2012 Arcc Cat M800 ProClimb
INTERCOOLED
Turbo Kit Installaon Instrucons
To ensure proper break-in of the turbocharger it is required for the rst two tanks of fuel to mix 91 octane premium fuel with
110 octane race fuel at a rao 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 rao of race fuel
should be used.
Tools Required for install
• Spring puller
• 3/16” drill bit and drill
• Philips head screwdriver
• Flat head screwdriver
• 8mm wrench and 8mm socket
• locking hose clamp
• Reciprocang saw
• 5-3/4” hole saw
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Addional informaon and updates on BoonDocker
products may be available on the following sites.
• www.boondockers.com
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1. Remove the side panels. Remove the six torx bolts
holding the hood. Two bolts are located underneath
the nose cone, two bolts in the shock tower and two
bolts holding the hood to the tank cowl. Un-hook the
instrument/headlight harness then remove the hood.
2. Remove the springs holding the expansion chamber to
the Y-pipe. Remove the spring holding the expansion
chamber to the chassis. Remove the springs holding the
silencer to the Y-pipe and chassis. Remove the temperature sensor from the expansion chamber. Remove the expansion chamber and silencer from the machine.
3. Remove the three rubber bumpers from the silencer.
These bumpers will be re-used later in the turbo installaon.
5. Un-hook the two connectors from the ECU and remove the ECU and cowl as an assembly.
4. Remove the ECU heatshield by removing the two
screws holding it to the chassis.
6. Using a 3/16” drill bit drill out the three rivets holding
the powervalve servo motor to the chassis.
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7. Remove the front chassis crossbar by removing the
nut and bolt on each end of the crossbar.
8. Loosen the hose clamps on the intake and engine side
of the throle bodies.
9. Remove the throle bodies from the boots. Remove
the coolant line from the PTO side of the throle bodies. Detach oil linkage ball ng and li the throle
bodies out of place.
11. Re-route the PTO side throle body coolant line under the engine on the MAG side of the chassis.
10. Remove the intake from the machine by pulling it
through the engine side of the chassis.
12. Remove the coolant line from the MAG side of the
throle bodies and re-route it under the engine so
that it exits in a similar locaon to the other coolant
line. These coolant lines will be re-used to cool the
turbocharger later in the installaon. No coolant will
be ran through the throle bodies using the turbo kit.
The charged air will heat the throle bodies.
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13. Re-aach the oil linkage, install the throle bodies
back on to the engine boots and ghten the clamps.
14. Remove the four screws holding the fuel rail to the
throle bodies. These screws are oen tough to remove so be careful to not strip them.
15. Remove the upper side panels from the hood center
secon by removing the four screws.
17. Flip over the hood and remove the inner nosecone.
16. Remove the four screws on the top side of the center
hood secon.
18. Remove the screws holding the metal gauge bracket
from the headlight cowl.
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19. Slide the headlight cowl forward out of the tabs on
the headlight.
20. Un-plug the gauge, key, 12v outlet and remove the
cowl from the hood.
21. Using a at headed screwdriver pry the factory air
temp sensor our of the intake behind the headlight.
This sensor will be re-used in the turbo kit so be careful not to damage it during removal.
23. Remove the two remaining screws on the topside of
the hood that hold the airbox together. Flip over the
hood and remove the airbox.
22. Remove the headlight by removing the four screws
holding it to the hood.
24. Remove the connector from stock temp sensor. Install the supplied resistor wire into the stock connector. Plug the connector back into the harness where
the stock temp sensor previously plugged in.
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25. Install the supplied connector onto the temp sensor.
26. Seal the temp sensor with silicone and aach the
temp sensor to the torque tubes using the supplied
screws.
27. Install either the 90 pust to connect or transducer into
the torque tubes. Kits equipped with an EBC come
with push to connect and without an EBC a pressure
transducer.
29. Install the keeper ange onto the torque tube and
secure it with the stock fasteners to the fuel rail.
28. Install the torque tube elbow onto the PTO side throttle body.
30. Move the MAG side torque tube into posion and attach it to the PTO side torque tube using the 3”x3” silicone tube. Aach the torque tube to the throle body
and secure using the keeper ange.
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31. Lubricate the upper and lower injector o-rings with
assembly lubricant and install the auxillary injectors
into the ngs on the torque tubes.
32. Install the fuel rails on to the auxilliary injectors with
the fuel line “T” on the mag side of the machine.
33. Locate the stock fuel line feeding the stock fuel rail.
Measure approximately 1-1/2” back from the fuel rail
and cut the fuel line.
35. Plug the Control Box injector harness into auxillary
injectors. Unplug the stock injector connectors and
plug the matching CB injector harness connecons
inline with these connectors. Unplug the Throle Posion Sensor on the MAG end of the throle-bodies
and plug the matching CB injector harness connectors inline.
34. Install the barbed “T” ng from the auxilliary injector fuel lines into the stock fuel line and secure using
the supplied hose clamps.
36. Unbolt the stock ground wire next to the chaincase
and add the Control Box injector harness ground
connector.
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37. Remove the upper tank shroud 38. On kits with a fuel booster board, plug the two pin
rubber molded connector into the accessory plug located next to the chaincase. Plug the matching connectors on the booster board inline with the fuel
pump connector.
39. Route the Control Box Injector and ADA harness along
the stock harness on the MAG side of the chassis, underneath and behind the jacksha, up the frame upright behind the clutch and out of the upper tank cowl.
Refer to the wiring diagram included in these instrucons to see the connecons between the BoonDocker
electronics.
41. If using a BoonDocker E-Key Timing Module plug it inline with the matching stock connectors. The “IN” connectors will be towards the front of the machine and
“OUT” towards the rear. Wrap the velcro jacket around
the harness connecons and secure the E-Key on the
outside of the jacket using zip-es.
40. Locate the stock wiring harness that runs down the
inside of the MAG side frame rail. Remove the zip-e
and unplug the three pin molded connector. Plug the
supplied power adaptor inline with the connector.
Later in the installaon the two molded connectors
will be used to power the oil pump and on intercooled
kits the fan intercooler fan.
42. Grind the upwards edges on the powervalve servo
motor bracket at. The bracket will be relocated to
the MAG side chassis diagonal, the removal of the
upward edges is to prevent rubbing on the throle
cable.
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43. To check tment before relocang the bracket install
the 90° rubber elbow.
44. With 90° rubber elbow and intake pipe relocate the
bracket. Drill three 3/16” holes in the chassis diagonal
and secure using the supplied rivets.
45. Replace the ECU cowl assembly and connect the two
harnesses to the ECU.
47. Replace the ECU heatshield and securing using the
stock fasteners
46. Replace the front chassis crossbar and secure using
the stock nuts and bolts.
48. Unbolt the spring tab from locaon A. Drill a 3/16” hole
in that chassis at locaon B. Use a washer on the rivet
and rivet in place.
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49. Install the three rubber bumpers that were previously used on the stock silencer and install them onto
the turbo assembly.
50. Hang the turbo assembly onto the chassis.
51. With the turbo in posion cut the longer of the two
coolant lines the corrent length to connect to the
inside turbo coolant ng and install the supplied
ng.
53. Install the copper washers on either side of the banjo
bolt and bolt to the inside coolant ng on the turbo.
52. Connect the barbed ng on the outside turbo coolant line to the other stock coolant line.
54. Secure the turbo to the chassis using the supplied
short exhaust spring hooked to the spring tab on the
chassis.
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55. Aach the oil pump to the belly pan in front of the
turbo using the the aached velcro.
56. Connect the oil pump to the previously installed
power adaptor. Remove the intercooler fan extension
from the fan and install into the same adaptor.
57. Install the 90 rubber boot underneath the chassis diagonal and onto the turbo inlet. The boot does not
need to be clamped to the turbo. The t is ght so
this step will require paence.
59. Install the 3”x4” silicone tube and clamps onto the
torque tubes.
58. Route the boost line from the push to connect tng on the intercooler underneath the ECU and heatshield.
60. Cut the inner airbox so that the torque tubes will clear.
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61. Install the inner airbox onto the machine and push the
intercooler into the silicone connector. Push the assembly backwards unl the holes on the inner airbox
line up.
62. Install the silicone reducer onto the turbo charger.
Install the silicone connector onto the charge tube
and connect to the intercooler. Sercure using the
supplied clamps.
63. With BoonDocker EBC: Mount the EBC boost solenoid using velcro to the chassis next to the chaincase.
Connect the 3/8 rubber hose from the charge tube
pito tube (locaon A) to the top top of the solenoid
(B). Connect the second rubber hose from the turbo
actuator (C) to the boom of the solenoid (D). One
ng on the solenoid is a vent and will be le open.
Connect the EBC harness to the solenoid. Secure the
clear chaincase vent tube with a zip-e to ensure it is
routed away from the pipe.
65. Install the supplied gasket and secure the turbo exhaust inlet to the turbocharger using the supplied
four nuts ad bolts.
64. Without EBC: Connect the 3/8 rubber hose from the
charge tube pito tube (locaon A) to the turbo actuator (B). Secure the clear chaincase vent tube with a
zip-e to ensure it is routed away from the pipe.
66. Install the stock expansion chamber to the Y-pipe and
secure using the four supplied high tension springs.
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67. Aach the expansion chamber to the turbo exhaust
inlet and secure using the stock springs that were
previously used to hold the Y-pipe to the expansion
chamber.
68. Install the muer through the stock bellypan hole
and add a bead of high temp silicone on the muer
ball connecon.
69. Using the ve supplied allen head bolts secure the exhaust outlet to the turbo. Secure the exhaust outlet
to the muer using the three supplied short spring.
70. NOTE: Due to the complexity and me involved in
re-assembling the hood it is recommended to skip to
step 83, temporarily aach the stock gauge and start
the machine to make sure the turbo ki is installed correctly.
72. Measure 9” back from the front of the stock inner airbox and mark a straight line.
71. Measure 5-1/2” back from the front of edge of the
hood and drill a 5-3/4” hole in the hood so that the
intercooler fan will clear.
73. Cut the stock airbox in two pieces. The front secon
of the airbox will be discarded to leave room for the
intercooler to clear.
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74. Install the turbo air-intake inlet onto the rubber boot.
Aach the airbox to the hood and place the hood on
the machine and mark where the inner airbox contacts
the air inlet.
75. Remove the airbox from the hood and cut a hole in
the inner airbox for the turbo air inlet.
76. Aach the airbox to the hood. Check the height of
the aluminium air intake tube by looking down the
air intake. The turbo intake tube should sit about 1/4”
inside the airbox it is important that the tube doesnt
touch the hood or intake air will be restricted.
78. Aach the headlight to the hood using the stock
screws.
77. Use the supplied heat tape seal the opening on the
front side of the airbox.
79. Cut the stock upper tank cowl so that the Boondocker harnesses can clear. Replace this cowl on the
machine.
80. Finish assembling the hood in the reverse order of
how it was disassembled.
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81. Install BoonDocker hood scoop by compressing the
hood scoop and slong it underneath the stock
painted hood panels.
82. Using the included velcro aach the Control Box and
EBC to the metal plate between the stock gauge and
steering post.
83. Fill turbo oil tank with included T2C Turbo Oil. BoonDocker recommends T2C Injector Oil for turbo and
high performance mahcines.
85. Install included primary clutch spring and weights
Before riding it is recommended to verify that
the numbers in the Control Box match these
starng numbers.
84. Remove upper oil line to verify oil is owing to the
turbo. Re-install line and ghten with 9/16” wrench.
86. It is recommended to change the turbo oil and lter every 300 miles or when the oil becomes discolored. BoonDocker oers a Turbo Oil Service Kit that
includes new oil, lter and clamps.
4300 00 00 00 A=-05
5100 00 00 05 B=70
5900 11 13 15 C=05
6700 12 16 19 D=09
7500 16 17 20 E=02
8200 10 22 26 OS=40
8500 00 23 31 CR=21
Extra -02 -05 -0Control Box Starng Numbers
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WIRING DIAGRAM - Control Box with Fuel Booster Board
Chassis Ground
Fuel Booster
sel
CB Capture Button
ADA Harness
Injector Harness
Arrows represent
Stock Connectors
Stock Accessory Plug
Stock Fuel Pump
TPS
Stock Injectors
Aux Injector Aux Injector
Temp Sensor
Boost Transducer
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WIRING DIAGRAM - Control Box with EBC and Fuel Booster Board
Chassis Ground
EBC Harness
Push-to-Pass Button
Fuel Booster
sel
008
CB Capture Button
ADA Harness
Injector Harness
Arrows represent
Stock Connectors
Stock Accessory Plug
Stock Fuel Pump
Boost Solenoid
TPS
Stock Injectors
Aux Injector Aux Injector
Temp Sensor
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