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Intercooler Expansion Package for BoonDocker for Ski-Doo Gen4 850 (Agility or SideKick)

Intercooler Expansion Package for BoonDocker for Ski-Doo Gen4 850 (Agility or SideKick)

Regular price $1,199.00

Unit price per 

Reduce charge-air temps and increase performance with our high-efficiency water-to-air intercooler packages for Ski-Doo Gen4 850. 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! 


For the highest-performance enthusiast, the water-to-air Intercooler Expansion Package for the Ski-Doo Gen4 850 (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.

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
  • 2017+ Ski-Doo Gen4 850 w/SideKick or Agility Turbo 
  • 2020+ Ski-Doo Gen4 850 w/Factory Turbo  Not Available
Kit Configurations

Only one configuration is available for this product. This configuration fits BOTH Agility AND SideKick.

  1. 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
    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 10% av-gas mix
      • Ethanol Gas (91-octane, 10-15% ethanol)  Not Available   
      • Mix (50% Av-Gas / 50% 91-Octane)
      • Av-Gas (100LL or higher octane) 
        • Black actuator required for >8 PSI
        • Fuel system upgrade 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.
        • Clutching:
          • We STRONGLY suggest our BoonDocker High Energy ™ clutching.
          • Base Kits: For low-boost, high-elevation only
          • Premium Kits: suggested for all applications
          • 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
            • Double-Black: 8-12 PSI, not suggested for any application, will may demand more octane than Av-Gas
          Frequently Asked Questions

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

          The same kit, with just a few additional parts, can produce a wide range of results. Upgrades are purchased separately. Here are our standard minimum configurations:
          • Pump Gas (91-octane, non ethanol) Requirements (>4,000 feet)
            • Suggested 10% mix of av-gas
            • Intercooled or Non-Intercooled kit
            • Adjustable or Non-adjustable control box
            • High Energy ™ Base clutch kit or High Energy ™ Premium clutch kit
            • Blue Actuator (Black actuator may work above 10,000 ft)
          • 50/50 Mix (>2,000 feet)
            • Intercooled or Non-Intercooled kit
            • Adjustable or Non-adjustable control box
            • High Energy ™ Premium clutch kit
            • Blue Actuator or Black Actuator
          • Av-Gas
            • Intercooled or Non-Intercooled kit
            • Adjustable or Non-adjustable control box
            • High Energy ™ Premium clutch kit
            • Fuel system upgrade
            • Black Actuator

          How long does it take to install? 

          A qualified technician should be able to install this product as follows:
          • Airbox style intercooler: 2.5 hours

          Can BoonDocker install this product?

          Absolutely! We have a fully-staffed service department. We know our products best, and can go beyond a simple installation with our dyno tune-and-test service. Know that your vehicle is ready for the weekend. We also have a strong dealer network across the nation. Our premiere dealers have demonstrated the knowledge of our products and sell enough volume to be competent in both installation and service.

          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)


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            Hand crafted products built in Idaho

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