Reduce charge-air temps and increase performance with our high-efficiency water-to-air intercooler packages for Polaris AXYS 800. Hotter charge air contains less oxygen and will make less power. Additionally, high charge-air temperatures can cause lazy performance. Get the most out of your machine with an intercooler! 

Summary

For the highest-performance enthusiast, the water-to-air Intercooler Expansion Package for the Polaris AXYS 800 (SideKick or Agility) cools charge air temperatures up to 30% over non-intercooled. It delivers consistent, reliable power, regardless of conditions, so you can have more fun, every weekend.

Compressing air makes heat. This heat is manifested in your charge air temperatures. Hotter charge air holds fewer molecules of oxygen. Less oxygen means less fuel for a proper stoichiometric combustion. Less fuel and less oxygen mean less power. Don't cheat yourself out of potential power; get an intercooler today.

Agilty style intercooler fits SideKick OR Agility!

SideKick-style intercooler fits SideKick ONLY

An intercooler should be considered if your riding includes: extended periods of Wide Open Throttle (WOT), running above 10 PSI boost, or if you want the most consistent runability, regardless of conditions!

Fit and Compatibility

• 2016+ Polaris AXYS 800 w/SideKick or Agility Turbo ✔
• Charge-tube style intercooler will NOT fit Agility turbo kits
• Air-box style intercoolers will fit either SideKick or Agility
• 2019+ Polaris AXYS 850 (Patriot) w/SideKick or Agility Turbo ✔
• Charge-tube style intercooler will NOT fit Agility turbo kits
• Air-box style intercoolers will fit either SideKick or Agility

Kit Configurations

1. Intercooler Style
   
1. Charge-Tube Style
   
1. Water-to-air Intercooler located inside charge tube
2. Less cooling capacity than Airbox style
3. Does not fit Agility
2. Airbox Style
   
1. Newest design
2. Water-to-air Intercooler located in charge-air-box plenum
3. Increased cooling capacity over Charge-Tube style
4. Fits Agility or SideKick
2. Fuel Controller
1. No-None
1. No fuel controller is included.
2. Does not fit SideKick; fuel controller upgrade required for SideKick
2. Yes-Adjustable
1. Includes our ST 2.0 control box
2. USB-updatable
3. Adjustable
3. Yes-Non-Adjustable
1. Includes our SideKick 2.0 control box
2. USB-updatable
3. Non-Adjustable

Stats and Specs

• Includes intercooler, heat-exchanger, coolant pump, coolant reservoir (if required)
• Produces up to a 30% drop in charge air temperatures
• CLUTCHING NOT INCLUDED: Clutching purchased separately (REQUIRED to run higher boost, ie more power)
• ACTUATOR NOT INCLUDED: Actuator is purchased separately (REQUIRED to run higher boost, ie more power)

Fuel Requirements

• Pump Gas (91-octane, non-ethanol) ✔ 
• Requires Idaho or Colorado head for Polaris Patriot 850
• Ethanol Gas (91-octane, 10-15% ethanol) ✔  
• Requires Idaho or Colorado head
• Not available ⦸ for Polaris 800
• Mix (50% Av-Gas / 50% 91-Octane) (standard kit configuration) ✔
  
• Av-Gas (100LL or higher octane)  ✔
• Black actuator required for >8 PSI
• E85 - ⦸ Not Available 

Suggested Upgrades

Click the link next to ANY upgrade to learn more or buy now

• Fuel System Upgrade:
• An upgraded fuel system includes auxiliary injectors in our charge-air box (on some models, an upgraded fuel system may include larger injectors to replace stock injectors), fuel rail, and electronics to control these injectors. An upgraded fuel system is required to run pump-gas in most applications (if available) and required to run high-boost in all applications. An upgraded fuel system is also required to our kits at low elevations. Fuel System Upgrade is included in all Polaris snowmobile kits.
  
• Agility Intercooler:
• While it's best to buy the intercooler when you buy the kit, our Agility Intercooler is available as an upgrade
• Clutching:
• We STRONGLY suggest our BoonDocker High Energy ™ clutching.
• Base Kits: For low-boost, high-elevation only
• Premium Kits: suggested for all applications
• Heads: 
• Polaris AXYS 850 (Patriot) ONLY
• Colorado (Billet or re-cut)
  
• Larger combustion chamber vs. stock
• Allows for Pump gas above 8,500 feet 
• High-Boost applications - Turn up your boost even higher with the Colorado head
• Great for low elevation applications with higher boost or higher octane
• Idaho (Billet or re-cut)
• Larger combustion chamber vs. Colorado head
• Allows for Pump gas above 4,000 feet
• Should ONLY be used in pump-gas application
• Actuators: 
• Blue: 4-8 PSI (max 8.4), comes standard with kit
  
• Black: 6-10 PSI (max 11.2), required for high-boost. Will increase throttle response and produces a more powerful seat-of-the-pants feeling, even on lower-boost kits. All things equal, upgrading your actuator will increase the octane requirement
• Double-Black: 8-12 PSI suggested only for seasoned mod-sled builders. All things equal, upgrading your actuator will increase the octane requirement

Frequently Asked Questions

How do I need to configure my kit for different scenarios? 

How long does it take to install? 

Can BoonDocker install this product?

Where are the installation instructions?

The installation instructions are provided below. Please click on the image to download the PDF. We suggest you browse the instructions before you determine if you want to install this product yourself or if you want a dealer to install.

How do I get my tune(s) for my BoonDocker Control Box?

We provide tunes for download: downloads.boondocker.com

Does BoonDocker offer an ECU Re-flash option?

Yes, we offer ECU re-flash options. However, at this time, our re-flash(es) work in conjunction with our piggyback fuel controller

Why does BoonDocker use a piggyback fuel controller?

We utilize a piggyback-style fuel controller for several reasons. Primarily, to electronically control boost. BoonDocker is the ONLY kit on the market that uses active electronic boost control, meaning your sled will work, regardless of conditions.

How do I need to configure my clutching?

Please visit our Clutching page for this application

Can I install this product myself?

This product requires a moderate skill level to install. A mechanically inclined person can easily tackle this project. We suggest that you look at the instructions and determine if you need assistance from our service department or one of our dealers.

Are any specialty tools required?

You will need a secondary-clutch compression tool to install the clutch kit. Intercooled kits require cutting tools and a drill. Otherwise, simple hand tools are required.

Do you have an E85 tune

No, we don't produce E-85 tunes.

Is the Kit complete

The Intercooler Expansion Package is complete, other than clutching and actuator.

Airbox Style Intercooler Instructions

(click image for instructions)

Charge-tube Style Intercooler Instructions

(click image for instructions)