Video of How to Install Power Steering for ski-doo 900R Gen 4-5 | 4 stroke

Ski-Doo Gen 4 & 5 900R Turbo Power Steering Assist Kit Installation Guide

By Brad from Brad’s AC Performance

Tools Required:

• Basic hand tools (screwdrivers, wrenches, etc.)
• Chop saw
• Welding equipment
• Electrical tape
• Wire connectors
• Drill
• Safety glasses and gloves

Preparation:

1. Disconnect the battery’s negative terminal.
2. Remove the hood, intercooler, and steering rack and pinion.
3. Clean the cleared area.

Motor and Unit Assembly:

1. Locate the designated area under the turbo for motor placement.
2. Gather the kit parts and identify those reused from your original setup.
3. Mount the potentiometer bracket with the provided screws.
4. Grind the potentiometer edge to clear screws for proper installation.
5. Assemble the motor unit, ensuring tight connections and parallel placement of the rod ends for correct potentiometer reading.
6. Test fit the unit for proper placement and tie rod alignment.

Motor Installation and Clearance:

1. Modify the turbo cover for clearance with the motor (if necessary).
2. Omit the factory shim plate if it interferes with the belly pan on your sled.
3. Secure the modular unit to the motor with the Allen screw (ensure proper locking).
4. Re-tighten the Allen screw after checking for movement. Blue Loctite is recommended.
5. Install the bracket on the assembled unit.
6. Align the bracket with the 6 and 12 o’clock positions on the motor housing.

Additional Assembly:

1. Install the washer beneath the potentiometer’s connecting heim joint.
2. Mount the support rod on the bracket during installation.
3. Refer to the provided instruction sheet for bolt identification and placement.
4. Secure the bracket with the stainless steel Allen bolt and matching nut.
5. Attach the brace holding the motor and potentiometer using the provided screws.
6. Mount the brace to the bulkhead using the designated bolts and nuts.
7. Install the brace to the chassis using the provided flare nuts and locking nuts.
8. Secure the bracket underneath the belly pan using the designated nuts.

Steering Post and Alignment:

1. Install the potentiometer wire before bolting in the motor.
2. Tighten the motor’s mounting nuts.
3. Install the tie rods with left-handed threads on the motor side and right-handed threads on the spindle side.
4. Apply grease to the left-handed heim joints for a tighter fit.
5. Do not adjust the tie rods at this stage. Alignment will be done later.

Safety and Adjustments:

1. Ensure the U-joint doesn’t contact the water return line for the turbo at full turn.
2. Adjust the tie rod if clearance with the water return line is an issue.
3. Aim for nine threads showing on both sides of the tie rod for proper adjustment.
4. Roughly check the toe by measuring 41 ½ inches between the ski centers.
5. Install the control box with the locking collar to prevent handlebar separation.
6. Tighten the Allen screws on the locking collar, leaving a ¼ inch gap to the nun.

Steering Post Assembly:

1. Choose the appropriate steering post length based on your preference.
2. Secure the U-joint to the steering post using the set screws.
3. Tighten the Allen screws on the steering pitman arm for a secure fit.
4. Test the handlebar alignment by turning the post to the stops and checking for twisting.
5. Mark the Double D post with a punch and drill a hole for the lynch pin (3/16 to 5/16 size).
6. Install the 5/16 grade 8 bolt as the lynch pin.

Electrical Connections:

1. Mount the ECU to the right-hand side intercooler support with the plugs facing the steering shaft.
2. Route the wires to the designated location and create a secure holder (not finalized yet).
3. Run the other set of wires under the nun for connection.
4. Connect the white wire (excer wire) to a 12-volt power source using a blue Scotch Lock.
5. Connect the other wire to the cell solenoid using a crimped connector.
6. Ground the unit at the footrest.

Intercooler Fan Adjustments (for 900r Turbo):

1. Grind the motor mounting bolts for additional clearance with the intercooler fan (if necessary).
2. Use a screwdriver to carefully bend the aluminum brace at the fan’s bottom for additional clearance.
3. Adjust the motor’s rotation for optimal clearance.

Final Touches and Testing:

1. Reinstall the hood and ensure the gauge is not connected for initial testing.

WHY UPGRADE?

Power steering offers several advantages for snowmobile riders, especially in challenging snowy conditions:

• Improved Maneuverability: Power steering makes it easier to turn the snowmobile, particularly at low speeds or in tight spaces. This is especially helpful when navigating through trees, around obstacles, or in confined areas.

• Reduced Rider Fatigue: The physical effort required to turn a snowmobile without power steering can be tiring, especially during long rides or in demanding conditions. Power steering reduces this strain, allowing riders to enjoy their experience for longer periods.

• Enhanced Control: Power steering provides more precise control over the snowmobile’s direction, making it easier to maintain a stable course, especially in uneven terrain or high winds.

• Increased Safety: By reducing rider fatigue and improving control, power steering can contribute to increased safety on the trail. It can help prevent accidents caused by loss of control or excessive strain on the rider.