can-am spyder - Aerocharger.com

CAN-AM SPYDER
Turbo Kit Installation Manual v1.3
1
Table of Contents
Section
Page
Introduction
3
Preparation
5
Aero-Commander Installation
14
Air Box Installation
23
Oil Catch Can Installation
27
Aerocharger Exhaust Side Installation
30
Aerocharger Cold Side Installation
35
Gauge Installation
37
Preparing to Ride
44
Aero-Commander Tuning
44
2
Introduction
Congratulations on your purchase of the Aerocharger Turbo system for the
Can-Am Spyder. You are now the owner of the most powerful, reliable, and
technologically advanced turbocharger in the world. With your new intercooled
turbo system installed, you will experience substantial performance gains on just
pump gas. Not only will you get amazing performance but our unique system
which combines VATN technology (Variable Area Turbine Nozzle) and our
frictionless, non-flooded ceramic ball bearing design will provide you with our
famous zero turbo-lag.
This kit is made and assembled by HiPerfomance, LLC., the manufacturer of the
Aerocharger. We manufacture turbos with a passion.
The installation of this kit consists of two major components:
1. Installation of the turbos system
2. Installing the electronics
Note: Before getting started, refer to your Packing List and identify all the
components of your turbo kit. This will also aid in the installation process.
WARNING!
Installation of the Turbo system is not for the mechanically challenged! If
you are uncomfortable with anything about 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.
3
WARNING!
This kit is designed for use on a STOCK Spyder only!
WARNING:
If your Spyder has been modified, consult HiPerformance (913.541.0200) before
proceeding. This Turbo system is intended for use on STOCK, well-maintained
Spyder with strong running, well-maintained engines/transmissions. Installation of
this kit on brand-new Spyders 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 Spyder is brand new, consult your local
dealership and owner’s manual to determine proper break-in procedures
BEFORE continuing with this installation. Failure to do so may result in
significant internal engine/transmission damage. HIPERFORMANCE WILL NOT
BE HELD RESPONSIBLE FOR DAMAGE TO VEHICLES POWERTRAIN.
HiPerformance is not responsible for ECU tuning/programming on Spyders that
were not stock before the installation of this turbo kit.
WARNING:
For best performance and reliability always use minimum 91-octane premium
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 HiPerformance 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:
HiPerformance holds no responsibility for any powertrain damage that results
from misuse of this turbo kit!
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 HiPerformance 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 void our warranty.
4
Preparation
1.) Remove plastics.
a. Remove all of the plastics from both sides of the Spyder.
2.) Trim the bottom right fairing
a. Mark the plastic can cut as shown using a body saw or cut off wheel.
5
3.) Remove the negative battery cable.
a. Using a Phillips head screwdriver, remove the bolt from the negative battery
cable.
b. Tuck the cable aside.
6
4.) Remove the stock muffler.
a. Using a spring tool or locking pliers, grab and remove the spring from the slip
joint.
b. Using a 10 mm socket, loosen the t-bolt clamp attached to the muffler.
c. Using an 8 mm hex key and 15mm wrench, remove the bolt supporting the
muffler.
d. Slide the muffler out and set aside.
7
5.) Remove the stock exhaust piping.
a. Disconnect the Oxygen sensor connector.
b. Using a 7/8” wrench, remove the oxygen sensor and set aside.
c. Using a spring tool or locking pliers, remove the springs holding the exhaust pipe
to the header on both sides of the Spyder.
8
d. Using a 10 mm socket, loosen the t-bolt clamps.
e. Remove the rubber hanger from the bracket on the exhaust piping. You will be
mounting the rubber hanger onto the provided Y-pipe before installing later.
f.
Remove the stock exhaust piping from the Spyder.
g. Be sure to save the springs, clamps and exhaust hanger that were just removed:
these will be reused later in the installation.
9
6.) Remove the stock Air Box
a. Release the nine clamps from the air box lid and remove the hose from the front
right side of the air box.
10
b. Remove the air box lid by sliding it towards the right side of the Spyder.
c. Remove the air filter.
11
d. Push the rubber inlet tubes into the air box.
e. Cut the zip ties found on the air box on the left side and disconnect the hose.
12
f.
Remove the six retaining screws from the air box housing.
g. Remove the air box housing by sliding towards the right side.
13
Aero-Commander Installation
1.) Set the Aero-Commander on the console bezel.
2.) Route all of the wires and hose as shown.
14
3.) Remove the connector from the fuel injector on the right side of the throttle body near
the rear cylinder head. If necessary, remove the metal spring clip on the connector.
4.) Using the shorter of the two fuel injector leads. Install the connector with a metal spring
clip onto the fuel injector. Install the other connector into the factory fuel injector that you
removed in the previous step.
15
5.) Remove the MAP sensor from the left side of the throttle body using a T-30 torx bit.
6.) Remove the fuel pressure regulator using a T-30 torx. This will leak fuel. Use a rag to
catch the fuel.
16
7.) Remove the connector going to the left side fuel injector.
8.) Using the longer fuel injector leads on the Aero-Commander, install the connection with
the metal spring clip onto the fuel injector. Install the other end into the connection you
just removed.
17
9.) Reinstall the fuel pressure regulator.
10.) Reinstall the MAP sensor onto the throttle body.
18
11.) Disconnect the connector from the MAP sensor.
12.) Plug the mating female connector from the Aerocommander wiring harness into this
plug.
13.) Then plug the male connector from the Aerocommander wiring harness into the sensor.
14.) Connect the 4 pin oxygen sensor connectors into the stock Oxygen sensor and the
factory wiring harness connector.
15.) Coil up the factory oxygen sensor and tie out of the way so the tip of the sensor does not
come in contact with anything.
19
16.) Using a T-25 torx and 8mm wrench, remove the bolt shown and attach the ground lead.
20
Air Box Installation
1.) Make sure there are o-rings installed on the six 6mm bolts.
2.) Put Loctite 242 (blue) on the bolt threads. Place the six 6 mm bolts into the air box from
the top side.
21
3.) Set the provided throttle body gasket in place and slide the air box into position above
the throttle body from the right side of the bike.
4.) Start each bolt by hand being sure not to cross-thread any of them. Once they have all
been started, tighten the bolts with a 10mm wrench.
22
5.) Attach the hose from the Aero-Commander to one of the nipples on the air box.
6.) Attach the hose from the Idle Air Control Valve onto the aluminum T and tighten the
clamp.
23
7.) Using the 3/16” hose barb tee fitting, connect the blow off valve to the fuel regulator and
throttle body.
24
Oil Catch-Can Installation
1.) Remove the hose clamp from the hose on the left side of the rear cylinder head.
2.) Remove the Hose.
25
3.) Install the Catch-can using the hole on the oil reservoir and the provided 6mm bolt and
lock nut.
4.) Transfer the clamp from the original hose and route the hose as shown.
26
5.) Attach the clamp onto the fitting.
6.) Using a provided zip tie, retain the hose as shown.
27
Aerocharger Exhaust Side Installation
1.) Install the new exhaust piping. NOTE: using an air compressor, blow out any debris that
may have found it’s way into the exhaust pipes before installation
a. Install the provided gaskets into the new down pipe.
b. Using the factory clamps, install the down pipe.
c. Using a 10 mm socket, tighten the t-bolt clamps to 159 in-lbs or about 13 ft-lbs.
d. Using a spring tool or locking pliers, reinstall the springs onto the down pipe.
e. Reinstall the rubber exhaust hanger.
28
f.
Using a 10mm socket, reinstall the bolt shown to attach the support bracket.
2.) Install the Aerocharger.
a. Using the provided gaskets, install the Aerocharger onto the down pipe as
shown.
29
b. Remove the fill plug from the Aerocharger. Use the photo below as a reference.
c. Put one bottle of Aerocharger Oil into the turbo.
d. Put Loctite 242 on the fill plug and tighten to 30 in-lbs.
e. Before installing the air filter be sure there is no oil on the turbo or inside the filter
to ensure the filter cannot slip off. Install the air filter and tighten the clamp using
a 5/16” socket.
30
f.
Run and attach the boost signal line from the air box to the Aerocharger boost
controller as shown.
3.) Install the muffler
a. Place the exhaust wrap into the turbine heat shield as shown.
31
b. Place the heat shield on the turbo as shown.
c. Using the provided M8 bolts, install the muffler onto the Aerocharger.
d. Using the bolt and nut from the original muffler, attach the muffler support bracket
onto the Spyder frame.
32
Aerocharger Cold Side Installation
1.) Install charge tubes as shown and tighten the hose clamps.
33
Gauge Installation
1.) Install the gauge mounts
a. Using a permanent marker, mark the hole locations on both sides of the handle
bars by using the mounts as shown.
b. Drill the marked holes using a 1/8” drill bit. Be sure not to go too deep, you are
just going though the plastic.
34
c. Prepare the gauge mounts as shown, use Loctite 242 (blue) on the screw.
d. Using the self-tapping screws, attach the mounts to the handlebar bezel
35
2.) Install the AEM Wide-Band Oxygen Sensor.
a. Run the sensor wire from the oxygen sensor in the muffler to the handlebars as
shown. Be sure to secure the wires in place with zip ties to keep them safe from
the exhaust or any moving parts.
b. Attach the harness the gauge as shown.
36
c. Run the lead with four wires from the gauge to the fuse box.
d. Use the provided splice and connect the red lead from the AEM wiring harness to
the Violet/Yellow wire going to the fuse box.
e. Crimp on and shrink the spade connector onto the black wire.
37
f.
Attach the black wire onto the ignition coil mount as shown.
g. Attach the four pin lead onto the gauge as shown.
38
h. Install the gauge into the pod as shown.
i.
Install the gauge into the mount. Use loctite 242 (blue) on the screw.
3.) Install the boost gauge.
39
a. Run the boost signal line from the air box to the handle bars and through the
gauge mounting ring as shown.
b. Install the signal line onto the gauge.
40
c. Install the boost gauge into the pod.
d. Install the pod onto the gauge mount. Use Loctite 242(blue) on the screw.
41
Preparing to Ride
1.) Drain the fuel tank into an approved container.
2.) Fill the tank with 91+ octane fuel.
3.) Reconnect the negative battery cable.
4.) Put the key to the “On” position and check for any fuel leaks.
5.) Start the engine and check for any air leaks. Also make sure the wide-band gauge is
operating.
6.) Turn the engine off.
7.) Reinstall all of the plastic fairings.
Aero-Commander Tuning
For tuning instructions and guidelines refer to the included laminated Aero-Commander Field
Guide.
42