1.Remove the gauge, side panels, hood and headlight. Remove the air box from the throttle bodies then remove the seat and gas tank. 2.Carefully remove temp sensor from air box using a small pick or screw driver. DO NOT THROW AWAY; this will be used for later use in the install. 3.Remove the muffler and EGT. Remove the stock rubber muffler isolators from the bottom of the muffler. DO NOT THROW AWAY; these will be used later in the install. 4.Remove hood from headlight assembly and 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. 5.Cut the upper air box matching both sides on the cut (as seen in picture). 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 10/23/2015 Page 2 of 10
7.Remove the throttle bodies & reed cages from the machine. 8.Remove the stock reed pedals and replace them with new turbo reeds. DO NOT mix them up. Reinstall back in engine and install the throttle bodies. 9.Install the power adapter cable into the open fuse holder. Install supplied fuse. 10. 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. 11. Remove fuse holders from stock location and install the power harness on the end of the power adapter cable. Make sure red wire goes to red wire. 12. Hook up throttle position harness to throttle body. Zip tie all wires so they don t chaff or break off. Revised 10/23/2015 Page 3 of 10
13. Route wiring down the stock harness to the power adapter harness and throttle position hook ups. Use zip ties accordingly. 14. Install the throttle body tab clamp on the throttle body with the tightening screw at the top of the assembly. Install the silicone hose and twist clamp into position then tighten clamp. 15. Install silicone on the left side of the aluminum Y. Tighten the hose clamp. Leave all the other clamps loose for proper alignment and fitting. 16. Install the rest of the air box. Make sure you index the hose clamps so you can access them for tightening after you install the gas tank. Leave the hose clamps loose. 17. Install the injectors in the injector rails. Use assembly lube so you don t tear an o-ring. 18. Route the fuel line as shown in picture. Don t over tighten these bolts. Zip tie fuel lines so they don t kink then zip tie the wire harnesses securely. Revised 10/23/2015 Page 4 of 10
19. Cut and splice into the return fuel line. Install brass T into fuel line and tighten clamps. Position for clearance, zip tie and secure as shown. 20. Install the gas tank and tank support member. The Y will touch gas tank slightly on PTO side. There should be reasonable clearance elsewhere. 21. Remove the clear line on rave valve solenoid & Install check valve. Turn the blow off to down position. Route and zip tie. 22. Remove pipe and apply silicone to exhaust doughnut. Triple up springs on pipe and reinstall. 23. Install intercooler using hose clamps on cross bar. Install fan and route adapter harness. 24. Install the 3 charge tube. Do not tighten hose clamps. Try to slide the charge tube closer to the Y end for proper fit. Hook up the air temp sensor to the control box. Zip tie into place. Revised 10/23/2015 Page 5 of 10
25. Install clutch cover then turn the Y on the PTO side upwards until the clutch cover fits properly. 26. Install stock temp sensor and zip tie. Hook up the boost reference line to the push to connect on the intercooler. Route so it does not chaff or break. 27. CAREFULLY trim oil tank as shown using sharp knife or cutters. DO NOT puncture oil tank during this process. 28. Install heat tape on the chain case, hoses, stock EGT cable, and oil tank. Newer models do not require heat tape on chain case. 29. Drill the hole for the spring tab with a 3/16 drill bit. This hole already exists so you only will drill the plastic in the bell pan on the right side. 30. Install the stock muffler rubber bumpers on the turbo bracket using a flat blade screw driver. Revised 10/23/2015 Page 6 of 10
31.Install the turbo assembly then install the spring supplied for turbo bracket tab to bulk head spring tab. 32.Route the inside coolant line under the bulk head bracket. 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. 34.Route the outside turbo coolant hose under the bulk head cross member to coolant bottle. On standard turbo kits clean the belly pan, apply heat to velcro, then install oil pump as shown. 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. 36.Install the waste gate solenoid. Use the Velcro supplied to mount the solenoid. Use heat to activate the glue on the Velcro. Revised 10/23/2015 Page 7 of 10
37.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. 38. Using an air saw, cut exhaust side plastic for exhaust to fit through. This hole will be approximately a 3 1/2 hole. If desired, install heat tape to the lower inside side panel. 39. Test fit the head light assembly to the intercooler mount bracket. Tighten all the hose clamps into position making sure the head light assembly and charge tubes fit correctly. 40. Check for clearance on the clutch cover and the 3 charge tube. Tighten all air box and charge tube hose clamps. 41.Install Tial muffler. When installing the muffler rotate the top of muffler to the inside of the snow machine for a equal clearance to both the side panel, chain case and stock oil tank. 42. Install the factory EGT sensor into the turbo muffler, then remove the stock heat tape and insulation from the side panel then install the heat tape as shown. Revised 10/23/2015 Page 8 of 10
43. Cut the shroud just enough to run control box wiring and boost reference line through, then zip tie wires as needed. 44. Turn handle bars all the way to the left and install the cold air intake as shown in picture. 45. Install the hose from boost solenoid to the intercooler. 46. Install the hose from ECM onto cold air intake box. Install the hose clamp on the cold air bracket. Test fit the head light then tighten the hose clamp. 47. Install the silicone hose on the cold air intake box tube. Install the hose clamps between the cold air intake tube and turbo. 48. Install the head light assembly. Route the control box as shown in picture. Clean the console then install Velcro. Heat the glue on the Velcro to activate. Revised 10/23/2015 Page 9 of 10
49. Remove primary clutch. Remove the old ramps. Install roll pins in ramps, index roll pins as seen in picture. Be sure to perform clutch adjustments to Ski-Doo specifications. 50. 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. 51. On Standard Turbo Kits fill the turbo oil tank with12oz of TC2 Turbo oil. Remove the oil feed line off of the turbo then start the snow machine. Verify oil is flowing, then reinstall the oil line and tighten. Revised 10/23/2015 Page 10 of 10