XP/XM 600/800 ETEC Turbo System Installation
Contents
1. 41 Electronics and Boost Lines ccccceccccccccccccccccuccccuccccucucesaueusaueusaueusueeeauneueuneeauauensueesuueusanensanes 42 Power Harness lnstallatiOn ei ote nine HA ten sin SN mas tete 42 Solenoid Valve Install tion siiinennininnann nine 43 Aero Commander MSAIAUON Re tatin Emme tte teneur 44 Gra STS CaN a OU E ar ne nn nn en Mon desta 46 AP Ome MS Fall 46 XAN Cause msta 48 Rave st O 53 Putting the Snowmobile back together EEE EENE 54 Reconnect 54 AP PARIS eee eda alee 57 AMR POPE ne Se E 61 the Side Panels eee listes 65 D NS a ste Error Bookmark not defined IM N dace a Error Bookmark not defined Air Snow Intercooler Installation Error Bookmark not defined DD2. 67 move VLE Xels Error COS SUR cans enews 67 Skidoo Pressure ine 68 aa ae ced acne 70 Clute Dino a cto toa cnn sh ne ies le eatin ae ee Se none 71 INTRODUCTION Congratulations on your purchase of the Aerocharger Turbo system for the Skidoo Etec Snowmobile You are now the owner of the most powerful reliable and technologically advanced turbocharger in the world With your new intercooled turbocharger and fuel system installed you will experience substantial performance gains Not only will you get amazing performance but our unique system which combines VATN technology Variable Area Turbine Nozzle and our nearly frictionless non flooded ceramic ball bearing design will provide you with our famous zero turbo lag This system is made and assembled by Aerocharger LLC We manufacture turbo systems with a passion The installation of this kit consists of 1 Installation of the turbo system hardware 2 Installing the fuel control electronics 3 Tuning the clutching Note Before getting started refer to the Packing List and identify all the components of your turbo system This will also aid in the installation process Note This Installation guide covers all Etec models including
3. 4 7 g 2 AERULRARGER TURBO SYSTEMS XP XM 600 800 ETEC Turbo System Installation Manual V2 0 TABLE OF CONTENTS DATE 0078 D CEE LOL RES RS ee 1 ET 3 Preparan CO 4 XP ONY yanks EU 4 Remove BOUT Pane RES eae 4 Remove Front oes hs a cn duces de 10 ANON 6g et 12 Remove Body Pane tn en RE 12 Remove Air Plenum From the 14 PROTO CAS ac dd Lt 18 Reovee tot a 20 REMOVE nest ba nement bestest 21 Pe tre a mince aba nines 22 Croc Nat Ser INS ta AOU ten 32 Tube URANII T 39 Euel Tire St et E
4. 4 Clip the panel back in and check to make sure the gauges fit in the sled Then use the included rivets to rivet the panel in place 5 Connect the boost line from the turbocharger to the boost gauge and install the boost gauge into the panel Then secure the gauges with the included U Clamps to the plastic panel 48 6 Now have to relocate the DES Switch the other panel the other side Start by removing the panel Then using the included template mark where the hole goes on the panel 49 7 Using 7 8 drill bit or holes saw drill a hole in the panel at the location marked on the template Use a Razer blade to cut the notch at the top so that the switch will fit flush 8 Screw the DES Switch into the panel and re install the panel onto the sled d 9 Connect the power plug on the AFR Gauge to one of the Female power receptacles on the included wiring harness Both receptacles provided the same power output Then connect the sensor plug on the AFR Gauge to the sensor wire 50 10 The two extra wires on the AFR Gauge are for programming and datalogging purposes For a basic installation you will not need them Simply zip tie them out of the way If you wish to cut them off then you will not be able to use many programmable features of the Innovate AFR Gauge View the Innovate MTX L user manual online for more information on the feature of your innovate AFR Gauge 91 11 Install the AFR S
5. SS S 31 AEROCHARGER INSTALLATION 1 Using the provided cover and rivets cover the factory exhaust hole location 2 Use the pattern included in the kit to mark the location of the new exhaust hole Use a 2 5 Hole saw to cut a hole where the template indicates Note The XM and XP use the same template however you will have to cut the template out on the line marked for the XM to locate the XM exhaust hole 32 3 Seat the cradle in its place The holes in the base will correspond with the stock rivets Note Old muffler design is shown in photograph 4 Bolt the cradle to the frame using the stainless steel washers and four nuts and bolts supplied in the kit on the other side of the foot well 5 Install the ceramic coated heat shield and exhaust wrap onto the turbine housing of the Aerocharger 33 6 Install the Aerocharger onto the exhaust cradle using the provided M8 bolts and lock washers Do not completely tighten the bolts as it may be necessary to rotate the turbo for final fitment Note Old muffler design is shown in photograph gt R a fF 34 7 Remove your expansion pipe and check for any welding debris We found mig wire Our pipe and were able to remove it using a sanding wheel After inspection make sure to blow out any debris 2010112108 14 46 37 8 Bolt the turbine inlet pipe to the turbo using the M10 flange bolts provided in the Put the
6. person that likes to tinker to get every ounce of performance out of your system then you should read these If you just want to have fun and not worry about this then simply use the default settings and enjoy your turbo system e The Yellow Blue mode is the mode you will adjust more than any other when tuning your sled It will control the fueling at wide open throttle under boost If your sled is lean at wide open throttle move the lights to the right in this mode to add more fuel Also if you make very large changes in elevation gt 5000ft you might want to look at adjusting this mode Also if you change your boost levels drastically this mode will also be used to dial in wide open throttle e The Red Blue mode can be used to create a snappier throttle response when climing hills If you increase the lights on this mode it will clean up the midrange of the power band and increase throttle response However if you are cruising on a trail with this mode turned up then your sled will run lean and this could damage your engine This is why we do not set it higher as a default setting If you want the maximum longevity out of your system then leave this mode set to default or lower e The Red mode can be turned up to add more fuel during cruising This will lower engine temps and run your engine safer on long trail rides However once again turning this mode up to high will hurt climbing performance and throttle response outside of cruising condi
7. T27 torx screws connected to the gas tank 2 Use 7 mm socket to remove the coolant tank from the front of the air plenum and disconnect hoses Note this is not required on sleds with a 600cc engines 10 4 Loosen the hose clamp the top of the air box then remove the top section of the plenum 11 XM ONLY PREP Only use this section of the manual if you have a XM model If you have a XP model then you should skip to the next section REMOVE BODY PANELS 1 Start by taking the side panels off the sled 2 Remove the bolts holding on the hood assembly using a T27 Torx to remove the 2 bolts under the gauge cluster and the 2 bolts on either side of the hood 3 There is also a Velcro strap holding the hood assembly to the chasis that needs to be unstrapped Then loosen the velocity tube on the clutch side of the sled connecting the two air plenums together with a flat head screwdriver 12 4 Disconnect the main electrical plugs from the back of the gauge cluster and the air temperature sensor on the velocity tube connecting the two air plenums 5 At this point you can remove the hood from the sled by puling forward and up 6 Remove the 2 27 bolts on either side of the gas tank plastic connecting it to the gas tank 13 7 Disconnect the two electrical plugs that connect to the switches the gas tank plastic REMOVE AIR PLENUM FROM THE HOOD 1 First remove the small accent pieces f
8. a 13mm ratchet to remove the nuts on both sides of the gas tank 18 2 Remove gas tank vent line 19 REMOVE STOCK MUFFLER 1 The Muffler is held on with 4 exhaust springs one on both sides near the bottom and two connecting it to the exhaust pipe There is also a temperature sensor on top of the muffler Remove this using a 17mm wrench and use a spring puller to remove the springs The muffler will easily come off Two spring tabs connect theynuffler to the exhaust pipe A f QU 4 The clip toward the front of the muffler The clip toward the rear of the muffler Note The temp sensor in the muffler is fragile take care not to break it 20 REMOVE STOCK AIR BOX 1 Remove the intake air temperature sensor from the airbox tube using a flat head screwdriver to pry up the two retainers Leave it connected to the wiring harness and move it aside 2 Loosen the two hose clamps holding the airbox onto the throttle bodies using a long Phillips head screwdriver 4 2 21 REMOVE SECONDARY CVT 1 Using the clutch tool provided with the sled open the secondary clutch and remove the belt 22 5 Use non marring rod the Ski doo gear retaining tool to drive out the jackshaft using a rod leave it in place to hold the gear and spacer after the jackshaft is removed INSTALL REED PEDALS REMOVE STOCK COMPONENTS 1 Use along straight slot screwdriver
9. feed the wires down the steering shaft into the engine bay Then connect the connectors to their appropriate locations rm This is the default mounting position for the Aero Run the electrical harness through the handlebars Commander and into the sled Connect the long leg of the harness to the solenoid valve included in the system Unplug the ignition coil plug this is directly across from the fuel rail and is pictured above The Aero Commander harness gets connected inline at this plug 44 Note There are many acceptable places to mount the Aerocommander depending on your personal preference The installation shown in the manual installs the Aerocommander in the easiest spot for access while riding Other mounting locations include but are not limited to inside the side panel on the dash on the handlebars behind the headlights Many of these locations do not allow easy access to the Aerocommander but you will not need to tune it much after your first ride on your sled Connect the fuel injectors to their matching plugs There are two of these plugs with about 6 of wire between them these are for the fuel injectors it does not matter which injector they get plugged into 2 Attach the signal line labeled to Aero Commander on the solenoid to the Aero Commander 45 3 Power the Aerocommander by plugging the male weather pack connector into one of the female receptacle in the power harness Either rec
10. inlet pipe on as shown in the picture Remember to put the gasket included with the kit in between the turbine inlet pipe and the Aerocharger Use the original graphite gasket on the exhaust pipe If gasket is damaged replace with a new gasket 39 9 Tighten the bolts on the Turbo Tighten the Turbine Outlet bolts using a 138mm Tighten the four turbine inlet bolts using a 15mm open ended wrench wrench 10 Using a spring tool install two springs per side onto the connection between the turbine inlet pipe and the expansion pipe 11 Using a 16mm wrench reinstall the temperature sensor into the bung on the muffler The sensor needs to be oriented as pictured to prevent damage to the sensor 36 12 Remove the brass pipe plug shown 37 14 Put LocTite 262 Red the plug and then torque to 35 in lbs 38 CHARGE TUBE INSTALLATION 1 Route the Charge tube from the turbocharger to the Air Plenum and tighten the hose clamps 2 The blow off valve side of the charge tube gets connected to the top of the air box The other end gets connected to the compressor outlet on the Aerocharger 39 3 The tube is routed behind the headlights 40 FUEL LINE INSTALLATION 1 Install the fuel line The fuel line should be routed right in front of the ECU and behind the chasis members If the fuel line seems to short then route it more directly Be sure to check all along the line to make sure it will not
11. to loosen hose the clamps holding the throttle bodies onto the reed boots Then remove the throttle bodies do not disconnect the throttle cable 24 INSTALL REED PEDALS We have included 4 outer reed pedals that are designed for turbo Etec engines They replace the stock outer reeds The inner reeds do not suffer any additional wear and tear from the turbo system so they do not need to be replaced 1 Remove the reed cage and unscrew the stock outer reeds They are the reeds on the case side of the reed cage and have a solid bar holding them to the cage Fe 2 With the stock outer reeds removed install the new reeds included with your system The reeds have a concave side and a convex side If they are not installed correctly you will experience poor throttle response In case you cannot see which side is concave then there is a notch in the corner of the reed pedals This notch goes in the upper right part of the cage as pictured below 25 3 Replace the bar and screws to secure the reed to the Make sure to use Loctite 641 retaining compound or low strength 222 thread locker 4 Reinstall the reeds and boots onto the engine 26 REASSEMBLE INSTALL THE AIR PLENUM 1 Re attach the throttle bodies and tighten the hose clamps 2 Reattach the driveshaft support arm Torque the bottom bolts to 18 ft lbs Torque the top bolt to 124 in lbs 27 REINSTALL THE SECONDARY CLUTCH 1
12. void your warranty 2 TOOLS NEEDED 9 Metric socket and wrench set 7 17 T27 torx wrench Stubby Phillips head screwdriver Long Phillips head screwdriver 2 5 hole saw 6 8 3 8 socket extension Spring tool Torque wrench 4mm Allen wrench 10 1 5 Hole Saw 11 7 8 Wrench 12 Razor Blade PREPARATION XP ONLY PREP Only use this section of the manual if you have a XP model If you have a XM model then you should skip to the next section REMOVE BODY PANELS 1 Remove the left and right side panels 3 Remove the gauge panel by unscrewing the 5 T27 torx screws the two on each side and one in the front 4 Disconnect the Gauge panel electronics Press with your thumb as shown in the picture and pull the clip off Squeeze with your thumb and pull the clip off Press with your thumb as shown in Push up and out with your thumb the picture and pull the clip off as shown 5 Remove the headlights there are two 27 torx screws under the windscreen holding them on Do not discard hardware as they will be reused later 7 Remove the gas tank panel First unscrew the gas cap and remove the threaded plastic retainer There are also two T27 torx screws toward the front that need to be removed Disconnect the electrical connections from the gas tank panel There may be fewer connections depending on the sled model REMOVE FRONT AIR PLENUM 1 Unscrew the
13. 600 engines 800 engines XP models XM models Non Intercooled Systems Air Snow Intercooled Systems Read the entire manual before installing and skip sections the do not apply to your system WARNING Installation of the turbo system 15 not for the mechanically challenged If you are uncomfortable performing any of the tasks outlined in this manual please refer to trained professionals at your local performance shop If you are performing the installation of this system it is suggested that you read this ENTIRE manual prior to proceeding with the installation It is also suggested that you review each section as you progress to ensure everything Is installed correctly WARNING Do NOT hit the rev limiter It will lead to detonation and you will damage your engine WARNING This system is designed for use on a STOCK 600 800 Rev XP only WARNING lf your Rev XP has been modified consult Aerocharger 913 541 0200 before proceeding This Turbo system is intended for use on a STOCK well maintained 600 800 Rev XP with a strong running well maintained engine Installation of this kit on brand new snowmobiles with very few miles hours on them is NOT recommended New engines require specific break in procedures that do not include adding forced induction If your snowmobile is brand new consult your local dealership owners manual to determine proper break in procedures BEFORE continuing with this installation Failure to do so ma
14. AEROCOMMANDER SQiEMGID OPEN TO BOY STOCK SYSTEM LINES TO MANIFOLD TO MANIFOLD art wx M IE DO EHO TO WALVES Stack Soalenaid Valve UNLESS IFIED PIWEHS He SRE IH IH CHES T LERA CES FRA CTO HA La 1 21 AAS UL R ti OH 1 Two PLA CE 071 THREE PLO 100 IHT ERF RET Ec TOLER AHS TIAS 1702 FIH H AST C LE 3 iE DATE D RAWH CHECKED EHG APPR WEG APPR 2 TO AEROCHARGER BOOST GAUGE Aerocnarger TITLE A aA LES 1 1 TO TURBO CONTROLLER TO MANIFOLD SKIDOO PRESSURE LINES SIZE DG 29640 WEISS REW SHEET 1 68 SKIDOO WIRING DIAGRAM AFR GAUGE FOR Lo HoT LEED SEH OR EZE q TT 21 TS WOH IT E BR HoT LEED AEROCOMMANDER TELLS Was 4 247 4 ATTA LHA 24 24 SUB 55 REDYSELUE 1 STOCK IGNITION COIL PICKUP DATE Aerocharder TITLE FLUG HOT SO LEH GIP IH CLUBEL IH S 7ST Etat ETEC WIRING SIZE DWG A SAL
15. E 1 RED 14 BLACK 15 BLACK 1S OPEN STOCK tee REDS BLUE 12 J wae IT ES ELL TOSTOCK GROUHD LOCATION g TO FUEL INJECTOR al la AIR FLEN LUM gt YELLOW 4 Es UNLESS SPEC IFIED H A RE IH IH CHES E TO LERA HA Le 1 22 SHEKEL A HG ULA CH 1 EHS AFPR Tid PLACE DECIMAL 201 THREE DECIMAL 3005 MFS A PPR INTERPRET GEO TRI aa TOLER AH GINS HS La Site 188 CO LE 1 DO SCALED RAWUIHG 5 4 a REW SHEET 69 FUEL The following fuel chart is recommended octane levels based on boost and altitude This chart is for reference only Many factors play a role in safe octane such as air density temperature and tolerance specific to your motor This chart is intended to give an idea of what octane levels you should expect to run during the most common of circumstances Octane Based on Boost and Altitude eeee 116 5 5 111 GPS PS 106 Octane SPs 101 9 5 96 LOPS 11 5 a 4 4 4 4 0 5000 10000 15000 Elevation FT 91 12 5 FUEL CONTROLLER ADJUSTMENTS The fuel controller has adjustability in it so that you can fine tune your fuel
16. Put the driveshaft back in its original location Do not drop the gear that it slides into or you will have to open the chain case to get it out When installing the jackshaft you need to have the bearing retainer started before completely sliding in the shaft 2 Thread the bolt and washer into the driveshaft and tighten it down with a torque wrench Torque the bolt to 38 ft lbs Reinstall the rubber cap Torque the nuts on the bearing retainer flange to 133 in lbs 28 4 Reinstall the belt and remove the compression tool from the CVT driven 29 INSTALL AIR PLENUM 1 Remove the throttle body screws and the vacuum plugs pictured These will no longer be needed 2 Using the supplied silicone packet lubricate the o rings 3 Press on the air box j T ee 4 p i The holes the air plenum y support will line up with the screws ra gt 2 you removed from the throttle the air plenum to 2 bodies t 4 ue 3 press it onto the f throttle bodies This will take significant force It may be helpful to use a heat gun and warm up the air plenum and o rings Press on the back of 30 4 Using the longer screws provided attach the air box to the throttle body 5 Instal the spring on the bottom of the air plenum The spring hooks onto the bracket that holes the clutch shield in place xf
17. Replace Sensor Reference cell _ Short in sensor cable _ Inspect sensor cable for or tears circuit shorted _ Short in sensor _ Replace sensor Reference cell Cable connector not fully Very Sensor is fully seated into circuit open seated connector make sure it clicks 2 Damaged sensor cable _ Inspect sensor cable for or tears 3 Damaged Sensor Replace sensor General System Software error Reboot MTX L by cycling power error typically a Reload firmware if necessary software error Sensor Timing 1 Sensor overheating Perform sensor heater error typically a The Bosch 504 2 ts rated to recalibration b Move your sensor damaged operate at a sensor housing bung as far downstream as possible sensor temperature of lt 900 degrees Right before the cat or 2 3 feet from the measured at the bung for end of the tailpipe are good locations c maximum accuracy and control Add a heatsink to isolate the sensor When this operating temperature from the pipe The 1 is range is exceeded the sensor can available accessory no longer be accurately 2 Replace sensor controlled 3 Correct Tune and recalibrate the 2 Sensor is damaged sensor 3 Overly Rich condition supply Voltage Supply voltage too low for sensor Check your 12V connection for corrosion too low regulation Whenever Error 2 ts displayed existing sensor calibration data 15 discarded 67 SKIDOO PRESSURE LINE DIAGRAM TO
18. ded hose clamps to attach it to the chassis member Tighten the clamps and the top screw when the headlights are seated correctly 64 VENTING THE SIDE PANELS 1 Using the clutch vent mark the rivet hole locations 2 Using a 3 16 drill bit drill out the holes 3 Using the provided rivets and washers install the clutch vent 65 4 Cut out or drill holes within the area for the vent 5 Remove the backing paper and stick the vent or vents to the panel like a sticker Make sure the surface Is clean and free of dust and debris 73 66 APPENDIX INNOVATE MTX L ERROR CODES Code Error 1 Heater circuit 1 Short in cable 1 Repair replace cable shorted 2 Short in sensor 2 Replace sensor Heater circuit 1 Damaged sensor cable 1 Inspect sensor cable for or tears open 2 Cable connector not fully seated 2 Verify Sensor ts fully seated into 3 Sensor Damaged connector make sure it clicks 3 Replace Sensor Pump cell circuit Short in sensor cable 1 Repair sensor cable shorted _ Short in sensor 2 Replace sensor Sensor overheating 3 Move your sensor bung as far EGT gt 17009 downstream as possible OR add a heatsink to isolate the sensor from the Pump cell circuit Damaged sensor cable Inspect Sensor cable for rips tears open Cable connector not fully Verity Sensor is fully seated into seated connector make sure it clicks Sensor Damaged 3
19. ds cut in half the opening response 15 not slowed any giving good throttle response but when the reeds try to slam open and hit the case they cannot because the extra half a reed adds extra stiffness the further the reeds open This method works just as well as using siffer turbo reeds and does not sacrifice bottom end performance 1 Take your old set of reeds and cut half the length of the pedals off with a razor blade 2 Install the half reeds on the outside of the outer reeds on your new reed cage or pedals 72 Ski Doo Aerocharger Turbo System By Aerocharger LLC 913 541 0200 www AEROCHARGER com 73
20. ensor into the muffler included with your system Use 7 8 Wrench to tighten the sensor into place Do not over tighten the sensor or you may damage it Connect the sensor to the AFR gauge wire 12 The AFR Gauge may need to be calibrated before use For full calibration procedure consult quick start guide that came with the AFR Gauge The simple calibration procedure is a Disconect the sensor from the AFR Gauge Start the sled and you will recive and E2 Code Turn off the sled Remove the sensor from the muffler bung Reconnect the sensor to the AFR Gauge and start the sled with the sensor in the open air The sensor will say HTR for approximately 30 40sec and then it will flash CAL for 2 sec At this point the sensor is calibrated Reinstall the sensor into the muffler 52 RAVE VALVE INSTALLATION 1 Install the white check valve between the RAVE valves and the factory RAVE solenoid as pictured Do not install the check valve on the new solenoid included with your system 2 Install the vacuum side check valve onto the line going to the top of the factory RAVE solenoid You will need to remove and cut about 1 2 of the spring off You should also use a clamp or wire tie to hold the hose on See the Appendix in the back of this manual to see a complete diagram of the vacuum lines 93 PUTTING THE SNOWMOBILE BACK TOGETHER RECONNECT THE GAS TANK 1 Reconnect the electrical and fuel lines at the
21. eptacle will work GAUGE INSTALLATION XP GAUGE INSTALLATION Only use this section if you have a XP model If you have a XM model then skip this section 1 Install the gauges on the top panel of the sled Use a 2 hole saw for the AFR gauge and 1 5 hole saw for the boost gauge The boost gauge hole will have to be shaved out to 1 575 diameter for the boost gauge to fit in the hole The gauges can install anywhere on these panels that you wish to put them the recommended set up is both gauges on the mag side panel 46 2 Connect the Air Fuel gauge line to the oxygen sensor the exhaust and run the end to the gauge pod location 3 Connect the sensor harness to the Air Fuel gauge and connect the boost gauge line from the turbocharger to the boost gauge 47 XM GAUGE INSTALLATION Only use this section if you have a XM model If you have a XP model then skip this section 1 The gauges on the XM install on the small panel to the right of the steering column This location protects the gauges from debris while riding 2 Remove the right hand side clip in panel that has the DES Switch located on it 3 Remove the DES switch by unscrewing it and use the provided gauge plate to cut the holes in the stock panel to clearance the gauges Also using a razer blade clearance the gas tank plastic so that the gauges will fit in the panel Try not to cut into the clip holes or the panel may not clip back into place securely
22. front of the tank The hose coming off the front of the gas tank goes back to the filter from which it came Reconnect the electrical connector on the fuel pump housing Just press the quick disconnect fitting onto the a post coming out of the 7 Use the Factory hose clamp to front of the tank attach it The fittings all go back on the same way they were taken off 54 2 Reconnect other connections Re connect the breather line at the top of the tank Re connect the plug coming off the bottom of the tank hee Use a zip tie to reattach the wire at the bottom of the tank 99 3 Bolt the gas tank back Slide the tank forward on the sled to get the chassis Line up the bolt holes at the neck and replace the bolts supports and the gas tank over the studs on either the same way they came off Torque the bolts to 124 side in lbs Remember to use the aluminum washer inserts that hold the plastic gas tank onto the frame stud Torque the bolts to 25 ft lbs 56 XP 800 COOLANT TANK RELOCATION This step is only required on the 800cc E Tec engines If you are installing ona 600cc engine the coolant tank is already in the correct location 1 Drain the coolant fluid from the reservoir 57 Re attach the coolant bottle to the hose with the included hose clamp 58 XP REPLACE PANELS Only use this section if you have a XP model If you have a XM model t
23. hen skip to the next section 1 Replace the gas tank cover panel Screw in the two T 27 torx screw at the front to connect it to the front panel Re connect the kill switch plug Re connect the switch on the right Screw the gas cap nut back on top hat down Make sure the tabs toward the back are underneath the frame 59 This step is for the 800cc version only It is not necessary for the 600cc a 2 Detach vent panels from plenum lt PR LES There is another snap tab at the bottom the vent 3 Attach the vent panel Place the vent under the gas tank panel just like it would sit if the plenum were still there Then screw in the T27 torx screw that connects it to the gas tank It may seem secured but when the other panels are on it will be held securely in place double sided tape can also be used on the top of the vent to help hold it in place 4 Attach the air temperature sensor that was removed from the factory airbox to the frame near the clutch side vent 60 5 Included with the non intercooled system is a headlight support bracket This bracket bolts on to the chassis bar that the intercooler would bolt onto and support the headlights in place of the stock air box Use and extra stock clip nut and bolt to attach the support to the headlight XM REPLACE PANELS Only use this section if you have a XM model If you have a XP model then skip this section 1 First rea
24. ing to your particular engine and needs Once you have your sled dialed in there is rarely any reason to further tune it The Aerocommander comes preprogrammed with the base settings These are settings that work for most conditions There are 6 adjustable modes that can be used to fine tune your system e Green mode This mode controls how much fuel is being added under low RPM conditions 0 4900 such as cruising at low RPMs and riding downhill Yellow Mode Controls how much fuel is being added in the mid range of the RPM band 4900 6500 such as general trail riding e Red Mode Controls how much fuel is being added at the top of the RPM range 6500 Max RPM such as in a high speed cruise or at wide open throttle Green Blue This is the fuel added when the blue light initially turns on or when boost is first created This mode rarely needs any adjustment 70 e Yellow Blue The maximum added fuel when under boost This mode is the mode to adjust for large changes in elevation If you are lean or rich while at wide open throttle or high load conditions under boost then adjust this mode to correct the problem e Red Blue This mode controls the switch point from the yellow mode to the red mode By adjusting this mode up you will raise the RPM of the yellow mode It is adjustable from 6400 7600 RPMs Fueling Tips and Tricks These are some of the things you can do with your Aerocommander If you are the type of
25. rom the side of the hood with a flat head screwdriver and remove the T27 bolt under them 14 2 Remove the 2 127 Bolts on the underside of the hood toward the front At this point the headlights gauge cluster and air plenum will come free of the hood plastic 15 3 Remove the snow deflector by pulling it off No tools needed 4 Remove the 127 screws under the snow deflector so that the gauge cluster will come free from the headlights Make sure to disconnect the headlight electrical connectors as well 5 Remove the Intake vents from the side of the headlight assembly by removing the 2 screws that hold each of them on The 2 screws are located on the bottom of each vent 16 6 Remove the 2 bolts holding the headlights on The headlights and glove box will come free of the stock air plenum 17 REMOVE GAS TANK 1 Unbolt the gas tank there are two 13 mm nuts on either side of the seat There are two 10mm bolts at the handle bars and 2 more 10mm bolts connecting support members There are two vertical members attached at the we handle bar neck connected with two 10mm bolts running along the gas tank to the handle bar neck Remove the four 10mm bolts and the frame members over the gas tank will be loose from the handlebar neck On either side of the gas tank midway down there are two 13mm nuts covered by panels that snap off Pull outward on the panels to remove them Use
26. rub excessively on anything and rupture Also be sure all of the fittings are connected securely and not broken The long leg of the fuel line gets screwed onto the fuel tank fuel line and the ECU rail The short legs of the line get installed between the gas 41 ELECTRONICS AND BOOST LINES POWER HARNESS INSTALLATION 1 The wiring harness uses the extra fuse block on the oil tank to supply power to our electronics 2 Insert the power wire into the open fuse block and connect the ground the the stock grounding bolt located behind the mag side footwell 3 Insert the fuse included with the wiring into the fuse block and route the wiring harness up to the Aercommander and AFR Gauge Either plug will work for both devices 42 SOLENOID VALVE INSTALLATION 1 The solenoid valve comes pre assembled with lines marked for their locations 2 Connect the lines marked to manifold to the barbs on the throttle bodies zip tie the solenoid valve the chasis The line that is marked Line to Aerocommander is connected to the barb on the blue line of the Aerocommander Photo for this step is in the AeroCommander Installation Section 43 AEROCOMMANDER INSTALLATION Note The basic installation of the Aerocommander is the same for the XM and XP models The photographs show the installation on a XP model The basic routing of the wires and connectors is the same for both 1 With the Aerocommander near the handlebars
27. ssemble the headlights gauge cluster and glove box The glove box fits in between the gauge cluster and headlights and is held in place by the two parts The gauge cluster screws onto the headlights using the same bolts that disassembled it 61 2 Now to secure the vents onto the side of the headlight use the brackets that came with the system Snap the vents into place and using extra stock thread tabs and 27 screws attach the brackets as shown 3 Now take the other set of brackets included with the system and attach them to the hood panels Once again use the hardware left over from removing the air plenum to attach the brackets 4 Now put the hood panel on the sled Secure it in place with the 2 T27 screws on the sides The brackets that you just attached will slip under the gas tank plastic mounting holes 62 5 Now screw the headlight support adapter onto the headlights using the included Phillips head screws The headlight support adapter allows you to use the same headlight support bracket that was on the XP models After you install the bracket use the extra hardware from removing the air plenum to attach the headlight support bracket 6 Drop the headlight assembly into the sled Use the stock screws to attach it Make sure that you are also threading the screws throught the hood plastic supports that were included in the system 63 7 Adjust the headlight support to ensure proper height Use the provi
28. tions CLUTCHING Creating a perfect clutching for all applications is nearly impossible to do with a CVT Many factors are involved in clutching performance such as rider weight snow conditions eleveation boost levels air density style of riding and personal preferences to name a few We have included some pin weights that are a very good starting point for most of our customers We encourage any customer to experiment with different clutching on their own to achieve their personal perfect clutching The following graph gives a basic starting point for clutch tuning based on boost and altitude 71 Pin Weight Based on Boost and Altitude 26 5 5 24 22 2 7 5 20 18 16 10 5 14 12 12 5 0 5000 10000 15000 Elevation FT This graph is based on a 441 ramp and a 200 290 Green Black Primary spring This is also based on stock gearing and a 154 track Make note that this graph gives an idea of a starting point for clutch tuning if you are unfamiliar with tuning your clutch visit your local Ski doo dealer and have them tune it for you REEDS We have included a set of outer reeds that hold up on turbocharged Etec engines however there are other alternatives to reeds besides using these DOUBLE STACK METHOD The double stack method uses a new set of reeds and a set of used outer reeds cut in half By double stacking them with outer ree
29. y result in significant internal engine damage AEROCHARGER WILL NOT BE HELD RESPONSIBLE FOR DAMAGE TO VEHICLES POWERTRAIN Aerocharger is not responsible for tuning programming on 600 800 Rev XPs that were not stock before the installation of this turbo kit WARNING For best performance and reliability always use minimum 91 octane non ethanol fuels and listen for signs of detonation IF DETONATION SHOULD OCCUR OR IF YOU ARE UNSURE IF YOU ARE HEARING DETONATION DECREASE THROTTLE APPLICATION IMMEDIATELY and consult Aerocharger staff 913 541 0200 Detonation should NOT be an issue with this kit provided if it is installed correctly though OEM factory shipped engine and parts inconsistencies are possible on any new vehicle Note Aerocharger holds no responsibility for any powertrain damage that results from misuse of this turbo system 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 or inconsistent poor performance from the turbocharger system Contact Aerocharger for any questions or concerns Do NOT let any debris hard or soft enter the existing air intakes or exhaust ports during installation of this turbo kit Do NOT use any silicone sealants under any circumstances Doing so can result in F O D Foreign Object Damage to the turbo This will
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