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Polaris 2017+ Turbo & Turbo S High Flow Fuel Pump Kit — Install Guide

Polaris · 2017-2021 RZR Turbo · SKU 500FP0005

What's in the Box

Polaris RZR Turbo kit contents
Included parts
AEM All Fuel Compatible High Qty 1
Flow Fuel Pump.
AEM Pump Pre-Filter Qty 1
14.5mm hose clamps Qty 2
3 1/8” Fuel Hose Qty 1
20 AMP Fuse Qty 1
Removal Instructions:
Required tools
Small flat blade screwdriver
(Optional) Polaris service tool PU-
50326 and 1/2” ratchet.
Safety glasses
Rubber gloves
Flashlight
Razor Blade
Silver Sharpie

Installation

1
Remove passenger seat and access cover by lifting on tab, to access fuel pump. With a damp rag or shop vacuum, clean the top of the fuel tank where the fuel pump nut ring is located. Failure to do so may result in foreign debris dropping into the tank, causing premature failure of the AEM High Flow Fuel Pump. NOTE: Mark the orientation of the fuel pump assembly so when you reassemble its orientated correctly and you will not receive false fuel readings.
2
Put your safety glasses and rubber gloves on at this point. Unplug 4 pin sending unit and disconnect fuel lines. Slide the green clips towards the passenger side of the vehicle to release the fuel line. You can then pull the fuel lines off.
3
Unscrew the fuel pump nut ring. We recommend buying the Polaris Tool, so no damage is done to the fuel pump nut ring.
4
Genteelly remove the entire fuel pump assembly. Turning the pump at a 90-degree angle will help not damage the float and pre pump filter while removing.
5
Once the OEM fuel pump assembly is removed, place it on a clean dry surface. With a flathead screwdriver, remove the OEM pre filter. Also remove both positive (+) and negative (-) terminals off the OEM fuel pump.
Polaris RZR Turbo installation
6
With a razor blade, cut the hose down the ribs of the OEM fuel pump fitting. Do the same on the assembly side. Remove the hose completely and discharge.
7
Pull the top of the fuel pump away from the fuel pump assembly and push up on the bottom of the fuel pump, and the pump will release. Now the fuel pump assembly stands alone.
8
Install the 3 1/8” fuel hose onto the AEM fuel pump. Fasten down with a 14.5 pinch clamp.
9
Install the AEM fuel pump back into the OEM assembly. This is a direct replacement for the OEM fuel pump. Push the pump down until it seats into the fuel pump assembly. Slide the second 14.5 pinch clamp onto the fuel hose and connect it to the fuel pump assembly. Clamp it down.
10
Reconnect the positive (+) and negative (-) terminals onto the AEM fuel pump. The positive (+) terminal is larger than the negative (-) so they can only go on one way.
Polaris RZR Turbo installation
11
Install the new pre filter onto the bottom of the AEM fuel pump.
12
Start by holding the fuel pump assembly at a 90-degree angle. Place the float and filter in the tank first. Slide the rest of the assembly into the tank. Make sure the O-ring is sitting flush on top of the fuel tank. Place fuel pump nut ring on the fuel tank threads and torque to 70 ft/lbs. Verify that the fuel line connections are free of debris. Connect the fuel lines onto the pump module. Slide the green clip towards the driver’s side of the vehicle to lock it into place. Re-connect the 4-pin sending unit.
6
Underneath the dash, remove the fuse box cover. On the back of the fuse box, you will see a diagram showing a 10AMP fuse in the fuel spot. Switch this fuse out with a 20amp fuse.
7
Test the fuel pump by turning on the key and listen for the pump to activate. Do this several times to prime the fuel system. Check for leaks. If there are no leaks, re-install the access cover and passenger seat.
Polaris RZR Turbo installation

Note: This product is exempt from the emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code§§ 27156 and 38391]. This product is sold only for use in connection with EPA certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/that purchase this product represent and warrant that the product is purchased only in connection with EPA -certified, emission-regulations-exempt and noise- regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.