AEROCHARGER TURBO SYSTEM INSTALLATION MANUAL Can-Am Maverick 1000 Version 1.0 R
INTRODUCTION Congratulations on your purchase of an Aerocharger Turbo system for the Can-Am Maverick 1000! You now own the most powerful, reliable, and technologically advanced turbo system in the world. With your new intercooled turbo system installed, you will experience substantial performance gains. Aerocharger s unique system combines VATN technology with our frictionless, non-flooded ceramic ball bearing system, which provides zero-lag performance. This system is proudly made and assembled in the USA by Aerocharger LLC. CONTENTS Warnings and Disclaimers... i I. Initial Disassembly... 1 II. Airfilter Removal... 3 III. Remove Throttle Body... 4 IV. Clutch Compartment Disassembly... 5 V. Remove Exhaust... 5 VI. Turbo And Exhaust... 7 VII. Install the Filter... 9 VIII. Install Charge Tubes... 11 IX. Install the Intercooler... 12 X. Gauges and Wiring... 14 XI. Calibrate the AFR Gauge... 17 XII. Final Reassembly... 18 Appendix... 19 A. Clutching... 19 B. Fuel... 19 C. AFR Gauge Guidelines... 19 D. Innovate MTX-L AFR Gauge Error Codes... 20
i Can-Am Maverick 1000 Turbo System Installation Manual WARNINGS AND DISCLAIMERS Any aftermarket power-adding product can be potentially dangerous to a vehicle if not used as directed. Aerocharger Turbo Systems are properly engineered, manufactured with high-quality components, and heavily tested to ensure best possible reliability. However, many factors that are out of our control, such as installation errors or misuse, can potentially cause damage. When properly installed and configured, this system should outlast the life of the vehicle. Please note the following warnings, carefully follow all instructions, and do not hesitate to contact an Aerocharger tech if you are unclear about any of these installation and operating guidelines. INSTALLATION WARNING If you are uncomfortable performing any of the installation tasks outlined in this manual, please refer to a trained professional at your local performance shop. If you are performing the installation of this system yourself, we recommend reading the entire manual prior to proceeding with the installation. We also suggest that you review your progress after each section to ensure everything has been installed correctly. MODIFICATION WARNING This system is designed for use on a stock Maverick 1000 with an undamaged, well-maintained engine. If your Maverick is modified, consult with Aerocharger at (913)829-3400 or info@aerocharger.com before proceeding. Aerocharger is not responsible for ECU tuning and programming for Maverick 1000s that were not stock before the installation of this turbo system. ENGINE BREAK-IN WARNING Installation of turbo systems on brand-new vehicles is not recommended. New engines generally require a specific break-in procedure that does not factor in extra stress from forced induction. If your vehicle is brand new, consult your local dealership and owner s manual to determine the proper break-in procedure before continuing with this installation. Failure to do so can result in significant engine damage. WARNINGS AND DISCLAIMERS, CONT D Aerocharger Turbo Systems ii MINIMUM OCTANE WARNING: For best performance and reliability, always use at minimum 91 octane non-ethanol fuels at 5 psi. See Appendix B for recommended octane at other boost levels. Always listen for signs of detonation. IF DETONATION SHOULD OCCUR, OR YOU ARE UNSURE IF WHAT YOU ARE HEARING IS DETONATION, DECREASE THROTTLE IMMEDIATELY and consult Aerocharger staff at (913)829-3400. If the system is installed and configured correctly, detonation should NOT be an issue. Please understand that inconsistencies on stock engines and parts are possible on any new vehicle from an OEM. IMPORTANT NOTES NOTE: Read and understand ALL safety and technical precautions in this manual before proceeding. Failure to comply with the instructions in this manual could result in personal injury, property damage, voiding your warranty, and inconsistent or poor performance from the turbocharger system. Contact Aerocharger for any questions or concerns. DO NOT let any debris (hard or soft) enter air intakes or exhaust ports during installation of this turbo kit. DO NOT use any silicone sealants except as prescribed in this manual. Doing otherwise can result in FOD (Foreign Object Damage) to the turbo. THIS WILL VOID YOUR WARRANTY. AEROCHARGER WILL NOT BE HELD RESPONSIBLE FOR DAMAGE TO THE VEHICLES POWERTRAIN.
1 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 2 I. INITIAL DISASSEMBLY 1.1 Remove seats from vehicle. The front seats remove by pulling a locking tab. The rear seats require partial removal of the bed to access 4 retaining screws. 1.2 (4-Seater Only) Remove center compartment, which is retained by several push tabs. 1.6 Remove the side plastics which cover the engine by removing the retaining tabs. 1.7 Remove the rear driver s side bottom pan in order to access the clutch. 1 bolt (10mm wrench and socket) 1.3 Remove screws retaining the passenger handle grips and pull the handles off their rods. 1.4 Pull the switch panel off the dashboard. Leave it plugged in, but set it out of the way. 1.5 Remove screws retaining the plastic console in the center of the vehicle. Lift the panel enough to disconnect the switch wire, then remove the panel and set aside. 1.8 Remove front wheel well plastics to access the area under the hood. (10mm socket)
3 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 4 II. AIRFILTER REMOVAL 2.1 Remove the hood cover and pull the top cover off of the stock airfilter. 2.2 Loosen hose clamps and disconnect all hoses from the airfilter. 2.3 Push the large tube out through the back of the airfilter. This tube is glued to the airfilter, so it will be necessary to use a screwdriver or pry bar to break the glue. 2.4 Remove clamp and disconnect breather hose from filter. 2.7 Remove clamp from the radiator tube to allow the tube to be pushed out of the way. III. REMOVE THROTTLE BODY 2.8 Remove plastic screen from bottom of the front compartment. 2.5 Remove the airfilter from the frame. With the hood plastics installed, it will most likely be necessary to break the tabs off of the air filter compartment. Complete hood removal will be necessary to remove this assembly intact. 2.6 Remove airfilter connector tube from the vehicle. 3.1 (4- Seater Only) Loosen the clamps and remove the connector air tube attached to the throttle body. The middle connector air tube will be retained for use with the turbo system. 3.2 Remove the throttle body and place to the side, leaving it connected. 3.3 Re-route the stock breather hose to the back of the engine compartment. Do not allow the breather hose to kink or come into contact with any exhaust components.
5 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 6 IV. CLUTCH COMPARTMENT DISASSEMBLY 4.1 Remove Clutch Vent Tube. 4.2 Remove bolts from clutch cover. Bolts are located on the entire perimeter of the clutch cover. (8mm socket) 4.3 Remove hose clamp and disconnect tube from the clutch cover. 4.4 Remove the clutch cover. 5.3 Remove bolts from the headers. Retain the springs and collars from the ball joint connections for use later. 5.4 Unhook the header hanger from the frame and remove the header pipe. V. REMOVE EXHAUST 5.5 At this time remove the rest of the exhaust system, with the exception of the two header pipes coming off the engine. 5.1 Loosen collars from the stock mufflers, then remove the mufflers. 5.2 Uninstall the stock exhaust from the vehicle.
7 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 8 VI. TURBO AND EXHAUST 6.1 Set up the 53 series Aerocharger turbo. Fill the Aerocharger with the bottle of oil provided in the kit. When reinstalling the fill plug, use thread lock fluid on the threads and torque to 35 in-lbs. 6.2 Line up the turbo Y-pipe with the stock exhaust 6.3 Place exhaust donuts on stock engine pipe, then connect turbo y-pipe using provided bolts and stock springs and collars. NOTE: The pipes might need to be loosened at the engine to properly line everything up. 6.4 Connect the turbo support bracket to the stock muffler hangers using included hardware. AEROCHARGER OVERVIEW BOOST SPRINGS Aerocharger boost springs are used to set the boost pressure. Every Aerocharger is shipped with a green 5 PSI spring already installed. Available springs include: 5 PSI GREEN 6 PSI GREEN BLUE 7 PSI BLUE AEROCHARGER OIL SPRING SHIMS Specialized oil for ultra-high rpm machinery. Only use genuine Aerocharger Turbo Oil. The wrong oil can lead to bearing failure. X 1 X 2 8 PSI BLUE ORANGE 9 PSI ORANGE 11+ PSI BLACK Shims can be added to the springs to increase the boost in increments of about.5 to. 75 PSI. ADD 1 BOTTLE FOR 53 SERIES ADD 2 BOTTLES FOR 66 SERIES NOTE: NEVER attempt to disassemble the main Aerocharger housings. The bearing and vane systems require specialized tools to take it apart without damaging it. Contact Aerocharger for all service and repairs. The Aerocharger is a sophisticated and highly efficient variable vane turbocharger. Unlike conventional turbos, it does not require oil pumps or lines. The Aerocharger will not need more maintenance than any other turbo - this graphic contains information for adjusting the Aerocharger to ensure best performance. JAM NUT PN # 66337 CONTROLLER BONNET PN # 66328 DIAPHRAGM SHIM PN # 66333 CONTROLLER TOP PN # 66323 BOOST SPRING PN # 66341 CONTROL ROD PN # 66078 INTEGRATED BOOST CONTROLLER BOOST FITTING PN # 66335 RETAINING CLIP PN # 66325 SPRING SHIMS PN # 66338 DUST SHIELD PN # 66340 Housing PN # 66326 PISTON PN # 66322 DIAPHRAGM PN # 66321 PISTON SHIM PN # 66342 The Integrated boost controller on the Aerocharger is a simple mechanical actuator where pressure in a chamber pushes against a spring to move the vanes. It can be easily disassembled to adjust the boost by changing springs and/or shims. Manual & electronic boost controllers are compatible with Aerocharger systems, but are not recommended. OIL LEVELS Aerochargers consume oil throughout their use. The amount of oil consumed is very small, and the oil level must only be checked once a year or every 30,000 miles. Aerocharger oil never has to be changed - only added. There is no benefit to changing the oil unless it has been contaminated with a foreign substance, such as if the vehicle has been underwater for a long time. CHECKING OIL LEVEL Remove the fill plug and use a zip tie as a dip stick to measure the oil level. Oil should be added if the level is lower 1 (2.5 cm) 1/2 (1.3 cm) than.5 (1.3 cm.) Oil is full at 1 height (2.5 cm.) Use red thread lock fluid on the threads when replacing the fill plug and tighten down securely. VISIT AEROCHARGER.COM TO SEE A VIDEO TUTORIAL ABOUT ADJUSTING THE AEROCHARGER S BOOST CONTROLLER TO AFFECT TURBO RESPONSE HORIZONTAL ORIENTATION 6.5 Loosely bolt the Aerocharger to the Y-pipe and support bracket using the included screws. 6.6 Tighten down the Y-Pipe to the stock headers. Avoid overightening and coil binding the exhaust springs - they require some flex in them.
9 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 10 6.7 Tighten the support bracket to the frame and tighten bolts to the turbo. 6.8 Loosely mount the muffler to the turbo. Leave the muffler unattached to the frame for now. 7.3 Loosen 2 bolts holding rear bracket and plastic on. (13mm socket) 7.4 Re-use this hardware to mount up the second filter bracket. Be sure to re-use the plastic bushings with the hardware. VII. INSTALL THE FILTER 7.1 Double check the orientation of the donaldson filter. The outlet faces towards the front of the vehicle, and the drain will point downward. 7.2 Install the Filter mount to the frame. The angled part will face upward, and it secures to the frame with two hose clamps. 7.5 Thread the large hose clamp through both brackets. Loop around the air filter assembly and tighten down. 7.6 Mount the intake tube. The large end connects to the air filter, and the small end connects to the turbo inlet. 7.7 Connect the breather tube that has been routed to the rear of the vehicle to the tube with the barb attached to the donaldson filter. Secure with the stock clamp, and zip tie the tube to the frame.
11 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 12 VIII. INSTALL CHARGE TUBES 8.1 Route Charge Tube 1 from the Turbo through the engine compartment toward the front of the cab. It will only fit in one way. The tube should rest along the skid plate at the bottom of the vehicle. 8.2 Remove the passenger side floor panels in order to run charge tubes. (10mm socket) 8.5 (4 Seater Only) Connect the Aluminum charge tube from Charge Tube 2, running it into the front of the vehicle. 8.6 (4 Seater Only) Attach hanger to the frame and hook up to the hose clamp on the aluminum charge tube to secure it away from the drive shaft. Tighten down. IX. INSTALL THE INTERCOOLER 8.7 Place the Air to Air Charge Tube under hood and attach to the aluminum charge tube. 8.3 Route Charge Tube 2 along the center of the cab so the smaller end meets up with Charge Tube 1. 8.4 Connect and tighten both charge tubes together. Connect and tighten Charge Tube 1 with the turbo. 9.1 Attach the inlet silicone tube to the intercooler. Make sure the BOV faces towards the drivers side. Use silicone lube to help fit on if neccessary and tighten down. (7mm socket) 9.2 Use the 4 included self-tapping screws to attach the plastic shroud to the top of the intercooler. (1/4 socket) 9.3 Place the intercooler assembly into the hood with the mounts resting on the subframe.
13 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 14 9.4 Attach the air to air charge tube to the inlet end of the intercooler and tighten down. 9.5 (4 Seater Only) push inlet silicone onto stock plastic air tube going to the throttle body. (7mm socket) 9.7 (2 Seater Only) Connect the inlet silicone to the throttle body and tighten hose clamps. (7mm socket) 9.6 Secure the intercooler supports to the subframe using the included hose clamps. Tighten down securely. (7mm socket) 9.10 Unhook the OEM fuel line and plug it into the powerjet fuel line. Then connect the powerjet fuel line back into the OEM location. Be careful of any leaking fuel. X. GAUGES AND WIRING 9.11 (4 Seater Model) There will be a small silicone coupler to connect the OEM plastic air tube and the throttle body. Tighten down the hose clamps. 9.12 Hook up boost reference line from Powerjet Collar to the the blow off valve. 9.8 Mount the fuel line to the power jet collar (11/16 wrench, 3/4 wrench) 9.9 Attach the throttle body to the Powerjet collar, then reinstall onto the stock airbox with the included hardware. For maximum performance, make sure the throttle body is accurately centered in relation to the powerjet collar. (5mm allen wrench) 10.1 In the Accesory compartment in the dash, drill two holes for the gauge wires. (1 hole saw) 10.2 Use the gauge plate as a template to drill holes in the accessory compartment to mount the gauge plate 10.3 Mount the boost and AFR Gauge into the Gauge plate. 10.4 Cut a small length of boost line from the line provided. Connect to the boost gauge
15 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 16 10.5 Run the boost line and gauge cables through their respective holes, and then mount the gauge panel using the included plastic rivets. 10.6 Connect the boost gauge line to the t-fitting on the Blow off valve line. 10.10 Drill holes in order to locate the fuel controller in the glove box. Drill one hole in the side of the dash compartment, and the other in the underside of the glove box. Be careful to avoid drilling into the anti-freeze line. (1.5 hole saw) 10.11 Place the fuel controller in the airbox, and run the plugs through the holes that were just drilled. Plug into the Aerocommander wiring harness. 10.8 Plug the AFR Gauge power line into the Power harness. 10.7 Remove the blank weather pack from the factory accessory plug, and install the included power harness in it s place. Be sure to match the wire colors when connecting. 10.12 Connect the single MAP sensor plug on the Aerocommander wiring harness into the sensor on the power jet collar. Connect the Aerocommander wiring harness in line with the stock map sensor and stock harness. 10.13 Connect the fuel injector in the power jet collar to the Aerocommander wiring harness. 10.9 Connect the ground on the fuel controller to the remaining plug on the power harness.
17 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 18 XII. FINAL REASSEMBLY 12.1 Reinstall the cargo deck. The cargo deck bolt on the driver s side will also secure the turbo muffler. 12.2 Tighten all exhaust system bolts. 10.14 Unplug the stock injectors. Plug the Aerocommander wiring harness into the stock injectors, and then reconnect the stock injector wires in line with the Aerocommander wiring harness. Be sure to maintain the original order, Front and Rear. 10.15 Connect the AFR Sensor Cable to the AFR Gauge and route it through the vehicle to the engine compartment. 10.16 At this time, the dash can be reinstalled and mounted. Take care that no wires are pinched or loose. 10.17 Clean up, secure and zip tie all wiring. XI. CALIBRATE THE AFR GAUGE 12.3 Use the provided template to cut out a section of the plastic hood panel for the intercooler. Install the provided trim around the hole to help seal it 12.4 Reinstall the Hood. You may need to loosen and relocate the intercooler for proper fitment 11.1 The AFR gauge is connected and powered, and the o2 Sensor is still unconnected and uninstalled. Turn on the ignition. 11.2 The AFR Gauge will enter setup mode and display an E2 error message. Turn off the ignition and wait several moments for the vehicle to completely power down. 11.3 Connect the o2 Sensor to the AFR harness and leave loose to calibrate it to open air. 11.4 Turn the ignition on again. The gauge will now display Htr. After 30 seconds, it will display Cal, and then read 22.4 indicating it has been calibrated to the atmosphere. Turn off the vehicle. 11.5 Disconnect the sensor, then screw into the muffler with a 7/8 wrench. Reconnect the sensor to the AFR sensor cable and take up any excess slack into the cab with zip ties. 12.5 Double-check all turbo system connections, then reassemble the vehicle including plastics, rocker panels, and seats. 12.6 At this time, the CVT clutching can now be adjusted for turbocharged use. Refer to the included clutching reference materials for instructions and guidelines on how to set your turbocharged Can-Am Maverick clutching. IMPORTANT: DO NOT drive the vehicle before configuring the clutching. Stock clutching is insufficient for forcedinduction applications. INCORRECT CLUTCHING CAN CAUSE SEVERE ENGINE DAMAGE.
19 Can-Am Maverick 1000 Turbo System Installation Manual Aerocharger Turbo Systems 20 APPENDIX A. CLUTCHING 105 Maverick Clutch Weight D. INNOVATE MTX-L AFR GAUGE ERROR CODES 100 95 Weight (g) 90 85 5PSI 7PSI 10PSI 80 75 0 2000 4000 6000 8000 10000 Elevation (ft) Clutching is a critical step for the turbo system to perform with full power and reliability. If you do not have the proper tools or experience to adjust the clutching on your Can-Am Maverick 1000, take the vehicle to a qualified performance shop to clutch the vehicle B. FUEL Many factors play a role in octane requirements, such as elevation, air density, temperature, and tolerances specific to the motor. Aerocharger advises using a minimum of 91 octane fuel at 5.5psi, 100 octane (aviation) fuel for boost up to 7.5 psi, and 110 octane race fuel for any boost level greater than 7.5 psi. Pay attention to your engine s performance, and carefully listen for signs of detonation which could be an indication that higher octane fuel is required. Contact Aerocharger for additional recommendations. This chart offers Aerocharger s recommendations for clutch weight settings based on boost and elevation. Every riding condition and configuration is unique, but this should provide a close starting point for dialing in clutching on your Aerocharged Can-Am Maverick 1000. C. AFR GAUGE GUIDELINES AFR numbers are most important to monitor when the engine is under heavy load, such as heavy acceleration or climbing a hill. Monitor your air/fuel ratio to ensure that it stays below 12.8 when the engine is under heavy load. The AFR will spike to very lean levels when decelerating. This is normal. Sensors should be periodically recalibrated. Always completely remove the sensor from the pipe to get an accurate reading.
CAN-AM MAVERICK 1000 AEROCHARGER TURBO SYSTEM By Aerocharger, LLC 402 New Century Parkway New Century, KS 66031 (913)829-3400 www.aerocharger.com