Arctic Cat Z-1 GT28/60 Turbo Upgrade
Installation Instructions
BoonDocker Turbo Z-1 GT28/60
Arctic Cat Z-1 GT28/60 Upgrade Turbo Kit Contents
o = included in kit bag
Kit Bag # 1 (step 1-2)
o (1) 3” x 7/8” aluminum ring
o (2) aluminum rivets
o (1) 3” x 2” silicone hose
o (2) #48 hose clamp
Kit Bag # 2 (step 3)
GT 28/60 (Z-1 index)
Exhaust header
(1) Exhaust outlet
o (5) 8mm c 25 mm bolt allen head
o (1) 3/16” x 12” boost hose
o (2) small zip-tie
o (1) 3/8” x 30” hose
o (1) 6AN 90° 3/8” barb fitting
o (1) 3/8” x 17” hose
o (1) 6mm lock nut
o (1) 10” of 3/16 hose
o (1) 3/16 Y
o (1) 6AN straight 3/8” barb fitting
o (3) 8mm x 20mm bolts
o (3) 5/16” lock washers
Kit Bag # 2A (step 3)
o (1) Pre-bent oil line
o (1) 4AN 10mm x 1.25 fitting
o (4) 8mm x 35 mm bolt
o (4) 8mm x lock nut (no nylon)
o (6) 8mm x 25mm bolt
o (6) 8mm lock washer
o (1) 6AN 90° 3/8” barb fitting
o (1) 3/8” x 16” hose
o Upper heat shield bracket
Kit Bag #3 (set 4-5)
(1) intercooler
(1) 1/8” npt male x 1/8” straight barb
fitting
(1) 2 ½” x 3 ¾” aluminum tube
(1) 2 ½ “ x 90° aluminum charge tube
o upper charge tube
o (9) #40 hose clamp
o (1) #32 hose clamp
= packaged separately
o (1) 2 ½” x 2” rubber reducer
o (2) 2 ½”x 2 ½” silicone hose
o (2) 2 ½’ x 3“ hump hose
Kits Bag #4 (step 6)
o (1) auxiliary injectors
o (1) auxiliary fuel rail
o (1) 5/16” x 1/2” bolt
o (1) 5/16” lock washer
o (1) 1/4" npt male x 5/16” barb 90°
o (1) 5/16” brass tee
o (1) #4 hose clamps
o (1) 5/16” x 8” fuel hose (blue liner)
o (1) auxiliary injectors harness
o (2) blue heat shrink but connectors
o (1) Turbo mount bracket
(1)
Fuel Pump
Intercooler fan kit upgrade
(optional)
(1) electric fan w/accessory plug
o (2) 1/4”-20 x 1/2” bolt
o (1) 1/4” 20 x 3/4" bolt
o (1) 1/4" lock washer
o (1) 3’ harness with rubber molded
connector
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 2
www.boondockers.com............................BoonDocker..........................................877-522-7805
BoonDocker Turbo Z-1 GT28/60
Insert ¼” deep
Rivet here
Step 1: Tear Down
A. Remove hood, side panels, headlight
assembly, and muffler.
Step 2: Modify Stock Air Box
A. Cut 3” hole in stock air box.
C. Install silicone hose to air box.
B. Remove intercooler, turbo, oil hoses,
coolant hoses, header, stud bolts out of
cylinder heads and charge tubes.
B. Insert 3” aluminum ring to air box, and
rivet in place.
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 3
www.boondockers.com............................BoonDocker..........................................877-522-7805
BoonDocker Turbo Z-1 GT28/60
Do not tighten yet
Install bolt first
Install bolt first
Connect
Connect
Conect here
Conect here
Step 3: Install Turbo Charger
A. Install straight fitting in 6an fitting. Install
turbo outlet pipe.
C. Install rear coolant hose. D. Install front coolant hose.
E. Install boost controller hose. F. Install oil hose 4an fitting.
B. Install mounting bracket and exhaust
flange on turbo, Install turbo.
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 4
www.boondockers.com............................BoonDocker..........................................877-522-7805
BoonDocker Turbo Z-1 GT28/60
Step 3 (continued): Install Turbo Charger
G. Install oil hose. H. Install lower heat shield to header.
I. Install header. J. Tighten turbo mount bolts.
K. Install upper heat shield. L. Install oil drain.
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 5
www.boondockers.com............................BoonDocker..........................................877-522-7805
BoonDocker Turbo Z-1 GT28/60
Step 4: Install Intercooler
A. Install intercooler. B. Install fan wiring harness.
Step 5: Install Charge Tubes and Muffler
A. Install fuel rail and injector (see step A
of following instructions). Install upper
charge tube.
C. Install intermediate charge tube. D. Install muffler.
B. Install lower charge tube.
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 6
www.boondockers.com............................BoonDocker..........................................877-522-7805
BoonDocker Turbo Z-1 GT28/60
Use red wire in position #2
Step 6: Install Auxiliary Fuel Injector
A. Should be completed before charge tub
installed. Install fuel injector, rail and brass
fitting into upper charge tube.
C. Install 5/16” hose from tee to fitting on fuel rail.
D. Tee red and purple wires from auxiliary injector harness to red and purple wires on female
Hijacker injector connector.
B. Install 5/16” brass tee into fuel presser
hose.
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 7
www.boondockers.com............................BoonDocker..........................................877-522-7805
BoonDocker Turbo Z-1 GT28/60
Install Auxiliary Fuel Injector (continued):
E. Route auxiliary injector harness and connect to injector.
Step 7: Reinstall hood, side panels, and headlight.
Revised 06/05/09 Arctic Cat Z-1 GT28/60 Turbo Upgrade Installation instructions Page 8
www.boondockers.com............................BoonDocker..........................................877-522-7805
Loading...