BoonDocker POLARIS RZR XP 900 Turbo System User Manual

Hardware Kit Bag

 (4) 8mm x 30mm allen head bolts
 (4) 8mm x 25mm bolts
 (4) 8mm lock nuts
 (2) Gold exhaust springs
 (4) High tension exhaust springs
 (6) 8” zip ties
 (4) 4” zip ties
 (2) 3/8” barbed unions
 (4) #6 hose clamps
 (1) Turbo mount template

Separate Parts:

 1548 Turbocharger Indexed to turbo bracket
 Adustable actuator
 Exhaust inlet
 Exhaust outlet
 Body bracket for muffler
 Muffler
 (2) 3.5” x 12” decals

Silicone Kit Bag

 3” piece of 2” balck silicone
 (2) 2.125” piece of 2.25” pieces of black

silicone

 (4) #36 hose clamps
 (2) #32 hose clamps

Oil Drain Kit Bag

 Oil drain line with banjo fitting installed
 (1) #8 x 1/2” self tapping screws
 (2) rubber insulated clamps
 12mm banjo bolt
 (2) copper washers
 #12 hose clamp

Oil Feed Kit Bag

 Oil feed hose
 1/2” x 4an adaptor

Fuel System Kit Bag

 Fuel line assembly
 (2) Auxillary injectors
 (2) #4 hose clamps
 (2) 1/4” x 1.5” allen bead bolts

Intercooler Kit Bag

 Pull fan
 (2) 1/4” x 1/2” bolt
 1/4” x 3/4” bolt
 (3) 1/4” lock washers
 Fan power adaptor harness
 Intercooler

 Boondocker control box

 Control box
 Air solenoid valve
 Battery jumper
 Velcro
 30” of boost line
 (5) 8” zip ties
 (5) 4” zip ties

 Clutch kit

 Team Rooster weights
 Red with black/gold striped primary

spring

 Green with silver secondary spring

Performance Plus Kit Only:

 8 Valve seals
 8 Valve springs
 Headgasket

Revised 7/9/2013 Page 2 of 17

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1.REMOVE MUFFLER Remove the 2 exhaust
springs connected to the bottom of the muffler.

2 Remove the 2 exhaust springs connecting the
header to the muffler. The muffler can now slide
off the hangers. Slide toward the passenger side
of the vehicle.

3. REMOVE AIRBOX Remove the rubber
hose connecting the airbox to the air intake.

5. Loosen the 2 clamps holding the airbox to the
throttle bodies.

4. Remove the 2 bolts connecting the airbox to
the airbox bracket.

6. Remove the breather hose from the Idle Air
Control unit. Pull the airbox out of the vehicle
and reinstall the bolts, grommets and spacers to
the airbox mounting bracket.

Revised 7/9/2013 Page 3 of 17

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7. REMOVE SKIDPLATE Remove the 14
bolts and washers that fasten the skidplate to the
frame.

8. REMOVE SEATS AND REAR PANEL
Remove the seats from the vehicle and the rear
panel using a T 25 torx head bit.

9. REMOVE ENGINE HEAT SHIELD
Remove the 7 bolts holding the heat shield in
place, pull the heat shield down to remove it

10. DRAIN OIL Remove the factory drain plug
and set aside. We will not be reinstalling this
plug.

from the vehicle.

11. REMOVE MUFFLER MOUNT Using an
airsaw or hack saw, remove the passanger side
muffler mount to make room for the turbo inlet.

12. Cutting the bracket from the backside with an

airsaw is ideal. File any sharp edges.

Revised 7/9/2013 Page 4 of 17

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13. PREPPING THE STOCK MUFFLER
BRACKET Remove the nuts from the lower
rear engine mount bolts.

14. Center the turbo mount template to the stock
muffler bracket as shown. Secure the template to
the vehicle with vise grips.

15. drill 2x 11/32” holes into the stock muffler

bracket as shown.

16. MOUNTING THE TURBO/BRACKET

Using the 2 5/16 x 3/4” bolts, fasten the turbo

bracket to the stock muffler bracket. Use the
11/32” holes drilled in the previous step.

17. Using the factory lower engine mounting
bolts, fasten the bottom of the turbo bracket to
the vehicle.

18. INSTALLING WATER LINES Follow
the factory coolant line from thethermistat lamp
each side of the 90 degree bend with vise grips.
Make a cut after the 90 degree bend.

Revised 7/9/2013 Page 5 of 17

www.boondockers.com………………..... ……….………………....877-522-7805