Polaris 2021 Pro XP Big Injector High Pressure Fuel Pump Kit

What's in the Box

Included parts

AEM All Fuel Compatible High Qty 1

Flow Fuel Pump.

AEM Pump Pre-Filter Qty 1

13.3mm hose clamps Qty 2

8 1/2" Corrugated Hose Qty 1

20 AMP Fuse Qty 1

2” of Heat Shrink Qty 1

REMOVAL INSTRUCTIONS:

Required tools

Heat Gun

Solder Gun and Flux

Small flat blade screwdriver

(Optional) Polaris service tool PU-

50326 and 1/2” ratchet.

Safety glasses

Rubber gloves

Flashlight

Razor Blade

Silver Sharpie

Installation

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.

Put your safety glasses and rubber gloves on at this point. Unplug 4 pin sending unit and disconnect fuel line. Slide the blue clip towards the passenger side of the vehicle to release the fuel line. You can then pull fuel line off.

Unscrew the fuel pump nut ring. We recommend buying the Polaris Tool, so no damage is done to the fuel pump nut ring.

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.

Once the fuel pump assembly is removed, place it on a clean dry surface. Next step is pushing in the two black tabs on the pump, letting the pump pull out of the white cylinder housing.

Once the pump is released unplug both the Red (+) and Black (-) electrical terminals on the fuel pump. 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. Remove the pre filter by prying on the plastic ring with a small screwdriver.

Now it is just the pump and black housing standing alone. Pull the stock fuel pump out of the black housing. Remove the bottom white plastic spacer off the bottom of the fuel pump and the brass fitting with the spring from the black housing.

Grab the new AEM fuel pump and the 8.5” black corrugated fuel hose. Remove both red caps on the pump. Heat up the end of the fuel hose and slide it onto the green port located on the fuel pump. Fasten it with a 13.3mm pinch clamp.

Install the supplied electrical fitting into the new fuel pump. Reinstall the fuel pump into the black housing. Install the pre filter and place it back into the fuel pump assembly.

With a side cutters, cut both terminal ends off the fuel pump assembly. Cut supplied heat shrink in half and slide over both ground and power wires.

Solder both wires together, black to black, red to red. Slide the heat shrink over the bare wire and heat the shrink up with the heat gun.

Slide a 13.3mm pinch clamp onto the black corrugated hose. Heat up the other end of the fuel hose and slide it onto the fuel pump assembly. Fasten it with the pinch clamp.

Re-install the fuel pump assembly. 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 line onto the pump module. Slide the blue clip towards the driver’s side of the vehicle to lock it into place. Re-connect the 4-pin sending unit.

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.

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.

Create a Support Ticket

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.

Polaris 2021 Pro XP Big Injector High Pressure Fuel Pump Kit — Install Guide

Polaris · 2021 Pro XP (RZR) · SKU 500FP0018

What's in the Box

Installation