What's in the Box
Installation
1
Remove the center dash cover (if it hasn’t already fell off).
2
Remove the passenger side yellow panel. Slightly lift on each corner, (4) tabs are holding it in place.
3
With a T-25 socket, remove the cage trim piece. You can open the fuel door to help remove.
4
Remove the passenger side upper dash. (3) 10mm screws and (1) T-25 screw.
5
Remove the fuel pump safety bracket by removing (2) 10mm screws. NOTE: Notice the arrow on the fuel pump is facing the middle of the box. When reinstalling make sure the arrow is facing the middle of the box or your fuel float will read incorrectly.
6
Remove the silver safety clip on the electrical connector, then remove plug. Remove the blue safety clip on the fuel connector, press the black quick connect and remove the fuel hose.
7
Remove the fuel pump nut, be careful not to damage it. The fuel pump assembly has springs so the hat might spring up about one inch.
1
Unplug the fuel pump electrical connector, it wont be able to be removed at this point, as long as its unplugged. Disconnect the fuel float connector from the fuel hat.
2
Carefully push down 1 tab at a time on the surge tank, work your way around the top of the surge tank hat. Total of (3) tabs. DO NOT BREAK THE TABS!. Once complete you can slowly pull the top surge tank away from the lower half. BE CAREFUL!
3
Slide the top hat away from the surge tank. The fuel pump may come with the hat or stay in the surge tank. Remove the fuel pump and rubber gromet from the lid.
4
Compress the lid and springs a bit, remove the locking washer. Remove the lid from supports. Keep the springs!
5
On the lid you will find the fuel inlet and fuel pressure regulator. Cut both hoses off the grey fittings. Keep both black hose sleeves. NOTE: Don’t cut the grey fittings, be careful!
6
Remove the fuel pressure regulator by turning the grey fitting 1/16 of a turn counterclockwise. Then push up and remove, you can discard this part.
7
Remove the fuel inlet fitting. Notice it clicks into place between (2) tabs. Turn it counterclockwise, find the two flat sides and remove the fitting from the lid.
8
Discard the upper fuel hat, save the black sleeve.
9
Remove both fuel pump caps before installation.
10
Install the 8.0” corrugated fuel hose onto the grey fitting. It helps to apply dielectric grease onto the pump. Use supplied corrugated hand tool. Heat up the end of the fuel hose with a heat gun NOT A FLAME! You can notice the color turn shiny, remove heat source, let it cool for a few seconds. Install onto the fitting, use supplied 13.3mm pinch clamp to secure.
11
Install the new pump into the bottom surge tank. Make sure both tabs are locked into place. The pump shouldn’t move when properly locked into place.
12
Install the springs onto the new supplied fuel hat. Reinstall the lid to the fuel hat supports. Make sure orientation is correct, figure 26, otherwise the hat will be off-center. Push down and compress the springs slightly, install supplied distorted lock nuts so 2 threads show.
13
Slowly reinstall the upper lid to the surge tank, making sure all (3) clips meet and fuel pump and inlet meet. Watch the float wires. May help to pull the corrugated fuel hose to the side.
14
You may need to orientate the fuel pump so the lid doesn’t interfere.
15
Trim 2.0” off both sleeves, should be 7.0” in total length. Burn the ends you cut with a flame. Slide one sleeve onto the fuel return hose, and the other will be used on the fuel inlet hose.
16
Install sleeve and 13.3mm pinch clamp onto the fuel inlet hose. Notice orientation of hose. Apply dielectric grease to fuel filter inlet fitting. Heat up the hose with a heat gun and install. Secure pinch clamp when done.
17
Install the fuel pump connector, you will hear a click. Install the fuel return hose into the OLD fuel pressure regulator hole.
18
Cut off 5.0” from the float white connector that plugged into the OEM hat.
19
You have (2) terminals, a connector and wedge lock. Remove the orange seal if still installed in connector. Strip 1/4" of the 20awg float wire attached to the float.
20
Install the barrel connector into the supplied hand tool. The wire goes into the shallower side, that’s the side you want to see once the terminal is inserted into the tool. Make sure the tool is 100% open. Do this by squeezing the tool all the way shut, it will open all the way when your hand is released. Install the wire into the terminal and squeeze the handle 100% closed. Release.
21
Install the terminals into the connector, from the backside. You will push until you hear a click. Orientation dose not matter on this connector. 1 & 2 can be flip flopped. The terminals will be loose until you install the wedge lock. Install the wedge lock from the front.
22
Connect the float connectors.
23
Install the new fuel pump assembly with a seal. Apply dielectric grease on the seal. Clock the fuel pump assembly correctly.
24
Install the fuel pump relay harness into the vehicle. Use the positive and negative to the upper dash bus bar. Route the wires under the plastics, use a 10mm socket.
25
Locate the plastic opening right in front of the fuel pump. Install the relay mounting clip into the slot. Mark with a sharpie and drill a 1/4" hole. Install supplied M6 flange screw and nut. Install the fuel pump harness to the fuel pump and OEM harness.
26
Install supplied 3/16” 90-degree or straight barb into the charge tube, use supplied pinch clamp to fasten. Install vacuum hose and clamp to the barb, route the hose through the firewall and up through the center tunnel, up the dash and to the fuel pump regulator. Loosely zip tie the hose (without kinking). 2-seat models can cut off extra 50” vacuum line. 4-seat models will use all 144”.
27
Behind the driver’s seat you will find the fuse box. Locate the fuel pump fuse (F28), replace the 10amp with supplied 20amp.
28
Key the vehicle on a few times and look for fuel leaks. If everything checks out reinstall all plastics.
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.