BoonDocker POLARIS: 2007-10 Dragon Pump Gas - Manual (Page 11)

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 11
Step 10- Modifying the Exhaust Pipe
Tools Needed: Parts Needed:
Basic Tool Set Stock Exhaust Pipe
Measuring Tape Exhaust inlet pipe
Sander/sand paper or Grinder
Welder for 600 and 800 Dragon models
Saw or cutting tool
Important: Boondocker highly recommends using the stock pipe for this application,
aftermarket pipes can break at the seams under the increased pressure.
A. Polaris 700. (Note: The 700 is the only
model where you do not have to weld
on the inlet). You will need to cut the
pipe about 1 ½” from the shroud. You
will also have to grind off the spring
mounting tab. If you choose to weld on
the inlet lightly sand the finish on the
pipe to expose the raw metal (see
picture). See step 10 for installation
and fitting the pipe.
B. Polaris 600. The Polaris 600’s inlet will
have to be welded on, cut the exhaust
pipe about 1 ½” from the shroud and
grind off the spring tab as shown in
picture. Now lightly sand off the painted
surface to expose raw metal for welding.
Important: You will also have to weld
the entire seam of the pipe to keep it
from splitting under pressure. First
remove the shroud and trim off the extra
metal where the pipe is held together, cut
as close to the pipe as possible without
separating the 2 halves. Lightly sand the
painted surface were you will be welding.
Weld the entire seam. See step 10 for
installation and fitting the pipe.