BoonDocker POLARIS 2007-10 Dragon Pump Gas User Manual

Pump Gas Instructions for Polaris 600 700 And 800 Models

Important Information before Installing This System:

Before you begin your turbo install, read through these instructions to determine if you are
comfortable installing this system. If not please take it to an experienced mechanic for your install.
It is also a good idea to check the kit contents to verify all parts were provided in the kit before
getting started. This install requires time and patience. Do not rush the installation, if you have any
questions on your installation please contact Boondocker tech support at 1-877-522-7805.

 Improper installation could result in engine damage or personal injury.
 For the 2007 Dragon 700 we strongly suggest upgrading from the stock pistons

please call for details.

 It is highly recommended to run the factory reeds or the reeds recommended by

Boondocker. Some aftermarket reeds can break and cause engine damage.

Step 1- Disassembling your sled:

Tools Needed:

Basic Tool Set

A. Remove side panels

B. Remove the electrical cover (plastic) from the clutch cover.

C. Remove the sensor from the exhaust pipe, then remove the pipe and exhaust muffler. Be sure to
keep all of the exhaust springs, you will need these later in the install.

BoonDocker Performance 1585 Hollipark Dr. Idaho Falls, ID 83401

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D. Remove The Air Box. Disconnect the connector from
the TBAP sensor and remove the clamp that holds the fuel
lines to the air box. The 08-09 Polaris’ have a locking pin
to hold the air box in place. This is located on the clutch
side of the air box (See picture).You can remove it with a
long flat head screw driver or give the air box a good pull
and the plastic pin will break. You will not need the pin or
air box for the installation of this turbo kit.

E. Remove the TBAP sensor from the air box, Reconnect it
to the factory connector and find a new place to mount it.
We chose to zip-tie it to the wiring harness on the clutch
cover.

F. Remove seat and gas tank. This is only necessary for

the 07 models only but does make the install easier
on all models if removed. You will need a special quick

release tool to remove the fuel lines from your gas tank
(see picture). This tool can be found at your local
automotive store.

G. Remove the throttle Bodies.

Disconnect the throttle cable and the TPS sensor
connector. Remove the coolant lines from the throttle
bodies. You can use a pair of clamps to kink the lines or
you can insert a bolt to plug off the lines and keep them
from leaking.

BoonDocker Performance 1585 Hollipark Dr. Idaho Falls, ID 83401

Toll Free (US) 877-552-6127 or 208-542-4411 www.boondockers.com

Revised 10/01/2010 Page 2

Step 2- Modifying the throttle bodies

Tools Needed:

Basic tool set
Drill
Tap Lubricant
13/64” Drill bit
Thread sealant
¼ -20 Tap
Loc-tite

Important: It is highly recommended to run the factory reeds or the reeds recommended by
Boondocker. Some aftermarket reeds can break and
cause engine damage.

A. Drilling the holes for fastening the air box. Using a
13/64” Drill bit, carefully drill the 2 holes as shown below.
You can periodically shine a flashlight on the side of the
throttle bodies, when you can see the light shine through
the hole you have drilled far enough. Important: Do not
drill all the way into the throat of the throttle bodies.

B. Use a ¼-20 tap to thread these holes, be sure to use a tapping lubricant.

C. Remove the 10 bolts securing the rubber throttle body adaptor boot to the engine and reinstall
with the BD reinforcement plate. It will install on top of
the stock throttle body boot.

BoonDocker Performance 1585 Hollipark Dr. Idaho Falls, ID 83401

Toll Free (US) 877-552-6127 or 208-542-4411 www.boondockers.com

Revised 10/01/2010 Page 3

Step 3 - Installing the Air Box or Intercooler

Tools Needed: Parts Needed:

Basic Tool Set Boondocker Air Box with o-rings
Rivet Gun 4- rivets
Assembly Lubricant 1 ¼” rubber bumper with 5/16 studs
Drill 2- ¼-20 x 1/2” bolts with lock washers
3/16” Drill Bit Air Temperature Sensor
Thread sealant 2- Self drilling screws for the air temp sensor Silicone

A. Lubricate the o-rings on the inside of the air box. Insert
the air box onto the throttle bodies. Be sure the tabs of the
air box are flush with the newly drilled fastener holes in
the throttle bodies. You may have to tap the tabs with a
hammer to bend them flat against the throttle bodies. (See
picture).

B. Fasten the air box in place using the two ¼-20 x ½”
bolts with lock washers.

BoonDocker Performance 1585 Hollipark Dr. Idaho Falls, ID 83401

Toll Free (US) 877-552-6127 or 208-542-4411 www.boondockers.com

Revised 10/01/2010 Page 4

Air box Bracket Instructions

A. Locate the air box bracket, two- 5/16 lock nuts and

the 1 ¼” rubber bumper. Install the rubber bumper to

the bottom of the air box bracket and fasten with a
5/16 lock nut. Slide the air box bracket into place as
shown. Install the 2nd 5/16 lock nut, but leave it loose
for now.

B. Make sure the air box and throttle bodies are slid all

the way in place. Using a 3/16” drill bit, drill the 2 holes

towards the rear of the sled first (this will keep the
bracket from moving while riveting the front holes).
Fasten the bracket with the supplied rivets. Now drill and
rivet the front holes.

C. After riveting the bracket in place tighten the 5/16
lock nut on top of the air box bracket.

BoonDocker Performance 1585 Hollipark Dr. Idaho Falls, ID 83401

Toll Free (US) 877-552-6127 or 208-542-4411 www.boondockers.com

Revised 10/01/2010 Page 5

Step 4- Installing the Exhaust Outlet

Tools Needed: Parts Needed:

Drill Exhaust Outlet
2 ¼” Hole saw Five 8mm x 25mm bolts
Air saw or de-burring tool Cut out template for exhaust outlet
Basic Tool Set Cut out template for footrest
Vacuum

A. Locate the exhaust outlet template. Place the
template on to the tunnel. Line up the holes on the
template with the bolts and rivets on the sled, trace
the center outlet hole.

B. Using a 2 ¼” hole saw. Drill the center of the

newly traced outlet hole.

C. You may now finish cutting the hole with an air
saw or a de-burring tool.

BoonDocker Performance 1585 Hollipark Dr. Idaho Falls, ID 83401

Toll Free (US) 877-552-6127 or 208-542-4411 www.boondockers.com

Revised 10/01/2010 Page 6