Page 1
Page 2
1.Remove the instrument, side panels & Hood/head
light/air box module. Remove the Air box at throttle
bodies, seat, tank & body panels.
2.Carfuly remove temp sensor for later use in turbo
install.
3.Remove the stock muffler/can & EGT. Remove the
stock rubber muffler/can isolators from the bottom of
the muffler/can.
5.Cut the upper air box matching both sides on
the cut (as seen in picture).
4.Remove hood from headlight assembly & flip
upside down. Break off the weld dots on the air box
assembly. Pull apart the air box assembly. Discard
the lower air box & white air box tube.
6.Cut the upper hood/air box assembly as seen in
picture for clearance purposes. Cut remaining
weld dots off of the upper air box.
Revised 12/28/2012 Page 2 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 3
7.Remove the throttle bodies & reed cages from
the machine.
8.Remove & replace the reed pedals. DO NOT
mix them up. The new reeds are turbo reeds &
there are inner & outer reeds. Reinstall back in
engine & install the throttle bodies.
9.Unhook the PTO side coil wire & plug in the
green wired plug on the E-Key into the coil
10.Install the power adapter cable into the open
fuse holder. Install supplied fuse.
(PTO side). Plug in the yellow wired plug of the
E-Key to MAG side connector.
11.Hook up the ground right below the fuse
holder on the foot rest with the stock bolt.
Tighten the bolt so wires are pointed to the top
of the chain case.
12.Remove fuse holders from the stock oil tank
& install the power harness on the end of the
power adapter cable (as seen in picture). NOTE
make sure red wire goes to red wire.
Revised 12/28/2012 Page 3 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 4
13.Hook up BoonDocker box throttle position
harness to throttle body & to stock harness. Note
zip tie off all wires so they don’t chaff threw &
short to ground.
14.Route wiring through the side below the han-
dle bars as seen in picture down the stock har-
ness to the power adapter harness & throttle po-
sition hook ups (as seen in step13).
15.Install the throttle body tab clamp on the
throttle body with the tightening screw at the top
of the assembly. Then install the silicone hose &
twist clamp in to position & tighten clamp.
17.Install the rest of the air box & Y. NOTE
make sure you index the hose clamps so you can
access them for tightening after you install the
tank. Still leaving the hose clamps slightly loose.
16.Install silicone on the left side of the Y
tighten the hose clamp. Leave all the other
clamps loose for proper alignment & fitting.
18.Install the injectors in the injector rails. Use
assembly lube so you don’t tear an o-ring. Route
the fuel line as seen in picture. Install the injec-
tor & rail assemblies. Don’t over tighten bolts.
Revised 12/28/2012 Page 4 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 5
19.Zip tie fuel lines so they do not kink & zip tie
the wire harnesses securely.
20.Cut and splice into the return fuel line, install
T into fuel and tighten clamps. Position for
clearance, zip tie & secure.
21.Install the tank & Aluminum tank support
member. Make sure you are fitting the Y & air
box into position. NOTE this is a tight fit.
23.Cut hose between rave valve & solenoid. Install the check valve inline Turn the check valve
down & zip tie lines on. Make sure routing of
hoses have good clearance.
22.Remove the clear line on rave valve solenoid
& Install check valve. Turn the blow off to down
position. Zip tie the hoses on.
24.Install intercooler using 2– hose claps on
cross bar, do not tighten, install fan route power
to adapter harness , install 90 degree boost fit-
ting in to inner cooler tank
Revised 12/28/2012 Page 5 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 6
25.Install the 3” charge tube. Do not tighten the
hose clamps. Try to slide the charge tube closer
to the Y end for proper fit & for clearance. Hook
up the air temp sensor to the control box. Zip tie.
26.Turn the Y on the PTO side up ward until the
clutch cover fits properly. Be sure to test fit the
head light assembly for clearing the charge tube
setting on the intercooler mount.
27.Install stock temp sensor & zip tie to wiring
as seen in picture. Hook up the boost reference
line to the push to connect on the intercooler.
Route so it does not chaff.
29.Drill the hole for the spring tab with a 3/16”
drill bit. NOTE the hole is already in the bulk
head you only drill the plastic in the bell pan on
28.Install heat tape on the Chain case, hoses, the
stock EGT cable, oil tank & on the ECM
Bracket.
30.Install the stock can rubber bumpers on the
turbo bracket using a flat blade screw driver.
the right side.
Revised 12/28/2012 Page 6 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 7
31.Install the turbo assembly as seen in the picture. Install the spring supplied for turbo bracket
tab to bulk head spring tab.
32.Route the inside coolant line under the bulk
head bracket as seen. Route up to the back side
of coolant bottle.
33.Remove the small coolant line from the back
of the coolant bottle. Then route to the coolant
hose you just removed. Make sure you secure
hose so it won’t chaff wires or hose.
35.Route & hook up power for oil pump to
power harness. Route coolant hose to coolant
bottle. Zip tie the hose & power harness away
from any hazard. Tighten coolant hose clamps.
34.Route the outside turbo coolant hose under
the bulk head cross member to coolant bottle.
Clean the belly pan & attach oil pump Velcro.
Heat the glue on the Velcro for best adhesion.
36.Remove the pipe off of the doughnut apply
high temp silicone on both sides of the doughnut
& reinstall pipe. Triple up the springs on the
pipe as seen in the picture.
Revised 12/28/2012 Page 7 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 8
37.Install the inlet apply high temp silicone on
both sides of the doughnut. If you have a nonTial exhaust install the bolts now. If you have a
Tial exhaust then install the inlet clamp.
38.Install the waste gate solenoid & plug in. Use
the Velcro supplied to mount the solenoid. Use a
heat gun to activate the glue on the Velcro. The
hose that is headed upward goes to waste gate.
39.TIAL ONLY. Install the waste gate on the
inlet. Plug the remaining holes in the Tial waste
gate. You will not use the coolant fitting option
on this waste gate. As seen in picture.
41.Install heat tape to the lower inside side
panel. Install the 2-1/2” charge tube do not
tighten the hose clamps yet.
40.Drill the lower side panel as seen in picture.
If you have a Tial the hole will be a 3-1/2” hole
saw . If you have a nonTial drill hole to 2-1/2”
hole saw.
42.Test fit the head light assembly to the inter-
cooler mount bracket. Tighten all the hose
clamps into position making sure the head light
assembly & charge tubes fit correctly (no rub).
Revised 12/28/2012 Page 8 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 9
43.Check for clearance on the clutch cover & on
the head light to 3” charge tube. Tighten all air
box & charge tube hose clamps.
44.Install Tial muffler. NOTE when installing
the muffler rotate the top of the can to the inside
of the snow machine for a equal clearance to
both the side panel, chain case & stock oil tank.
45.Cut & remove the stock heat tape/insulation
from the side panel & install the heat tape as
seen in the picture.
47.Turn handle bars all the way to the left &
install the cold air intake as seen in picture to fit.
46.Cut the shroud just enough to run control box
wiring & boost reference line through this area.
Zip tie wires as needed to hold wires & boost
line.
48.Install the hose from boost solenoid headed
forward to the intercooler.
Revised 12/28/2012 Page 9 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
Page 10
49.Install the hose from ECM on to cold air intake box. Install the hose clamp on the cold air
bracket & tube. Test fit the head light & tighten
the hose clamp. As seen in picture.
50.Install the silicone hose on the cold air intake
box tube then install the tube with no hose
clamps. Install the hose & clamps between the
cold air intake tube & turbo. As seen in picture.
51.Install the head light assembly. Route the
control box as seen in picture. Clean the console
& install Velcro. Heat the glue on the Velcro to
activate.
53.Install the pins in the clutch. At the top of the
page is low elevation to 5,000ft clutching. At the
bottom is 5000 ft up clutching. Tighten the set
screws to cotter pins in both cases.
Revised 12/28/2012 Page 10 of 10
www.boondockers.com………………..... ……….………………....877-522-7805
52.Remove primary clutch. Remove the old
ramps. Install roll pins in ramps, index roll pins
as seen in picture. (perform clutch adjustments
to Ski-Doo specifications)
54.Fill the turbo oil tank with12oz of TC2 Turbo
oil. Remove the oil feed line off of the turbo
start the snow machine verify oil flow. Install
the oil line & tighten.
Loading...