2016+ RZR TURBO FUEL PUMP KIT INSTRUCTIONS

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Carmella Simmons
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11/27/2015 2016+ RZR TURBO FUEL PUMP KIT INSTRUCTIONS READ THROUGH ALL INSTRUCTIONS PRIOR TO BEGINNING THIS INSTALLATION PARTS LIST: (1) FUEL PUMP (1) 25-40MM HOSE CLAMP (1) 14.5MM PINCH CLAMP (1) 15.

WRENCH, DYKES THIS INSTALLATION SHOULD BE DONE OUTDOORS IN A WELL VENTILATED AREA WITH A COLD ENGINE AND AWAY FROM ANY POTENTIAL SPARK OR HEAT SOURCES.

1 11/27/ RZR TURBO FUEL PUMP KIT INSTRUCTIONS READ THROUGH ALL INSTRUCTIONS PRIOR TO BEGINNING THIS INSTALLATION PARTS LIST: (1) FUEL PUMP (1) 25-40MM HOSE CLAMP (1) 14.5MM PINCH CLAMP (1) 15.7MM PINCH CLAMP (2) ZIP TIES (1) WIRING HARNESS PIGTAIL (1) HEAT SHRINK TOOLS NEEDED: BOX CUTTER, DREMEL, SCREW DRIVER, SOLDER GUN, POLARIS FUEL TANK NUT REMOVAL TOOL OR A LARGE CHANNEL LOCKS, TORQUE WRENCH, DYKES THIS INSTALLATION SHOULD BE DONE OUTDOORS IN A WELL VENTILATED AREA WITH A COLD ENGINE AND AWAY FROM ANY POTENTIAL SPARK OR HEAT SOURCES. ALSO, THE FUEL TANK SHOULD BE EMPTY DISCONNECT BATTERY REMOVE PASSENGER SEAT TO FACILITATE ACCESS TO THE TOP OF THE FUEL TANK. REMOVE THE CLIPS SECURING THE FUEL LINES TO THE FITTINGS. REMOVE FUEL LINES FROM THE FITTINGS ON TOP OF TANK AND UNPLUG THE ELECTRIC CONNECTOR. USING A LARGE (VERY LARGE) CHANNEL LOCK PLIERS, OR THE OEM FUEL TANK NUT REMOVAL TOOL, TURN FUEL TANK NUT COUNTERCLOCKWISE. ONCE THE NUT IS REMOVED, THE ENTIRE FUEL PUMP ASSEMBLY CAN BE REMOVED FROM THE TANK. WORKING ON A CLEAN WORKBENCH, REMOVE THE FUEL PICKUP BY PRYING UP ON THE METAL TAB THAT SECURES THE PICKUP TO THE BOTTOM OF THE PUMP. SEE BELOW Arizona Manufacturing Design 1625 E Weber Dr. Tempe, AZ Colorado Mountain Testing Hummingbird Lane Steamboat Springs, CO Minnesota Research Development 2007 State Rd 35 Somerset WI EVO1 jim@evopowersports.com

REMOVE THE CLEAR FUEL LINE FROM THE OEM FUEL PUMP OUTLET BY CUTTING WITH A RAZOR KNIFE, REMOVE THE SAME LINE FROM THE FITTING ON THE FUEL PUMP BRAKET CAP DO NOT REMOVE THE

REMOVE FUEL ELECTRICAL CONNECTIONS FROM FUEL PUMP AND REMOVE PUMP CUT THE STRAP HOLDING THAT HELD THE FUEL PUMP NEAR THE BOTTOM OF THE FUEL PUMP BRACKET AND MODIFY THE

2 REMOVE THE CLEAR FUEL LINE FROM THE OEM FUEL PUMP OUTLET BY CUTTING WITH A RAZOR KNIFE, REMOVE THE SAME LINE FROM THE FITTING ON THE FUEL PUMP BRAKET CAP DO NOT REMOVE THE OTHER 2 CLEAR LINES THESE ARE STANDOFFS FOR THE PUMP ASSEMBLY AND MUST BE LEFT IN PLACE. REMOVE FUEL ELECTRICAL CONNECTIONS FROM FUEL PUMP AND REMOVE PUMP CUT THE STRAP HOLDING THAT HELD THE FUEL PUMP NEAR THE BOTTOM OF THE FUEL PUMP BRACKET AND MODIFY THE BRACKET AS SHOWN IN THE PICTURE BELOW MODIFY THE FUEL PUMP BRACKET WITH A DREMEL TOOL REMOVE TABS WHICH HELD THE OLD FUEL PUMP IN PLACE THE NEW PUMP WILL NOT FIT CORRECTLY UNLESS THESE TABS ARE REMOVED. CUT HOLD DOWN STRAP OFF THIS WILL BE REPLACED WITH A LARGE CLAMP

USING THE CLAMP AS A TEMPLATE, MARK THE RIDGES ON THE FUEL PUMP BRACKET THEN USE A DREMEL OR FILE, TO MAKE A GROOVE ON BOTH SIDES OF THE BRACKET FOR THE CLAMP

SOLDER AND SHRINK WRAP NEW CONNECTOR PIGTAIL ONTO THE OLD WIRES TEST FIT AND TRIM WIRES AS NECESSARY BEFORE MAKING THE SOLDER CONNECTION.

3 USING THE CLAMP AS A TEMPLATE, MARK THE RIDGES ON THE FUEL PUMP BRACKET THEN USE A DREMEL OR FILE, TO MAKE A GROOVE ON BOTH SIDES OF THE BRACKET FOR THE CLAMP TO SIT IN CUT CONNECTORS OFF OF THE EXISTING WIRES THAT WENT TO THE OLD FUEL PUMP. SOLDER AND SHRINK WRAP NEW CONNECTOR PIGTAIL ONTO THE OLD WIRES TEST FIT AND TRIM WIRES AS NECESSARY BEFORE MAKING THE SOLDER CONNECTION. PLUG IN NEW CONNECTOR TO FUEL PUMP INSTALL SUPPLIED 5/16 FUEL LINE ONTO THE OEM FUEL PUMP BRACKET ASSEMBY CAP BARB. USE THE 15.7MM CLAMP ON THIS END. SLIDE THE 14.5MM CLAMP ONTO THE FUEL PUMP END OF THE LINE. INSTALL THE NEW FUEL PUMP INTO THE BRACKET WHILE

4 SLIDING THE HOSE ONTO THE FUEL PUMP DISCHARGE. USING A DYKES OR PINCH CLAMP TOOL, PINCH THE EARS ON THE CLAMPS UNTIL THEY ARE SECURE. SEE BELOW. 15.7MM CLAMP, 14.5MM CLAMP INSTALL WORM DRIVE CLAMP AROUND BODY OF THE FUEL PUMP AND BRACKET IN THE GROOVES MADE PREVIOUSLY AND SECURE. MAKE SURE THE CLAMP DOES NOT INTERFERE WITH THE FLOAT FOR THE FUEL GAUGE. INSTALL 2 ZIP TIES TO HOLD THE TOP OF THE FUEL PUMP TO THE FUEL PUMP BRACKET SEE PICTURE ON NEXT PAGE

ONCE THE FITTINGS ARE ALIGNED, YOU CAN PUSH DOWN ON THE PICKUP TO SEAT IT CORRECTLY.

5 CONNECT ZIP TIES TOGETHER SO THEY CAN BE TIGHTEND FROM BOTH SIDES INSTALL FUEL PICKUP THAT WAS REMOVED IN THE FIRST STEP ONTO THE NEW PUMP. THERE IS ONLY ONE ORIENTATION IT CAN GO SO MAKE SURE THE FITTINGS ARE ALIGNED. ONCE THE FITTINGS ARE ALIGNED, YOU CAN PUSH DOWN ON THE PICKUP TO SEAT IT CORRECTLY. REINSTALL FUEL PUMP BACK INTO VEHICLE MAKE SURE FUEL TANK GASKET IS INSTALLED BETWEEN THE FUEL PUMP ASSEMBLY CAP AND THE TANK. INTALL FUEL TANK NUT AND TORQUE TO THE FACTORY SPEC OF 70 FT LBS. RECONNECT FUEL LINES AND MAKE SURE CLIPS ARE INSTALLED CORRECTLY. RECONNECT PLUG TO OEM HARNESS.

6 RECONNECT BATTERY TURN KEY ON AND LISTEN FOR FUEL PUMP TO COME ON. IT SHOULD COME ON FOR A FEW SECONDS AND SHUT OFF. INSPECT FOR LEAKS AND OR FUEL SMELLS. IF LEAKS ARE OR SMELLS ARE DETECTED, DOUBLE CHECK YOUR WORK, CORRECT AND RETEST. ONCE EVERYTHING CHECKS OUT, DRIVE THE VEHICLE NORMALLY

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS 1. Note: It is recommended this install be done with a minimal amount of fuel in the tank. This will reduce fuel spills and make installation easier and safer. Draining the tank is recommended. INSTALLATION