for locating the holes, but they can be drilled
wherever desired. De-burr the plastic to keep
debris out of the turbo.
powered. Uninstall the o2 sensor from the
muffler and unplug it from the AFR gauge. Start
the sled.
21.2 The AFR Gauge will enter setup mode
and display an “E2” error message. Turn off the
sled and wait several moments for the vehicle to
completely power down.
21.3 Reconnect the AFR harness to the o2
sensor, but leave the sensor uninstalled in order to
calibrate it to open air.
21.4
Start the sled again. The gauge will now
display “Htr.” After 30 seconds, it will display
“Cal,” and then read “22.4” indicating it has been
calibrated to the atmosphere. The AFR calibration
procedure is complete, and the o2 sensor can now
be screwed back into the muffler.
XXII. COMPLETING THE INSTALL
22.1 Review the install. Verify that all
20.2
Thoroughly clean all dirt and grease
from the panel. Remove the backing paper from
the vent and adhere it firmly to the panel.
connections are tight, all loose lines are secured
with zip ties, and all panels are reattached
22.2 The turbo system has now been installed
22.3 If the vehicle’s CVT clutch has not yet
been adjusted for turbocharged use, this must
now be done. Refer to the clutching section in the
appendix for more information.
and the vehicle can be safely started.
IMPORTANT: DO NOT ride the snowmobile before
configuring the clutching. Stock clutching is insufficient for
forced-induction applications. INCORRECT CLUTCHING
CAN CAUSE SEVERE ENGINE DAMAGE.
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APPENDIX
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
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 # 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
• 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.
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.
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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.
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
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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.
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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
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• Digital versions of manuals and field
guides
• Detailed video of installations to refer
to during your install
• Up-to-date tips, tricks, and upgrades
E-TEC 600 & 800 AEROCHARGER TURBO SYSTEM
By Aerocharger, LLC
402 New Century Parkway
New Century, KS 66031
(913)829-3400
www.AEROCHARGER.com
SERIES
A E R O C H A R G E R

installation manual

Transcription

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