INSTALLATION GUIDE

							                                  INSTALLATION GUIDE
              TTS ROTREX SUPERCHARGER CONVERSION
                                        HONDA S2000
 It is advisable to purchase a workshop manual, these are cheaply available on CD on the Internet.

1. Remove the original airbox , just 4 screws. Remove the sensors and solenoids from the airbox and
   find a reasonable place to mount them within the engine bay.
2. Remove the front bumper (read the manual if necessary).
3. Remove the front cross member.
4. Lay the intercooler over the up turned cross member and mark for drilling bolt holes.
5. Drill bolt holes, fit the intercooler and re fit the cross member.




6. Cut a hole as shown to run the ic pipes.




7. Using a 14mm long series ring spanner unload the Honda ancillary belt auto-tensioner and slide the
   belt off the water pump pulley. Leave the belt hanging loosely in place. Remove the 10mm centre
   bolt from the Honda idler pulley and replace it with the 19mm hexagonal spacer as shown. Torque
   up to 35 lb.ft.



              THIS THREAD REPLACES
              THE 10MM BOLT IN THE ->                         THIS SHORTER THREAD GOES
              CENTRE OF THE HONDA                             <THROUGH THE SUPERCHARGER
              IDLER PULLEY.                                   MOUNTING PLATE.
8. Using the crank pulley removing tool and a 19mm socket on a long knuckle bar remove the crank
   pulley bolt and crank pulley. THIS IS EXTREMLY TIGHT AND IS BEST TACKLED BY 2 PEOPLE.
9. Fit the exchange crank pulley supplied, put the new belt supplied over the new aluminium crank
   pulley at the same time as sliding the pulley into the centre of the crank pulley and screw in the




    original crank bolt.
10. Using the pulley steadying tool supplied re torque the crank pulley to 120lb.ft.
11. Refit the ancillary belt, the reverse way you removed it, make sure it’s located in all the grooved
    pulleys correctly and finally sliding it over the smooth waterpump pulley before releasing the auto
    tensioner to tension the belt. EXAMINE the belt around its run and ensure that it is properly
    located and running the correct path.
12. Remove the 6mm bolt from the front cover as shown. Replace it with the 6mm stud, lock two nuts


                                                                     SUPERCHARGER
                                                                     PLATE SIDE                     ENGINE SIDE


    together to tighten the stud into the engine case.
13. Slide over the spacer as shown.
14. Remove the 10mm bolt from the engine cover as shown. Replace it with the 10mm stud, lock two
    nuts together to tighten stud into the engine case.




15. Slide over the spacer as shown.
   16. Fit the supplied 1400mm long double sided vee belt over the crank pulley, make sure it rests in the
       position shown IMPORTANT otherwise you won’t get it into position when the main supercharger




       mounting bracket is located on the studs.
   17. Slide the main supercharger bracket complete with tensioner and supercharger onto the 3 studs
       that are now attached to the engine. Make sure you fit the large washers under the 2 x 10mm nuts.

                              Make sure the belt run is as the picture above.

   18. Loop the belt under the supercharger pulley and hook it over the left hand tensioner pulley.
   19. Slide the belt over the top of the left hand tensioner pulley.
   20. The belt should now follow its complete run as above.
   21. Tighten the RIGHT hand pulley bolt with the pulley about 12mm up from the bottom of the slot.




                                   Torque to 30 ft.lb.
   22. Using a long flat sturdy screw driver or lever bar insert it into the ‘V’ slot in the end of the supplied




      tensioner on the supercharger plate and lever it back,                     use the Honda belt
      tensioner as a pivot point. At the same time, tighten up the tension on the LEFT tensioner pulley


      using the 8 mm nut               . Make sure that the 12mm centre bolt is still loose by about 1 turn
      to allow the T nut to slide up the slot.

DO NOT AT ANY TIME WIND UP THE MANUAL TENSIONER WITHOUT TAKING THE LOAD OFF THE BELT BY
HOLDING THE AUTO TENSIONER BACK WITH THE LEVER BAR
   23. Systematically wind up the manual tensioner and let the auto tensioner back until the auto




       tensioner is at about midpoint of it’s range.                              Then tighten the idler
       pulley centre bolt to 30 lb. Ft.
   24. Remove the 2 x 8mm bolts from the end of the cylinder head and replace with the triangular black




      steel support bracket.                        It is quite tricky to get into position and locate the 2 x
      8mm allen bolts. The allen bolts and washers have been purposely held in place by the black ‘o’
      rings to ease assembly do not remove them. They will crush when the 8mm bolts are tightened
      down. With this bracket in place as the pictures, tighten up the 10mm nut to secure the installation




      to the cylinder head.

LATER AFTER AN INITIAL RUNNING IN PERIOD THIS TENSIONING PROCEEDURE WILL NEED REPEATING AS
THERE WILL BE INITIAL STRETCH AND BEDDING IN OF THE BELT.
   25. Supercharger oiling system

Locate the oil cooler on the intercooler brackets as shown.

Find a suitable place for the oil tank. See photo below for suggested




location.                                                                                   Drilling holes
where necessary.

       26. Once the oil tank and oil cooler are in place route the oil lines as per the Rotrex supercharger
                     instructions. Make sure all oil lines are blown clean before assembling.



   27. Fit all airpiping as the above picture using the silicon hose supplied and secure with clamps
       supplied.
   28. Fit the blow off valve using the silicon hose and clamps supplied.




   29. Fit the white plastic ‘T’ piece                          into the fuel pressure regulator line and




       feed it to the blow off valve.
   30. Using the silicon hose supplied feed it from the steel vacuum tubes on the engine to the ancillary




       units.

   31. Remove the fuel rail and injectors. Fit the RC750 cc injectors supplied, space up the fuel rail with the washers
       supplied. Fit the injector adapter plugs supplied.

   32. Fit your engine management and tune to suit.

   33. MAINTENANCE.

   Periodically check the auto belt tensioner to see how much movement is left. The tensioner alloy stops should
   have at least a 10mm gap. Back the 10mm nuts off slightly on the adjustable top pulley and with the engine
   running wind up the 8 and 6 mm nuts to keep the belt in the right plane and put more tension on the belt until
   the auto tensioner gap increases. Switch off engine and tighten up the 10mm nuts.
   Replace the supercharger oil once a year or 70,000 kilometres.


  Take care when road testing as the power is deceivingly progressive and you will find you may be going much
                                            faster than anticipated.

TTS PERFORMANCE PARTS LTD

UNIT 3 WEST END FARM

SILVERSTONE

NORTHANTS

ENGLAND

NN12 8UY