XP 900

Polaris RZR 900
Installation Instructions
BoonDocker RZR Turbo 900
KIT CONTENTS LIST
Hardware Kit Bag Steps 23, 25,
28, 47, 48, 49, 54, 66
Fuel System Kit Bag Steps 44,
45, 61, 62
O
O
O
O
O
O
O
O
O
O
O
O
O
O
(4) 8mm x 30mm allen head bolts
(4) 8mm x 25mm bolts
(4) 8mm lock nuts
(2) 5/16 x 3/4” bolts
(2) 5/16 nylon lock nuts
(2) 8mm or 5/16” lock washers
(2) Gold exhaust springs
(4) High tension exhaust springs
(6) 8” zip ties
(4) 4” zip ties
Silicone Kit Bag Steps 22, 56
O
O
O
O
O
O
3” to 2” silicone reducer
3” piece of 2” balck silicone
(2) 2.25” piece of 2.25” pieces of black
silicone
(4) #36 hose clamps
(3) #32 hose clamps
#48 hose clamp
Fuel line assembly
(2) Auxillary injectors
(2) #4 hose clamps
(2) 1/4” x 1.5” allen bead bolts
Intercooler Kit Bag Steps 55, 63
O
O
O
O
O
Pull fan
(2) 1/4” x 1/2” bolt
1/4” x 3/4” bolt
(3) 1/4” lock washers
Fan power adaptor harness
Donaldson Air Cleaner Kit Box
Steps 22, 24, 64, 65
O
O
O
Donaldson air cleaner with 1/2npt x 1/4npt
reducer and 31.5” piece of 1/2” hose installed
3” x 16” intake hose
(2) #48 hose clamps
Parts:
Water Line Kit Bag Steps 32, 34 Separate
O 1548 Turbocharger (step 20,21)
O
O
O
O
O
O
15” water line with banjo fitting installed
24” water line with banjo fitting installed
(2) 3/8” barbed unions
(4) #6 hose clamps
(4) copper washers
(2) 14mm banjo bolts
Oil Drain Kit Bag Steps 36-39
O
O
O
O
O
Oil drain line with banjo fitting installed
(2) #8 x 1/2” self tapping screws
(2) R12 rubber insulated clamps
12mm banjo bolt
(2) copper washers
Oil Feed Kit Bag Steps 40-43
O
O
O
O
O
O
O
O
O
O
Oil feed hose
1/2” x 4an adaptor
O
O
Turbocharger bracket (steps 18-21, 23-29)
Adustable actuator (steps 26-27)
Exhaust inlet (steps 46-48)
Exhaust outlet (steps 49,54)
Body bracket for muffler (step 51)
Muffler (steps 53, 54)
Intercooler (steps 55-60)
Boondocker control box (step 67)
O Control box
O Air solenoid valve
O Battery jumper
O Velcro
O 30” of boost line
O (5) 8” zip ties
O (5) 4” zip ties
Clutch kit (steps 68-80)
O Team Rooster weights
O Red with black/gold striped primary
spring
O Green with silver secondary spring
O (3) 3.5 gram tungsten washers
(2) 3.5” x 12” decals
Revised 5/6/2013
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BoonDocker RZR Turbo 900
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.
4. Remove the 2 bolts connecting the airbox to
the airbox bracket.
5. Loosen the 2 clamps holding the airbox to the
throttle bodies.
6. Remove the breather hose from the IAC unit.
Pull the airbox out of the vehicle and reinstall
the bolts, grommets and spacers to the airbox
mounting bracket.
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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
from the vehicle.
10. DRAIN COOLANT locate the water pump
under the passanger seat and pull back the clamp
from hose to relase the tension on this
connection.
11. Place a drain pan under the vehicle. Pry a
screwdriver between the hose and the water
pump. This will allow the coolant to drain and
will make less mess than removing the hose.
12. Remove the radiator cap to allow the coolant
to drain quicker.
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13.DRAIN OIL Remove the factory drain plug
and set aside. We will not be reinstalling this
plug.
14. REMOVE MUFFLER MOUNT Using an
airsaw or hack saw, remove the passanger side
muffler mount to make room for the turbo inlet.
15. Cutting the bracket from the backside with an
airsaw is ideal. Be sure to save this bracket. You will
need to reweld the bracket if you want to put your
vehicle back to stock. File any sharp edges.
16. LOOSE ENDS Remove the screwdriver and
reinstall the clamp on the coolant line, then
tighten the radiator cap to the radiator.
17. PREPPING THE STOCK MUFFLER
BRACKET Remove the nuts from the lower
rear engine mount bolts.
18. Line up the turbo mounting bracket to the
engine mount bolts and the 2 dimples on the
stock bracket. Using a set of vise grips secure
the turbo mount bracket to the stock bracket.
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19. Using the existing holes in the turbo bracket
drill 2x 11/32” holes into the stock muffler
bracket.
20.PREPPING THE TURBO Remove the
turbo bracket from the vehicle. Remove the 3
bolts from the turbo then install the turbo to the
bracket.
21. Fasten the turbo to the turbo bracket using
the 3 bolts removed on step 20.
22. Install the silicone reducer onto the
Donaldson air cleaner.
23. Install the 2 5/16” x 3/4” bolts and lock nuts
to the turbo bracket.
24. Install the Donaldson air cleaner onto the
turbo charger.
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BoonDocker RZR Turbo 900
25. Fasten the Donaldson air cleaner to the turbo
bracket using the 2 8mm x 20mm bolts and lock
washers. Tighten the 2 hose clamps on the
silicone reducer.
27. Note: you should not have to pull the rod
to get it to fit, when properly installed
the waste gate arm should have no play.
29. Using the factory lower engine mounting
bolts, fasten the bottom of the turbo bracket to
the vehicle.
26. Install the actuator to the turbo. Adjust
the actuator rod just enough to where it
easily slips on the waste gate arm and
does not rattle.
28.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 step 19.
30. INSTALLING WATER LINES Locate
the coolant line coming from the thermostat.
Pull the hose toward the rear of the vehicle and
cut the hose in the middle of the 90 degree bend.
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BoonDocker RZR Turbo 900
31. Rotate the 90 degree bend coming from the
thermostat toward the rear of the machine.
32. Locate the 15” water line, 2 copper washers
and a banjo bolt from the water line kit bag.
Sandwich the banjo fitting with the 2 washers
then fasten the line to the turbo with the banjo.
33. Trim line as needed, then using the provided
3/8” barbed union and 2 #6 hose clamps, fasten
the coolant hose from the thermostat to the 15”
water line installed on the turbo.
34. Install the 24” water line to the outside of the
turbo and route it to the open end of the coolant
line cut in step 30.
35. Trim line as needed and fasten this
connection with the provided 3/8” barbed union
and 2 #6 hose clamps.
36.INSTALLING OIL DRAIN LINE Locate
the oil drain line and fasten the 5/8” side of the
hose to the turbo oil drain using the provided #8
hose clamp.
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37. Route the 3/8” end of the oil drain line to the
oil drain on the motor. Use the 2 copper washers
to sandwich the banjo fitting and fasten to the
motor with the 12mm banjo bolt.
38. Use the provided rubber clamp and existing
bolt to fasten the oil drain hose to the motor.
39. Using the remaining rubber clamp and self
tapping screw fasten the oil drain hose to the
shifter cable bracket as shown in picture.
40. INSTALLING OIL FEED LINE
Remove the 1/2”oil plug from the front of the
motor. Keep this plug in case you want to return
vehicle to stock.
41.Apply a thread sealant to the 1/2” pipe thread
side of the 4an adaptor then install the adaptor to
the motor.
42. Locate the oil feed line and fasten to the oil
inlet on turbo as shown in picture.
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43. Route the oil feed line from the turbo and to
the 4an adaptor installed on step 41.
44. INSTALLING FUEL LINE Locate and
cut the factory fuel line as shown in picture.
45. Insert a #4 hose clamp from the fuel system
kit bag on either side of the factory fuel line.
Using the Boondocker fuel line “T” into the
stock fuel line as shown.
46. INSTALLING EXHAUST INLET
Apply hi-temp black silicone to the inside of the
turbo inlet. Remove the zip ties holding the 4
hole flange to the turbo.
47. With the 4-hole flange inserted between the
turbo and inlet, fasten the turbo inlet to the turbo
using the 4 8mm x 25mm bolts and lock nuts.
48. Fasten the turbo inlet to the stock header
using the 4 Boondocker supplied hi-tension
exhaust springs.
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49. INSTALL TURBO OUTLET Fasten the
turbo outlet to the turbo using the provided 8mm
x 30mm allen head bolts.
50. INSTALL MUFFLER Remove the bed
support bracket on the passanger side of the
vehicle.
51. Install the bed support bracket replacement.
52. Remove the 2 passenger side tie down
support brackets from the inside of the bed.
53. Pry the bed off of the mounting bracket and
slide the muffler mounting tabs in between the
bed and the bed mounting bracket. Loosen
addition bed bolts if needed.
54. Align the muffler to the turbo inlet, outlet
and tie down support bracket holes. Reinstall the
support brackets and fasten the muffler to the
outlet using the 2 provided gold springs.
Revised 5/6/2013
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BoonDocker RZR Turbo 900
55. INSTALLING THE INTERCOOLER
Mount the fan to the intercooler using the 3
provided bolts. Note the longer bolt will need to
be used on the raised fan mounting tab.
56. Install the 3 silicone hoses and clamps to the
intercooler. Do not tighten the clamps until the
intercooler is installed, this way you can find the
best angle to access the clamp.
57. Install the grommets and spacers used from
the factory airbox onto the intercooler mounting
bracket.
58. Slide the intercooler onto the throttle bodies
and the outlet on the compressor housing of the
turbo. Tighten the clamps connecting the
intercooler to the throttle bodies.
59. Fasten the intercooler mounting bracket to
the stock airbox mounting bracket using the
stock bolts.
60. Tighten the clamps connecting the
intercooler to the turbo.
Revised 5/6/2013
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BoonDocker RZR Turbo 900
61. INSTALLING THE FUEL RAIL Apply
assembly lubricant to the upper o-rings on the
fuel injectors and insert them into the fuel rails.
62.Apply assembly lubricant to the lower o-rings
on the fuel injectors and insert them into the
intercooler. Fasten the 2 fuel rails with the
provided 1/4-20 x 1 1/2” allen head bolts.
63. POWERING UP THE FAN Route the fan
power harness from the fan and “T” into the
tailight power harness located under the rear
fender on the drivers side.
64. PLUMBING THE AIR CLEANER Install
the provided intake hose from the Donaldson air
cleaner to the factory air intake.
65. Install the 1/2” hose from the Donaldson air
cleaner to the IAC.
66.Look over all the hose routing to make sure
the clamps are tight and there are no kinks or
sharp bends in the hoses. Make sure to keep
hoses away from sharp objects. Zip tie hoses.
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67. INSTALL BOONDOCKER CONTROL
BOX Refer to control box installation
instructions.
68. CLUTCHING
Remove the clutch cover, and rear shock.
69.Remove the belt and secondary clutch.
70. Remove bolts from helix, remove helix.
71. Get clutch press and remove snap ring. Make
sure you mark the position of the sheaves, rollers
and helix for reinstallation.
72. Replace stock spring with the provided
Green/ silver spring. Roller holder is indexed to
inner spindle. Install using the press.
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73. Install snap ring.
74. Reinstall the factory helix,Be sure to reindex
to the marks made previously on step 71. Use
blue locktite when reinstalling the factory
screws.
75. Reinstall factory clutch.
76. Remove primary clutch bolt.
77. Remove clutch cover.
78. Remove clutch weights.
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79. Install preloaded clutch weights
80.Install the red w/black and gold primary
spring. Reinstall the clutch belt and clutch cover.
Tighen all bolt to factory specs. Reisntall clutch
cover and shock.
81.FINISHING TOUCHES Be sure to refill
the coolant and oil before starting the vehicle.
Revised 5/6/2013
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