Polaris RZR XP 1000 Turbo
Installation Instructions
BoonDocker RZR 1000 Turbo
1. Remove muffler, air filter to air box tube, air
box, and header.
3. Install turbo support bracket to turbo. Leave
bolts loose, so bracket can be adjusted once
installed.
2. Clean header flange at head and install turbo
header and new header gasket.
4. Remove these 2 bolts from the driver side
front engine mount.
5. Install turbo assembly and steel gasket to
header using 4 8mm x 25mm bolts and lock
nuts. Leave bolts loose so adjustments can be
made when turbo bracket is tightened.
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6. Install the 2 stock engine mount bolts through
the turbo bracket. Tighten engine mount bolts
turbo to header bolts and turbo bracket to turbo
bolts simultaneously.
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BoonDocker RZR 1000 Turbo
7. Cut engine oil cooler coolant hoses at mid
point and T turbo coolant hose into each hose.
9. Remove plug and install AN fitting located
above magneto cover on passenger side of
engine.
8. Remove plug from engine case located just in
front of the clutch cover. Install AN fitting, route
turbo drain hose to fitting and attach.
10. Install oil feed hose. Be sure to route feed
hose away from header.
11. Install waste gate actuator and adjust rod
tension so that the waste gate door is held barely
closed.
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12. Install air intake tube from stock air box to
turbo. Attach stock crank case vent hose to air
intake tube.
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BoonDocker RZR 1000 Turbo
13. Install silicone hose to throttle bodies and
secure with hose clamps.
15. Install air box intercooler assembly. Adjust
transmission bracket to position air box
assembly so that there is clearance on all sides
and corners.
14. Install air box transmission mount bracket
using stock bolts and steel spacer from stock air
box. Leave bolts loose so air box can be
adjusted later.
16. Fasten air box assembly to transmission
bracket using 5/16”x1” bolts washers and lock
nuts and tighten transmission bracket bolts.
17. Remove grill and install water cooler to
stock radiator. Secure firmly using 4 push
through zip ties.
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18. Remove grommet from fire wall.
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BoonDocker RZR 1000 Turbo
19. Install coolant bottle and pump assembly.
And install hose from coolant bottle to water
cooler.
21. Route coolant hose from water pump to air
box cooler inlet. Lower rear connection.
20. Remove belly pans and install coolant hose
to water pump.
22. Connect remaining coolant hose to water
cooler.
23. Route coolant hose from water pump to air
box cooler outlet. Upper front connection. Secure all coolant hoses using zip ties.
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24. Connect water pump fused power wire to
stock ACC Terminal and connect black ground
to stock GRD terminal.
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BoonDocker RZR 1000 Turbo
25. Cut valance and reinstall grill and belly pans.
27. Rotate stock fuel fitting 90 degrees so that it
points up. You can twist this fitting inside the
hose with your hands.
26. Connect auxiliary fuel line to stock fuel rail.
28. Connect stock fuel line to auxiliary
connector.
29. Install charge tube.
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30. Connect 3/16” boost hose from charge tube
fitting to metal fitting on boost solenoid. Secure
hose to solenoid with zip tie.
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BoonDocker RZR 1000 Turbo
31. Connect 3/16” boost hose from waste gate
actuator fitting to perpendicular plastic fitting
on boost solenoid. Secure hose to solenoid with
zip tie.
33. Install turbo outlet pipe and muffler.
32. Secure boost solenoid with a zip tie to stock
harness bellow sway bar.
34. Install Boondocker Control Box as per control box instructions.
35. Check all fluids and Enjoy!
Revised 3/28/2014 Page 7 of 7
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……….………………....877-522-7805
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