Ski-Doo E-TEC Turbo System

Overview

FEATURES

  • 66 Series Aerocharger
  • Tuned Airbox
  • Stainless Steel Exhaust
  • Silicone Charge Tube
  • Snow to Air Intercooler Option
  • Stainless Heat Shield
  • Dome Filter
  • Fuel Controller
  • Boost & AFR Gauges
  • Complete Clutching on Non IC and A/S Kit

Back Country System

$4995

Non Intercooled System

$6300

Air/Snow Intercooled System

$6800


OVERVIEW

Aerocharger co-developed the Ski-Doo E-TEC turbo system with BRP Racing starting in 2009 for RMSHA, and the Aerocharger was the first working kit available at the E-TECs release in 2011. BRP Racing dyno’d the Aerocharger system and registered 240hp at only 7psi, and this system can be set to produce a range of 200-300hp. This system was designed in close collaboration with BRP Racing, who contributed design criteria and system specifications to ensure that a properly designed aftermarket turbo kit would be available for the E-TEC snowmobiles. The Aerocharger is a substantial innovation over conventional turbocharger technology, making it ideal for use with Rotax 2-stroke engines. The Aerocharger E-TEC system was built to prioritize horsepower-generating efficiency, and this equals an ultra-responsive, rideable system that excels at high altitude and on technical terrain.

Each kit we make goes through rigorous testing before it is released to the public. Aerocharger takes pride in the kits we make as each person who purchases an Aerocharger should feel the same way.

At a Glance:

Aerocharger was first on the snow with a comprehensive turbo kit when the E-TEC was first released, and this system has been rigorously proven and reproved every season since. This system was designed in close collaboration with BRP, who contributed design criteria and system specifications to ensure that a properly designed aftermarket turbo kit would be available for the E-TEC snowmobiles. The Aerocharger is a substantial innovation over conventional turbocharger technology, making it ideal for use with Rotax 2-stroke engines. The Aerocharger E-TEC system was built to prioritize horsepower-generating efficiency, and this equals an ultra-responsive, rideable system that excels at high altitude and on technical terrain.

 

Performance Gains:

BRP Racing dyno’d the Aerocharger E-TEC 800 system, and registered 240 hp at 7psi boost.

The average Aerocharger is set at 7psi boost. At higher elevations we have determined 7psi typically yields around 200 hp, reflecting a 60hp gain over stock. Ski-Doo riders understand that no two operating environments are the same, and different results can be obtained with higher boost settings and higher octane fuels.

Fuel Recommendations:

For best performance, Aerocharger recommends using a minimum of 100 octane fuel when running this system. Pump gas is not recommended, and should absolutely not be used under 7000 foot elevation.

Air-to-Snow Intercooler:

This optional performance upgrade rapidly cools the air charge from the turbo by directing water, snow and ice from the tunnel through the Intercooler. This Intercooler installs into the E-TEC tunnel, requiring moderate modification to the tunnel. Testing has established that this Intercooler provides a more consistent heat-sink than traditional Air-Air ICs, and is a much more engine-friendly install than Air-to-Water setups. Aerocharger developed this Intercooler for our race team, and it was so effective that it was made into an upgrade from the Non IC kits or a stand alone full kit purchase.

Big Bore/Compression Modifications:

The Aerocharger Kit is compatible with engine mods such as big bore kits or lower/higher compression.

Clutching:

Clutch setups have been the most requested item. Getting this right is one of the biggest factors in your turbo sled running the best it can, so now an extensive custom clutch setup is included with the Non Intercooled System and Air to Snow System. This includes custom ramps, weights, gearing, and a very cool custom helix with improved angles for turbocharged operation. Our Back Country Kit comes with Pin Weights only.

Sled Vents:

Heat dissipation is critical for best turbo performance, so we went ahead and included turbo side and clutch side Snow Silk vent kits in the Non Intercooled System and Air to Snow System. You can purchase vents for your Back Country kit at any time by visiting our online shop.

About the Aerocharger:

The Aerocharger offers major advantages over conventional turbocharger technology.

VATN Technology:

Aerocharger’s powerful Variable Area Turbine Nozzle system continuously optimizes turbine size. This allows for excellent boost response and performance, and is ideal for riding at high altitude or on technical terrain. The vehicles’ exhaust gases are entirely utilized at all times, eliminating the need for a waste gate or spark arrester.

Independent Oil Supply:

While other turbos require tapping into the engine’s oil supply, the Aerocharger lubricates from a self-contained oil source. Aerocharger systems install cleanly and reliably with no oil pumps and lines, and hot shutdown problems are avoided. This is a waste-oil system, meaning the oil does not need to be changed – just check it once a year and top off as necessary.

Non-flooded Bearings:

An innovative oil misting system allows for drag-free bearing performance and ultra-fast spooling, resulting in substantial efficiency over typical saturated bearing systems.

Installation:

The Aerocharger E-TEC system is completely comprehensive, and was designed for easy installation with little modification from stock. The E-TEC system fits cleanly under stock paneling for a stealthy look that doesn’t block views or limit use of other features. Aerocharger systems are designed so they can be installed at home by a rider with moderate mechanical ability and common garage tools, but many Aerocharger customers prefer to have their turbo system installed at a dealership or performance shop.

Product Support:

Aerocharger has a well-tested, strong-running and reliable turbo system. The Aerocharger doesn’t require any more care or maintenance than any other turbocharger, and when properly installed your Aerocharger should outlast the life of your sled. We will make sure you have the support you need – for any questions, troubleshooting or maintenance, don’t hesitate to directly contact Aerocharger’s engineers or your nearest Aerocharger dealer.

 

System Specs

Performance Gains

BRP Racing dyno’d the Aerocharger E-TEC 800 system, and registered 240 hp at 7psi boost. The average Aerocharger is set at 7psi boost.

Fueling

For best performance, Aerocharger recommends using a minimum of 100 octane fuel when running this system. Pump gas can be used with our pump gas upgrade.

This fuel guide lists recommended octane levels based on boost and altitude. This chart is for reference only – many factors affect safe octane such as air density, temperature, and tolerance specific to your motor. This chart is intended to suggest rough guidelines based on the most common operating environments.

Please click here for the Fuel Tuning Guide Download

Please click here for Fuel Tuning and Aerocommander Guide

Boost Levels

Max boost level is mechanically set by a pre-loaded spring inside the Aerocharger’s integrated boost controller, and aftermarket boost controllers can also be used for additional boost control. See the Aerocharger page for additional information.

An Intercooler is recommended for E-TECs set at boost levels higher than 7psi. Exclusively for the Aerocharger E-TEC System, an innovative new Snow-to-Air Intercooler is available as an option for a consistently cooler air charge. Click the upgrade tab to read more about the Snow-to-Air Intercooler.

Big Bore/Compression Mods

The Aerocharger E-TEC System is compatible with engine mods such as big bore kits or lower/higher compression.

Reliability & Support

Aerocharger has a well-tested, strong-running and reliable turbo system. The Aerocharger doesn’t require any more care or maintenance than any other turbocharger, and when properly installed your Aerocharger system should outlast the life of your sled. We will make sure you have the support you need – for any questions, troubleshooting or maintenance, don’t hesitate to directly contact Aerocharger’s engineers or your nearest Aerocharger dealer.

Installation

Aerocharger systems are designed so they can be installed at home by a rider with moderate mechanical ability and common garage tools, but many Aerocharger customers prefer to have their turbo system installed at a dealership or performance shop. Dealers report preferring Aerocharger technology because Aerocharger systems are properly designed and either simplify or eliminate many fail-prone components, thereby requiring much less support and maintenance.

Contact Aerocharger for information about dealers in your area.

Components

AEROCHARGER E-TEC SYSTEMS

Aerocharger 66 Series

VATN Technology

Aerocharger’s powerful variable geometry tech optimizes turbine size, producing lag-free boost. Excellent performance for high altitude and technical riding. The ideal turbo for 2-strokes.

Independent Oil Supply

The Aerocharger contains it’s own oil supply allowing for clean and simple installation, and reduced risk of complications when riding.

Non-Flooded Bearings

Innovative oil misting system allows for drag free bearing performance and ultra-fast spooling. A major performance increase over conventional journal bearings.

Welded Turbine Inlet

Aerochargers for Ski-Doo snowmobiles now feature welded turbine inlets, which reduce weight and back-pressure while improving flow to the turbo.

Air Box

Durably Built

Robust design allows for best air flow from the turbo. Stainless Steel construction, finished with bake-on ceramic coating.

Tuned Backwall

Designed to correctly reflect acoustic waves from the E-TEC intake, maintaining stock engine system efficiency that are critical to the E-TECs performance.

Turbo Optimized

Correctly shaped to provide optimal air volume to the Aerocharged E-TEC engine.

Snow to Air Intercooler

Harness The Cold

The most effective intercooler ever made for a snowmobile. This performance upgrade is an intercooled airbox that rapidly cools the air charge from the turbo by directing water, snow and ice from the tunnel through the intercooler core. This intercooled airbox installs into the Ski-Doo tunnel, requiring moderate modification to the tunnel. Testing shows that this intercooler provides a more consistent heat-sink than traditional Air-Air ICs, and is significantly more engine-friendly than Air-to-Water setups. The air charge is being cooled as soon as the track is moving, without putting any additional load on the engine, coolant and electrical systems.

Competition-Grade Equipment

Aerocharger developed this intercooler to give our riders a competitive edge on race day. It proved to be extremely effective, and has now been made an option at the consumer level.

Stainless Steel Exhaust

Flow-Through Design

This muffler has been sized to flow exhaust from the turbo quickly and effectively.

TIG Welded

Durable construction by skilled production welders. Stainless Steel construction finished with ceramic coating.

Optimized Exit Angle

The front facing departure avoids blockage by trailing the snowmobile’s A-Arms. This placement was tested by top back-country riders, who found this to be the most effective setup.

Clutching

Best Performance

An extensive clutch setup is included in our Standard Non Intercooled and Air to Snow Kit,specifically configured for best operation on Aerocharged Ski-Doo snowmobiles.

Full Setup

Includes a dual-angle helix that can be set for racing performance or back-country conditions. Also comes with custom ramps, adjustable tungsten weights, primary spring, an alternate top gear, chain and oil, and Aerocharger’s recommended settings based on boost and altitude.

Fuel Management

Exclusive Fuel Programming

The Aerocommander fuel controller is pre-mapped with a proprietary program to fully optimize the Aerocharger’s performance with the E-TEC. Maps are updated annually for improved performance. The Aerocommander is fully plug-and-play right out of the box.

Sequential Injection

Sequential injection improves fuel injection to enhance throttle response.

External MAP Sensor

New for 2013, the fuel controller hardware now includes an external three-bar manifold absolute pressure sensor. An external sensor provides an improved reading for smooth fueling, and makes the Aerocommander unit 100% water proof. Comes with a 2 Year Warranty.

Also Included with the Non Intercooled System and Air to Snow System

etec_chargetubemed

Custom Charge Tube

Silicone Construction – lightweight and durable for high pressurization.

etec_guagepodmed

Guage Panel

Innovate AFR Gauge and Custom Boost Gauges are included.

stingerKit

Stinger Kit

Parts and instructions are included to modify the stock pipe with an Aerocharger stinger. This pipe is larger in diameter and improves exhaust flow for better performance. Will require cutting and welding the stock pipe.

turboReeds

Turbo Reeds

Upgraded turbo reeds are provided with every Aerocharger E-TEC system. Developed by BRP based on use with Aerocharged E-TECs, these reeds are more robust and have a longer life during turbocharged use.

heatShield

Heat Shield

Ceramic Coated stainless steel for best thermal control.

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Dome Filter

Stainless steel mesh intake screen filter.

ventsSkidooBasic

Vent Kit

Heat dissipation is critical for best turbo performance. 7 Snow Silk vents are included, with templates and instructions for easy installation. An Advanced Snow Silk Ski-Doo vent package is available in the Upgrade section.

Upgrades

UPGRADES

Aerocharger offers several E-TEC performance upgrades. These options were developed for our race team, and are frequently requested by advanced tuners and riders.

Air-to-Snow Intercooler – $800.00

airSnowBox-Package

Harness The Cold

Upgrades a non-intercooled 600/800 E-TEC system with an Aerocharger Air-to-Snow Intercooler. This performance upgrade rapidly cools the air charge from the turbo by directing water, snow and ice from the tunnel through the intercooler. This intercooler installs into the E-TEC tunnel, requiring moderate modification to the tunnel. Testing has established that this intercooler provides a more consistent heat-sink than traditional Air-Air ICs, and is significantly more engine-friendly than Air-to-Water setups. The air charge is being cooled as soon as the track is moving, without putting any additional load on the engine, coolant and electrical systems. This product is available in the Aerocharger Store.

Hybrid Snorkel Intake- $350.00

Performance Cold Air Intake

This innovative Hybrid Snorkel Intake for Aerocharged E-TECs improves system efficiency in extremely deep conditions. By allowing for multiple intake areas, this design improves on traditional snorkel setups by increasing air flow and reducing the risk of blockage.Click Here for more info. This product is available in the Aerocharger Store.

 
Hybrid Snorkel Intake Installed - Inside 02
Hybrid Snorkel Intake Installed - Outside

Snow Silks Snowmobile Vent Kits

ventsSkidooDeluxe

Heat Dissipation

Reducing engine compartment heat is extremely important for best snowmobile performance, and these Snow Silk vents provide superior air flow compared to other leading brands. Snow Silk vents are resistant to tears, feature durable adhesive, and have water-repellant properties to keep the sled interior clean and dry. CAD modeled for perfect fitment to the Ski-Doo XP/XM compartment panels. Includes cutting templates for easy installation.

The Basic Kit covers all major sled panels. The Deluxe kit adds vents for every remaining panel on the sled.

Turbo Clutch Package – $450

clutchKitEtec

Mountain Performance Clutching

An extensive turbo snowmobile clutch kit for mountain use on Ski-Doo 800 E-TECs. This setup is included in all new systems. Includes a dual-angle helix that can be set for racing performance or back-country conditions. Also comes with custom ramps, adjustable tungsten weights, primary spring, an alternate top gear, chain and oil, and Aerocharger’s recommended settings based on boost and altitude. This product is available in the Aerocharger Store.

XP to XM Upgrade Package – $250.00

Model Upgrade

This package contains all components required to adapt an Aerocharger XP kit for use on a Ski-Doo XM. Includes updated boost gauge, XM DES switch and gauge brackets, basic vent kit, left and right side panel supports, headlight support bracket, and all necessary rivets and hardware.

Turbine Porting (Inquire for pricing)

Performance Upgrade

Ported turbines offer increased turbo efficiency and better throttle response. Allow 2-4 weeks to complete.

Downloads

Videos

Sunshine: 2015 Ski-Doo T3 Aerocharger Build

Aerocharger Install | Part 1 Ski-Doo E-TEC

Aerocharger Install | Part 2 Ski-Doo E-TEC

Setup Guide | Aerocharged Ski-Doo E-TEC

Air/Snow Turbo Ski-Doo Intercooler | Aerocharger

FELKER SHREDS: Turbo Ski-Doo 137 | Aerocharger

2014 Freeride Turbo: Aerocharger System Weight Tests

2013 Aerocharger Summit XM at Snowy Range, WY

Felker talks about the 2013 Ski-Doo Summit XM Turbo | Aerocharger

Summit XM Turbo Test Ride | Aerocharger Turbo Systems

Aerocharger | Calvin Felker talks about E-TECs at Hay Days 2012

Aerocharger & Calvin Felker on Sledhead 24/7

Aerocharger SkiDoo ETEC Turbo