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SKI-DOO 2011-12 XP E-TEC 800
User Manual
10 pgs2.92 Mb0

BoonDocker SKI-DOO 2011-12 XP E-TEC 800 User Manual

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Page 1
2011-12 Ski-Doo 800 R E-Tec
Turbo Kit Installaon Instrucons
The BoonDocker E-Tec turbo is a Race Gas only kit at this me. We recommend a minimum of 100 octane non-ethanol fuel or higher depending on boost levels and elevaon.
Addional informaon and updates on BoonDocker products may be available on the following sites.
• www.boondockers.com
• www.youtube.com/boondockerusa
• www.facebook.com/boondockerperformance
Page 2
1. Remove both side panels and hood.
2. Remove the seat by liing up on the white plasc le­ver under the front and pulling the seat rearward.
3. Remove the torx bolts holding on the headlight / gauge cluster. Disconnect the wiring harnesses hooked to the headlights and gauge. Remove headlight and gauge cluster.
5. Remove air intake screens from each side of the air box plenum. Be careful to not damage the clips when removing.
4. Remove the torx bolts holding the tank cowl to the air box plenum, remove the gas cap nut, remove gas cap and remove tank cowl.
6. Remove the hose clamp holding the air box plenum to the intake ute.
Page 3
7. Remove coolant bole from airbox plenum, remove velcro holding plenum to the chassis and remove the air box plenum from the machine.
8. Using a spring puller remove the two springs holding the silencer to the expansion chamber and the two springs holding the silencer to the chassis.
9. Remove the exhaust temp sensor from the top of the silencer and remove the silencer from the chassis.
11. Remove belt gaurd. 12. Disconnect sensor and twist the intake ute to re-
10. Remove the exhaust noise shield.
move.
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13. Remove air box by sliding it vercally o the throle body adaptor plate.
14. Remove clamps and remove throle body adaptor plate from the throle bodies.
15. Remove the throle bodies and reed cages. Install the included half reeds on top of the factory reeds. The half-reeds with sloed holes install on the matching inside reeds and the standard hole half­reeds on the matching outer reeds.
17. Connect the Control Box Injector harness to the stock coil connectors. Similar to the TPS connecon in step 15 these connectors plug inline. It does not maer which of the two coil connectors on the CB INJ harness plug to the stock Coil connectors. They can be connected either way.
16. Connect the Control Box ADA harness to the Throle Posion Sensor (TPS) on the mag end of the throle bodies. The factory connector should be removed and the harness plugged inline.
18. Install the Power Adaptor cable to the machine. Bolt the ground connector to the stock ground point on the footwell. Plug the spade connector into the fuse holder on the oil tank.
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19. Plug the BoonDocker Power Harness into the Power Adaptor and run the harness behind the fuel tank next to the throle bodies. Run all the the previously installed harnesses to the front of the chassis inline with the factory harness are shown above.
20. Install the throle body adaptors onto the throle bodies with keeper tabs. The tabs should be installed on the throle bodies 180 degrees apart at approxi­mately clock posions 10 and 4.
21. Install the Torque Tubes onto the throle body adap­tors and connect the the auxilliary injector connectors from the Injector Harness into the auxilliary injectors.
23. Remove the center coolant line from the coolant re­servior bole and re-route to inside coolant barb on the turbo. Install the outside turbo coolant line onto the center ng on the coolant bole. Ensure that the coolant line roung is clear of the pipe and other hazards.
22. Install the Torque Tube Y-Pipe onto the Torque Tubes.
24. Before installing the turbo mount the Boost Solenoid to the plasc bracket between the coolant lines.
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25. Bolt the turbo exhaust outlet to the turbo housing.
26. Install the rubber bumpers from the original silencer on to the turbo assembly. Check that the other stock silencer rubber mount is aached to the chassis.
27. Install the turbo assemblly into the chassis ensuring that the exhaust exits through the bellypan and the turbo bracket hangs on the chassis correctly.
29. Bolt exhaust inlet to turbo charger and secure to ex­pansion chamber using supplied exhaust springs.
28. Install the stock probe into the exhaust outlet.
30. Cut fuel line between fuel lter and voice coils. Install barbed T coming from auxilliary fuel injectors inline.
Install Rave Check Valves as per instrucons on page 9
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31. Install supplied sheet metal gauge cluster bracket to frame diagonals using supplied hose clamps.
32. Install the intercooler into the chassis by securing it to the chassis crossbar using the supplied hose clamps.
33. Install the charge tube between the turbo and inter­cooler using the supllied silicone tubes and clamps.
35. Install the coolant bole relocator bracket to the PTO side chassis diagonal. Secure the coolant bole to the bracket and secure the bracket to the chassis using the suppied hose clamps.
34. Connect the two pin rubber connector on the fan to the Power Harness.
36. Install the intercooler torque tube between the intercooler and Torque Tube Y. Connect using the supplied silicone tubes and secure using the sup­plied hose clamps.
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37. Install the air lter onto the turbo inlet and secure us­ing the supplied hose clamps.
38. Re-assemble the stock plascs in the reverse order of how they were remove.
39. Remove the foam from the inside of the hood so that the intercooler fan has room to clear.
41. Install supplied clutching components.
42. 8 oz of BoonDocker T2C Turbo Oil should be poured into the fuel tank everyme it is lled. This extra oil will compensate for the addional fuel being injected by the auxilliary injectors.
43. It is recommended to change the turbo oil and lter every 300 miles or when the oil becomes discolored. BoonDocker oers a Turbo Oil Service Kit that includes new oil, lter and clamps.
40. Fill the turbo tank with T2C oil. Remove the top turbo oil line, start the machine to verify oil ow to the tur­bo. Reconnect the oil line.
FUEL
The BoonDocker E-Tec turbo is a Race Gas only kit at this me. We recommend a minimum of 100 octane non-etha­nol fuel or higher depending on boost levels and elevaon.
Page 9
• • • • • • • • • • •• • • • •• • • • • •• • •• • •
RAVE VALVE CHECK VALVE INSTALLATION
1. Red and Black check valve assembly with 3/16” plastic vacuum T and hose.
3. Blue check valve assembly with 3/16” plastic vacuum T and hose. Note flow direction of check valve.
2. Install red and black check valve assembly to the metal (chrome) port on the RAVE valve solenoid, and reconnect the clear RAVE valve hose to the red and black check valve assembly.
4. Cut the hose to the RAVE valves before RAVE valves, install blue check valve assembly into RAVE valve hose . Do not do not connect anything to open end of the blue check valve.
Page 10
Injector Harness
Aux Injectors
EBC Harness
Push-to-Pass Button
Oil Pump
sel
008
CB Capture Button
Boost Solenoid
ADA Harness
Temp Sensor
Power Harness
TPS
Stock Coils
BoonDocker tollfree: 877-522-7805 local: 208-542-4411 fax: 208-524-7381 www.boondockers.com 10
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