BoonDocker M1000 User Manual
M 1000 Race Gas Installation instructions
Step 1: Tear Down
Parts Needed: Tools Needed:
None Basic Tool Set
Air Saw
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 1
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A. Remove hood and side panels. B. Remove pipe.
C. Remove can (remove the stock rubber
mount from the exhaust can, we will
need this later).
E. Remove air box and ECU.
D. Remove “Y” pipe and heat shield.
F. Remove right hand step panel and reverse
beeper.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 2
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Step 1: (continued) Tear Down
G. Remove throttle bodies. H. Cut and remove this portion of the bulk-
head.
Step 2: Throttle bodies
Parts Needed: Tools Needed:
2- 10/32 x 3/16” barbed 90 Basic Tool Set
3/16” Brass T Lock tite
2- 2.5” pieces of 3/16” hose 10/32 tap
30” piece of 3/16” hose Drill
6- 4” zip ties
5/8 hex bracket
A. Mark throttle bodies with center punch. B. Drill at punch mark using 5/32” drill bit.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 3
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Tap hole in throttle bodies using a 10-32
Use lock-tight here
Secure connections using small zip-ties
Connect 30”x 3/16” hose here
tap.
C. Install 10-32 x 3/16” 90° fittings, position
as shown.
Step 2: (continued) Throttle bodies
D. Install two 2 ½”x 3/16”, one 30”x 3/16” rubber boost hose, and one 3/16” brass tee.
E. Install air box mount to air box.
F. Temporarily install throttle body
machined rings and turbo air box to
throttle body.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 4
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G. With the Airbox installed mark where
Mark here with air box installed
the mounting bracket hits the throttle
body cross-support.
Step 3: Air Box
H. Drill cross-support at mark using 3/8”
drill bit.
Parts Needed: Tools Needed:
Airbox Air saw
5/16 x 1” bolt Assembly lube
5/16” lock washer
2-Machined rings with o-rings
B. Reinstall the throttle bodies. Cover the
holes on the throttle bodies to keep from
getting shavings into the throttle bodies.
C. Mark bulk head as shown, and trim.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 5
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A. Lubricate the o-rings in the Airbox,
Slide air box into place.
E. Install air box to machined rings
B. Lubricate the o-rings on the machined
rings before installing. Install machined
rings to throttle bodies.
F. Fasten air box in place using 5/16”x
1” bolt and lock washer.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 6
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Step 4: Installing the Control Box
Parts Needed: Tools Needed:
Control Box w/instructions Basic tool set
A. SEE CONTROL BOX INSTRUCTIONS FOR INSTALLATION.
Step 5: Oil Tank/Turbo Assembly Bracket
Parts Needed: Tools Needed:
2-8mm x 20mm bolts Basic tool set
2- lock washers Assembly lube
3 hole drain gasket (packaged in turbo box)
Oil drain
Rubber grommet from stock muffler
2- rubber boot seals
2- 5/16 x ½” bolts
Turbocharger
Oil tank assembly bracket
A. Install the stock rubber grommet (removed
from the stock muffler in step 1) and install it
to the oil tank assembly bracket as shown in
picture. Install the 2 rubber boot seals as
shown in picture. Important: DO NOT
LUBRICATE THESE BOOTS.
B. Loosen the 6 exhaust housing bolts on the turbo.
C. Loosen the 4 bolts on the intake or compressor housing of turbo.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 7
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D. Locate the 2- 8mm x 20mm bolts, lock
washers, oil drain and oil drain gasket. Now
LOOSLEY bolt to turbocharger as shown, this
will make it easier to install the turbo to the oil
tank assembly bracket.
E. The center cartridge should rotate freely, rotate
the center cartridge so that the oil drain is on the
opposite of the exhaust inlet as shown in
picture.
F. Using assembly grease, liberally lubricate the
oil drain before installing the turbo into the oil
tank boot.
G. Insert the turbo onto the oil tank, align the
remaining 2 holes on the turbo housing with the
2 holes in the turbo mounting bracket as shown
in picture. Use the 2 provided 5/16 x ½” bolts
and tighten these first.
H. Tighten the remaining 4 bolts on the turbo
housing.
I. Tighten the 2 oil drain bolts, snug 1 bolt on
exhaust side of turbo housing.
Revised 11/18/08 Arctic Cat M-1000 Turbo Installation instructions Page 8
www.boondockers.com............................BoonDocker..........................................877-522-7805
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