Arctic Cat 9000/1100T Big Chute Turbo

Remove hood & side panels

Remove the plastic turbo cover on the left side of the sled (it is the plastic cover that covers the intake elbow)

Label all of the vacuum hoses connected with the turbo, intercooler and boost control

Loosen clamp securing the intake elbow.

Loosen clamp securing the rubber boot to the turbo inlet

Loosen intercooler boost hose clamps (upper and lower) and disconnect hoses from intercooler end tanks.

Disconnect the 2 smaller hoses from the top of the intercooler end tank

Remove rearward intercooler brackets

Remove intercooler (do not remove front intercooler brackets – intercooler can be removed with these brackets attached)

Remove the rubber water line that goes from the tank to the top of the turbo. Have a 3/8” bolt handy that you insert into the end of the rubber hose. This will prevent all of the antifreeze from leaking out. Use a rubber cap on the turbo side to plug the inlet.

Remove the 5 screws that hold on the lower heat shield

Remove the 3 bolts that hold in the cross brace that holds the upper heat shield on. You will need to drill out the two rivets on the main spar that hold the heat shield to the main spar. You will also need to drill out the rivets that hold the very top heat shield which wraps around the main spar

Remove the cross brace

Remove the 10 mm bolt on the bottom of the turbo that holds the heat shield to the turbo.

Remove the muffler

Spray a good penetrating oil on ALL of the exhaust nuts – header pipe to engine, header pipe to turbo, down pipe, and turbo support brackets. Let it sit for an hour.

Remove the turbo downpipe nuts and washers (outlet pipe that connects to the turbo) The upper back one can be accessed from the right side of the sled with some ratchet extensions and a universal joint. Take a picture of how these bolts and retainers are stacked. Save all items as you will reuse them

Remove the turbo support bracket – the one behind the steering column is very difficult to remove. Although we do not recommend this, this job is made far easier by removing the steering column. If you have the vertical steering modification from Arctic Cat, you can use their instructions for the removal and reinstallation of the column.

Remove the nuts and washers holding the header pipe on

Using a 14 MM socket, remove the oil line from the top of the turbo. Save the bolt and two washers and be careful not to damage them!

Remove the nuts and washers holding the turbo to the header

Looking at the right side of the turbo (clutch side of the engine), you will see the turbo oil drain line – it is a rubber hose coming from the bottom of the engine. Using a long needle nose pliers, slide the hose clamp down, then using a screw driver, push the rubber oil drain line off of the turbo oil drain line.

Using a long needle nose pliers and coming from the clutch side, slide the hose clamp that holds the bottom water line on the turbo so you can remove the line from the turbo. Have a 3/8” bolt handy to slide into the water line once you remove it from the bottom of the turbo so all of the anti-freeze does not leak out of the engine.

Remove the header and turbo

Remove the metal water lines from the bottom side of the turbo – SAVE THE BOLTS AND WASHERS AND LINES -YOU WILL BE USING THEM ON THE NEW TURBO!

Remove the oil drain line – SAVE ALL PARTS.

Place all nuts, bolts and lines removed from the bottom of the turbo in a plastic bag and save – you will need them for the Big Chute install.

THE WASTEGATE ACTUATOR AND ALL ITEMS ASSOCIATED WITH THE WASTEGATE MUST BE INCLUDED WITH THE TURBO.

WITH TAPE AND A MAGIC MARKER, PLEASE WRITE YOUR NAME ON THE TURBO AND ECU. ALSO, PLEASE WRITE INCLUDE THE FOLLOWING IN THE BOX-

• Name:
• Address:
• Phone #
• Email address:
• Kit ordered:
• Fuel Requirement: (93 or 100 octane)
• Year, Make and Model of sled:
• Sled Modifications:

It is best to put a clean paper towel into the intake side and intake outlet side of the turbo to prevent debris from entering the turbo inlet and outlet – make sure you remove them before final hose connections are made

A few modifications will need to be made to the oil drain line and water lines prior to installation. Please refer to the pictures below:

Prep the Big Chute turbo by installing the hard water lines, hard oil drain line and vacuum line from the waste gate actuator to the turbo outlet. Refer to the picture taken in step 20 of the removal. For the water lines – install one washer below each of the banjo fittings and one above, then slide the bolt through and tighten

Do NOT adjust the waste gate – it has been set by us and should not be changed

Install all items in reverse above. Double check your work – make sure all clamps are on and tight.

Make sure the turbo oil supply line is installed properly – it requires one washer above and one washer below the banjo fitting. The oil line has a tight fit between the coolant lines and the waste gate bracket. You may have to bend the oil line to center it over the oil hole on the turbo. Do this carefully – do not kink the line or cross thread the bolt. Take your time. The coolant line may need a little grinding on the boss where it enters the banjo. The line is about 3/16 of an inch thick at this point. If needed, the water line boss can be ground down so the oil line does not touch. See below.

You may have to change the clocking of the EVO supplied intake boot so the hood fits properly

Fill coolant tank with 50/50 antifreeze. PUMP GAS KITS SKIP TO STEP 1 BELOW

Add 50/50 coolant to the overflow tank until full – leave the cap off of the tank for now.

Loosely Install the hood so it can be moved around for access to the engine coolant bleed screw on the and the coolant fill tank cap and reconnect the wiring enough so the engine can be started.

Do not install the side panels at this time

Install the EVO reflashed ECU.

Raise the front of the sled so the engine bleed screw (See the picture below) is higher than the rear heat exchanger.

Start the engine for 15 seconds and shut off – check for leaks. If no leaks are detected, proceed to next step.

Add more 50/50 coolant to the overflow tank and replace tank cap.

Start the engine. Crack the bleed screw so a small very small amount of antifreeze can be seen coming out. Let the motor idle until you can feel the rear heat exchanger getting hot. Tighten the coolant bleed screw on the engine and shut the motor off. See picture below.

Let the engine completely cool down. Refill the coolant tank to the top.

Start engine again, verify that the rear heat exchanger gets warm after idling for 5-7 minutes.

Install the hood and side panels and all other items removed and/or loosened.

Fuel requirements are crucial. If you have a pump gas kit, good 93 Octane, non-oxygenated pump gas is REQUIRED. If only 91 Octane fuel is available, mix in 2.5 gallons 100LL aviation fuel per tankful. If running a race gas kit, the Octane required is 100. This is standard 100LL aviation fuel.

If you have a Sno Pro with the deluxe gauge, you can monitor coolant temperatures by switching the key on and kill sw off so the display is illuminated. Push in and hold the two left hand buttons for 10 seconds. You will see the voltage appear on the bottom of the screen. Push the upper button until you see a “3” on the bottom left. Just to the right of the “3”, the water temperature will be displayed. Monitor this as you ride. If the snow conditions are decent, it should NEVER exceed 200 deg F. If it does, the cooling system is airlocked. Do NOT ride the snowmobile!!! Re bleed the system. If temperature remains constant and below 195, proceed riding. Check periodically for leaks.

If you do not have a snow pro, periodically check the rear heat exchanger. It should be very warm to the touch. Monitor the gauges for the temperature light to come on. Once you have ridden a few miles with no codes, stop and check for leaks. If no leaks are detected, proceed.

It is assumed that your sled has a Mechanical boost gauge and an AFR gauge. These instruments are necessary for high performance aftermarket modifications. They will also help us to diagnose problems if you have any.