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Probably corrosion. Go over the harness and connectors with anticorrosion/electrical spray. Guess you seen the explanation for 46 in the handbook?

No. You can't align it. It would require a lot of modifications.

Thanks! Yeah it's the perfect sled for me. Cheap, reliable, fast enough and fun as hell. It's a MCX intercooler. Actually the whole kit is/were MCX. Bought the kit used and changed it a lot, though I had a some ideas of how to reduce turbo lag. Tried to make it a bit more stealth (and quiet)...

MCX is producing a new kit with 0,4 boost and no headshim. Google is your friend. http://www.mcxpressturbos.com/yamaha_phazer_snowmobile.html

That would solve the problem. But I'm hoping to find a way to hide it under the hood. But no success so far...

Yup. Works great but looks a bit strange. I've ridden it with less camber, and this works best for me.

Yes and yes. Make sure that you lengthen the thread to. And then use shims or washers to get the camber that you like. Will make at huge improvement! I think it was at 2009(?) Yamaha changed them on Nytro. It's the later ones that you want. They are bolt on.

Are you changing the spindle? In that case, I recommend you to try to get hold of spindles from Nytro -09 (?) until now. They have another trail and offset, not much to the eye, but it improves the steering massively.

No, it's a straightforward job. While you're at it, take a bit of material off from the upper ball joint. That's the best thing I've done for free on my Phazer. The negative camber makes a lot of difference for handling. Set it about -6 degrees (I have set mine a lot more but I've changed more...

Where should I put the tool bag? The intercooler is taking its old space. Strapped it onto the tunnel for now but I do want another place for it.

I made my own out of acid resistant stainless steel. Cheap and strong. Forum (building) thread in Swedish: http://forum.snowmobile.se/showthread.php?t=67778

Its not optimal but it will work just fine.

Ridiculously cheap. Buy them.

Ok, great. Guess it depends on how much boost you are putting thru it..? Or what quality they are made of? Or what quality the silicone hose is made of? I just know that it never worked out for me. My clamps of that kind were made of acid resistant stainless steel AISI 316/ 2343 (a "good"...

Yup. I have also seen it work, not only good but pretty perfect. Of course it's a compromise but there's is lots of things you can do to avoid lag. A well placed, well working dump is more crucial than a short exhaust. Here we use gps to find each other. And I do think you have an organisation...

I've actually seen sleds with the muffler located before the turbo. That is usually done because of shortage of space. But that doesn't seem to be the case here..? And, yes – the turbo do silence the noice quite a bit. And to get it to unsilly levels that is bearable for us who isn't that...

1. There's been faulty advise in some manuals. Ask your local dealer, he will probably have some stories for you... Finger tight then back off 1/4 turn then tighten locknut.

Here in Sweden they are discussing to legislate against all free riding. Snowmobiling will in the future only be allowed on trails and tracks. That is due to "badass" riders who rides with no muffler and makes high noise – that pisses of everybody who lives in the fjells and those who is there...

I made a few changes to an old MCX kit and my Phazer runs perfectly. No turbo lag whatsoever. And lots of power 142,5 bhp. Check it out: in Swedish but lots of pictures. http://forum.snowmobile.se/showpost.php?p=564143

Turbo the thing! You are already half way there.