2011-12 Polaris RMK Pro-Ride NON

2011-12 Polaris RMK Pro-Ride
NON - INTERCOOLED
Turbo Kit Installation Instructions
To ensure proper break-in of the turbocharger it is required for the first two tanks of fuel to mix 91 octane premium fuel with
110 octane race fuel at a ratio not exceeding 30% race fuel. The 10% Ethanol plug on the machine should also be installed. It is
not recommeded to run premium pump fuel containing ethanol but if ethanol fuel cannot be avoided a higher ratio of race fuel
should be used.
Tools Required for install
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T-40 Torx wrench (located in stock toolkit)
10mm socket wrench
Flathead screwdriver
Spring puller
13mm socket
13mm wrench
Dykes
9/16” Wrench
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1. Remove hood, side panels, seat, gas tank, muffler and
airbox. Remove the rubber bumper from bottom of
muffler and save for later use. Remove the air temp
sensor from the airbox and zip-ty it to the machine
out of harms way.
2. Remove the fuel filter bracket from the stock airbox.
3. Grind the backside of the bracket flat.
4. Remove the stock oil tank.
5. Drill a 1/4” hole in the tab on the clutch cover.
6. Snap the fuel filter and fuel line into the bracket.
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7. Using the supplied 1/4” bolt and nut fasten the bracket to the backside of the clutch cover. Reinstall the oil
tank.
8. Use a punch to remove the center of each rivet then drill
out each of the five rivets holding the stock kickplate.
Remove the stock kick plate.
9. Using the supplied paper template on the back of
these instructions center punch the whole and cut
using a 2 – ¼” hole saw cut a hole in the tunnel.
10. Using a pair of pliers break off the chassis tab shown
in the image on the mag side of the chassis.
11. Remove the Velcro from the turbo oil pump and
install it on the bulkhead as shown in the image
12. Install the provided spring tab onto the chaincase reusing the stock bolt.
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13. Install the rubber bumper from the stock muffler
onto the bottom of the BoonDocker turbo oil tank
14. Hang the turbo oil tank assembly in the chassis by
situating the assembly so the lower pins sit in the
mounts and the upper hanger sits on the rubber
mount on the chassis.
15. Run a bead of high temp silicone around the ball
flange on the muffler where it connects to the turbo
outlet.
16. Install the muffler through the hole in the tunnel and
secure to the turbo outlet pipe using the supplied
four short springs.
17. Un-plug the throttle position sensor (TPS) on the PTO
end of the throttle body
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18. Plug the Control Box (CB) Transducer wiring harness
into the TPS and the stock TPS plug into the male TPS
plug on the CB harness.
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19. It is important to ensure that the CB harness is secured
correctly. Tuck the original TPS plug and harness in behind the TPS and secure with a cable tie. Secure the
CB harness to the original TPS cable with a cable tie.
Plug in the CB Injector harness to the auxilliary injectors and inline with the stock injector harness.
20. Loosen the throttle body adaptor rings. Push the throttle body adaptors onto the throttle bodies and tighten
the rings using the supplied spanner wrench. Connect
the auxiallary injectors to the Control Box fuel injection
harness.
21. Locate the stock fuel return line on the PTO side of
the frame (the line without the filter). Splice the new
throttle body adaptor fuel line into the stock fuel return line. Route the new fuel lines around the silicone
airbox towards the rear of the machine. Fasten the
connections using the provided #4 hose clamps.
22. Attach the molded silicone airbox to the throttle body
adaptors and secure using hose clamps.
23. Remove the stock coolant line that connects the
throttle bodies to the coolant bottle and discard.
Route the inside turbo coolant line from the turbo to
the coolant bottle.
24. Route the outside turbo coolant line to the throttle
bodies.
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25. Install the second set of hose clamps onto the silicone tubes. Before installing the intercooler install
the push-to-connect fitting (EBC) or boost transducer
(non-EBC) into the threaded fitting in the intercooler.
Then maneaver the intercooler into the silicone tubes.
26. Install the gasket between the turbo and inlet pipe.
Attach the exhaust inlet pipe to the turbo using the
supplied four bolts and nuts. Add another bead of
high temp silicone to the inlet pipe where it connects to the donut on the expansion chamber.
27. Attach the turbo inlet pipe to the expansion chamber
using the supplied four long springs.
28. Locate the factory harness behind clutch side shock
tower and underneath a velcro cover. Plug the supplied oil pump harness into the connector labeled
DC PWR, do not plug into a similar connector labeled
ECM PWR. Run the oil pump harness over the
engine and plug into the oil pump adaptor harness.
If running an EBC the oil pump will plug into the
EBC harness. Refer to the wiring diagrams for more
information.
29. If using the optional cold air intake follow steps 36-40.
If using the underhood mount intake, attach the air
intake elbow and filter to the turbo intake inlet and
secure using the supplied clamp then skip to step 41.
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30. Measure 2” from the top of the elbow and move the
hose clamp down to use as a cutting guide.
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31. Using a sharp knive and the clamp as a guide cut the
intake elbow to size.
32. Measure 1/2” back from the top vent as shown in
the image, drill a pilot hole.
33. Using a 3” hole saw cut a hole in the hood
34. Install the aluminum pipe on the intake eblow, secure
with hoseclamp. Install air filter onto pipe on outside
of the hood, secure with hoseclamp.
35. Fill turbo oil tank with the included 16oz bottle of
T2C turbo oil. BoonDocker also offers and recommends T2C Injector Oil for use in turbo applications.
36. Remove oil line from the top of the turbo and start
machine to verify oil is flowing to the turbo. Re-install
oil line and tighten using 9/16” wrench.
37. Reinstall hood, seat and sidepanels......RIDE!
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fax: 208-524-7381
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Turbo System Wiring Diagram - Non-Intercooled without EBC
EFI
TPS
Aux Injector
Aux Injector
Boost
Transducer
Temp Sensor
Transducer Harness
EFI Harness
Chassis Ground
sel
Handlebar Capture Button
Arrows represent
Stock Connectors
Turbo System Wiring Diagram
Intercooled with EBC
EFI
TPS
Aux Injector
Aux Injector
Fan Booster
DC PWR
Boost Solenoid
Temp Sensor
Turbo
Oil Pump
EFI Harness
DC PWR
EBC Harness
008
Push-to-Pass Button
Transducer
Harness
Chassis Ground
TPS pick-up
sel
Capture Button
(not included in kit) part#ACC-E009
Arrows represent
Stock Connectors
DEEPS SNOW EXHAUST
TUNNEL HOLE TEMPLATE
Cut out and use to find hole center
BoonDocker
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local: 208-542-4411
fax: 208-524-7381
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