Yamaha Nyrto Turbo

Transcription

Yamaha Nyrto Turbo

Yamaha Nyrto Turbo
Installation Instructions
Picture from www.yamaha‐motor.com BoonDocker Nytro Turbo
Step 1: Turbo Mounting Bracket
A. Remove stock header and heat shield.
B. Bolt turbo header in place using only two
bolts.
C. Bolt turbo in place.
D. Position turbo mount, and tunnel block-off
plate and, mark.
E. Remove turbo and header.
F. Drill 3/16” holes, and rivet turbo mount and
block-off plate in place.
Revised 10/02/08 Yamaha Nytro Race Gas Turbo Installation instructions Page 2 www.boondockers.com............................BoonDocker..........................................877‐522‐7805 BoonDocker Nytro Turbo
Step 2: Install Header and Turbo
A. Install header using 6 stock header bolts and
gasket.
B. Bolt turbo to header using 4, 5/16”x1” bolts
and lock nuts.
C. Fasten turbo support brackets together using rubber mount and lock nuts.
(Note: Do not use nylon lock nuts here.)
Step 3: Install Oil Return Hose
A. Fasten oil hose to drain at bottom of turbo.
C. Remove small plastic plug from mag cover.
B. Cover oil return hose with 6” heat insulator.
D. Install 90° 1/4” npt x 3/8” barb fitting.
E. Route oil return hose from turbo to mag cover.
Step 4: Install Turbo Oil Inlet Hose
A. Remove 8 mm bolt from cylinder block,
located on mag side near throttle body.
B. Install 8mm x 4AN fitting and brass
washer into cylinder block.
C. Route ¼” push-lock hose from cylinder head to turbo using two 90° 4 AN x 1/4” barb fitting.
D. Shield oil hose at turbo with 6” insulated heat shield.
Step 5: Install Exhaust Outlet Pipe
A. Using a cutting tool, enlarge exhaust hole in
tunnel for exhaust outlet pipe.
B. Bolt outlet pipe to turbo using 4- 8mm x
25mm bolts, 1- 8mm x 40 mm stud and nut
Step 6: Install Muffler
A. Install exhaust intermediate pipe.
B. Slide muffler in to intermediate pipe.
C. Bolt muffler bracket in place using three 1/4”
bolts, nuts and lock washers.
D. Bolt muffler to muffler bracket using clamp
and 3/8” bolt and nut.
A.
Step7: Remove Air Box and Throttle Bodies
A. Remove steering post.
B. Remove air box.
C. Remove radiator shroud.
D. Remove throttle bodies.
E. Reroute harness, and fasten to fan support
with factory zip-ties.
Step 8: Replace Radiator Brackets
A. Replace radiator brackets.
B. Relocate reverse beeper.
Step 9: Install Battery Box
A. Relocate relay bracket.
New location B. Remove and omit overflow hose clips.
Old location
C. Install battery box using 1- ¼” bolt and lock nut, 2- 3/16” rivets and 2- rubber mounts
Step 10: Install Boost Lines to Throttle Bodies
A. Remove vacuum port plugs and install boost lines and “T”s to Throttle bodies.
Throttle Body Boost Line and “T” Diagram Boost Ref. to Transducer/ BOV PTO Side B. Secure all boost and vacuum lines to throttle
bodys using zip-ties.
C. Install BD Control Box injector harness,
(see control box instructions).
Step 11: Install Throttle Bodies
A. Rotate fuel rail inlet 180°
B. Reinstall throttle bodies
C. Install machine rings on throttle bodies
D. Install control box injector harness (refer to
BD control box instructions)
Remove screws Rotate to this position Step 12: Install Turbo Coolant Hoses
A. Attach blue coolant hoses to turbo.
B. Shield coolant hoses at turbo with 6”
insulated heat shields.
C. Connect one coolant hose to throttle body.
D. Connect the remaining coolant hose to stock
throttle body coolant hose using barbed
coupler.
Step 13: Install Upper Steering Post Mounts
A. Bolt upper steering post mounts in place, using 5/16x2¾” bolt, 2 washers, lock nut, and stock
steering spacer from lower steering block.
Drill Here Stock Spacer
B. Drill 4 holes for the 4-5/16”x1½” cartage
bolts and lock nuts
C. Install 4-5/16”x1½” cartage bolts and
washers lock nuts, with nuts towards the
engine.
Step 14: Adjust Steering Drag Link
A.
B.
C.
D.
E.
Set steering riser block in place.
Install steering post, using stock bolts and spacers at upper mount.
Install machine nuts, and BD support at bottom mount, omit stock spacers here.
Adjust drag link so handle bars are straight with skis.
Once draglink is adjusted, remove steering shaft.
Adjust Draglink here Step 15: Install Battery
A. Place battery in battery box, and secure in place with rubber strap.
B. Route positive cable through hole in frame.
C. Use 1” piece of 5/16” hose, and 2 tip ties to protect cable from rubbing on the frame.
Step 16: Install Negative Battery Cable
A. Cut smaller black wire on negative cable.
B. Lengthen wire, using 30” piece of 12 gauge
black wire, and 2 heat shrink butt connectors.
C. Cover edge of battery box, using 2” piece of
1/4” hose.
D. Connect battery cable to battery, and white
connector.
Step 17: Install Intercooler
A. Install turn buckle assembly to oil cooler bolt.
B. Install intercooler to throttle bodies, fasten in
place with turn buckle assembly.
C. Connect turbo charger to intercooler, with 7” black silicone hose and 2 clamps.
Step 18: Assemble Fuel Rail
A. Install fuel pressure regulator to fuel rail using 1/8”x1/4” npt male fitting
B. Install fuel pressure regulator return (1/8” npt 45° & 1/8”npt x 5/16” barb fittings)
Pres. Adj. Boost Ref.
Fuel Inlet Fuel Return
Note: Use thread‐sealant at npt connections
C. Install 3 auxiliary injectors into fuel rail
Step 19: Install BOV and Fuel Rail
A. Install BOV (blow-off valve) to intercooler.
B. Install fuel rail to intercooler, adjust position
of fuel regulator to fit intercooler and cassis,
(use 5/16”x1/2” bolts to fasten fuel in place
in place).
Step 20: Bridge Fuel Rails
A. Install 1/4”npt x 5/16” barb “L” fitting to fuel
rail.
B. Install 5/16”x6” fuel injection (blue liner)
hose between “L” fitting and stock fuel inlet.
Note: Use thread‐sealant at npt connection
Step 21: Install Fuel Pump
A. Install fuel pump bracket, using stock battery
bracket bolt, and threaded mount.
B. Install fuel pump to bracket, using #32 hose
clamps, with rubber liners supplied with
pump.
C. Connect fuel pump outlet to fuel rail, using
5/16”x10” fuel injection (blue liner) hose,
D. Cut stock fuel pump power harness, use 2
small crimp on eyelets to connect to pump
Step22: Mount Transducer
A. Connect 1/8”npt x 1/8” brass “T” fitting to transducer.
B. Mount transducer, and bracket to coolant overflow bottle, using stock bolt.
C. Install auxiliary injector/transducer harness (see BD control box instructions)
Note: Use thread‐sealant at npt connection
Step 23: Install Boost Reference
A.
B.
C.
D.
Connect boost reference hose from throttle bodies, to fuel pressure regulator.
Cut boost reference hose, between throttle bodies, and fuel regulator, insert transducer.
Cut boost reference hose, between throttle bodies, and transducer, insert 1/8”x1/8”x3/16” fitting.
Connect 3/16” hose, from 1/8”x1/8”x3/16” fitting to BOV.
E. Secure all hoses to fittings with zip-ties.
Transducer Throttle Bodies Fuel Reg. B.O.V.
Blow‐off Valve
Fuel Pressure Regulator
Transducer
Step 24: Install Boos Controller
A. Mount boost controller to frame, using self
tapping screw.
B. Connect 3/16” hose from turbo housing
fitting, to inlet on boost controller.
C. Connect 3/16” hose from outlet of boost
controller, to waste gate actuator.
D. Secure hose connections using zip-ties.
Turbo Housing fitting
Waste Gate Actuator
Step 25: Install Snorkel Ari Filter
A. Trim rubber boot to position snorkel air
filter.
B. Install snorkel filter and secure with
hose clamps.
Step 26: Install Fuel Gauge Resister
A. Locate and cut green 2 wire connector from
stock fuel tank leaving 2” of wire
B. Strip wire ends and remove green wire from
connector
D. Insulate resister, and wires with shrink tube.
E. Reinstall green wire to connector.
C. Solder resister in place between the green and
black wires
F. Wrap the 2 wires together with another
shrink tube, and plug connector into stock
harness.
Step 27: Tape and Drill Fuel Tank
A. Apply reflective heat tape to under side of
fuel tank
B. Drill ½’ hole in flat surface at lower mag.
side of fuel tank for fuel pick up
Fuel Pick up C. Drill ½” hole in upper mag. side of fuel
tank for fuel return
D. Drill 21/64” hole at top of tank for vent
Fuel Return 2 Vent
E. Tap vent hole at top of tank to 1/8” NPT
F. Clean tank of all debit
Step 28: Install Fuel Tank Fittings
A. Assemble fuel pick up hose using clear hose, pick up screen, and push-in tank fitting.
Push in Tank Fitting Pick up Screen B. Install fuel pick up hose assembly, into fuel
tank pick up hole,
C. Install push-in tank fitting, into fuel tank
return hole.
D. Install brass barb fitting into taped vent hole.
Step 29: Mount Fuel Tank
A. Drill (4) 1/4” holes in steering hoop, for
rubber tank mounts.
B. Install (4) rubber mounts
C. Install fuel tank and bolt in place
Step 30: Install Fuel Hose
A. Install 5/16” rubber fuel hose, from fuel tank
pick up fitting, to fuel pump inlet.
B. Install 5/16” rubber fuel hose, from fuel
pressure regulator, to fuel tank return fitting.
C. Connect stock vent hose, to fuel tank vent.
Step 31: Finishing Up
A. Install BD control box (see control box instructions).
B. Fill fuel tank, with race fuel.
C. Adjust idling fuel pressure to 45 psi
D. Reinstall seat, headlight assembly, side panels, and hood use stock radiator shroud screws to
attach hood to fuel tank.
Revised 10/02/08 Yamaha Nytro Race Gas Turbo Installation instructions Page 20 www.boondockers.com............................BoonDocker..........................................877‐522‐7805

Yamaha Nyrto Turbo

Transcription

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