BoonDocker POLARIS 2011-14 PRO RMK 800 Intercooled User Manual

1.

1. 1.Remove side panels, hood, seat, fuel tank, and
muffler. Save exhaust springs and rubber muf­fler mounts for turbo install.

2.Remove stock air box, remove fuel line
bracket. Sand back surface flat for mounting.

3.Remove factory TBAP sensor from stock air
box and zip tie to over structure.

5. With ECU in place hold the fuel filter on the
back side of fuel line bracket to ensure proper

fitment, drill a 1/4” hole in the tab for bracket

mounting

4. Un-bolt and un-strap the stock oil tank. Leave
oil line hooked up.

6. Snap the fuel filter and fuel line into the fuel
line bracket and secure to clutch cover using the
1/4” bolt and lock nut. Reinstall the oil tank.

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7. Use a punch to remove the steel center from
necessary rivets. Use a straight edge to mark the
cut line to remove lower portion of kick plate.
Leave the upper portion for side panel mounting.

8. Remove the stock exhaust deflector and seal. Install
exhaust block off plate using supplied rivets from the
top using plate as rivet backer.

9. Use the attached template to locate muffler hole

location, Center punch and then drill 2 1/2” hole for

exhaust outlet.

11.Install spring tab and heat deflector on belt

drive models using factory bolts as shown.

10. Remove front suspension bolts and install tunnel
support plates, Re-install suspension bolts and finish
securing using supplied rivets..

12. Using a pair of pliers break off chassis tab in
the image and grind to match the stock con­toured surface. (Not necessary to remove for
Tial exhaust system)

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13.

14. Attach the rubber exhaust mounts to turbo
Bracket as shown . Note: 2011-12’ are different
than 2013’.

15. Hang the turbo assembly in place using the
stock muffler mounting locations, make sure
turbo sits down on rubber mounts.

17. Route outside coolant line over to the throttle

Bodies and secure using supplied hose clamps.

16. Lower coolant level in bottle, remove stock
coolant line from coolant bottle to throttle bodies

Route the inside turbo coolant line to coolant bottle.
Proper routing will avoid pull rope, and sharp edges

18.

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