BoonDocker Z1 User Manual

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