BoonDocker POLARIS: 2007-10 Dragon Pump Gas - Manual (Page 12)

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 12
C. Polaris 800. To modify the exhaust pipe for
the 800 you will have to cut 1” inch of
material off the shroud. Make sure you do
not cut the exhaust pipe while trimming the
shroud. Next you will have to cut the
exhaust pipe just far enough to slip the
Boondocker inlet pipe inside the exhaust
pipe. Lightly sand the exhaust pipes surface
where you will be welding them together.
You can also bend over the edges of the
shroud with a hammer to eliminate the
sharp edge. See step 10 for installation
and fitting the pipe.
D. Set the modified stock pipe (see step 9) in place on the sled. For the Polaris 600 and 700 you
will triple the springs on the “Y” pipe connection. For the 800 you will only have to double
the spring count. (See picture).
E. Position the inlet pipe onto the exhaust pipe. You may have to trim the inlet for a proper fit.
Then using two of the four 5/16 bolts and the 4 hole gasket, loosely mount the inlet to the
turbo. Make sure that the exhaust pipe is square with the doughnut on the “Y” pipe, and
make sure the inlet is flush with the turbo before marking it for welding (see picture).
F. Once you verify that exhaust pipe is placed properly, mark the inlet and exhaust pipe for
welding. Remove the pipe and inlet from the sled and weld this connection. Important: Do
not weld anything while it is on the sled unless you unplug the ECU, this can fry the ECU.