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Polaris RZR Surge Tank Kit — Install Guide

Polaris · RZR · SKU 500FP0025 (XP Turbo/S), 500FP0026 (Pro XP & Turbo R)

What's in the Box

Polaris RZR kit contents
Included parts
EVP Surge Tank Assembly Qty 1
20amp Mini Fuse Qty 1
13.3mm Pinch Clamp Qty 1
2” Heat Shrink Qty 1
12v Connector Pigtail Qty 1
Required tools
EVP Fuel Pump Tool
Knife
Solder Gun
Heat Gun
Pinch Clamp Tool

Installation

1
Remove the OEM fuel pump assembly out of your vehicle. It will be located underneath the passenger seat (back passenger seat if 4-seater). DO NOT break the green/blue safety clips holding the fuel lines on. It is easiest to remove the fuel pump assembly nut with EVP tool (953RU0305).
2
Remove the float sending unit from the OEM fuel pump. On the XP Turbo/S assembly use a small screwdriver to push the black clip inward, push the sending unit upward. On a Pro XP/Turbo R use a small screwdriver and push the sending unit downward. Remove.
Polaris RZR installation
3
Cut (3) hoses attached to the fuel hat. (2) white hoses are supports and (1) hose is for the fuel pump. If there is a pitch clamp, remove that as well. On the Pro XP/Turbo R assembly you will NOT reuse the spring.
4
Remove the positive and ground wire from the pump. You can now remove the OEM fuel hat assembly from the fuel pump.
Polaris RZR installation
5
Cut the OEM power and ground terminals off from the fuel hat. Measure how much wire you will need to cut off the supplied pig tail connector.
6
Cut the supplied heat shrink in half, you should only need 1” per wire. Slide heat shrink onto each wire. Solder black to black and red to red.
Polaris RZR installation
7
Connect the solder connector to the pump. It will click once installed all the way. Install the supplied 13.3mm pinch clamp onto the fuel pump hose. If XP Turbo/S assembly, you will need to heat up all (3) hoses equally until they look shiny (DO NOT OVER HEAT). (If Pro XP/Turbo R assembly, you can install the black corrugated fuel hose first with a 13.3mm pinch clamp and install the supports together.) Once all (3) hoses are heated install the fuel hat barbs onto the white hoses. Make sure the float wires are in between both support hoses, they will lay in the half moon on the surge tank. MAKE SURE all (3) hoses are pressed on all the way!
1
Double check all hoses, clamps, float, and wiring harness before installing. Make sure to reuse the OEM circle gasket between the fuel hat and fuel tank.
Polaris RZR installation
2
Always install the fuel float first and fuel sock second. You can also remove the float arm from the assembly and install into the tank. Install the surge tank into the fuel tank about 2.0”. Then reinstall the float arm to the float assembly. See below.
3
Install the O-ring gasket between the fuel tank and fuel hat. Install the fuel pump nut and keep the same orientation if it is a XP Turbo/S model. If a Pro XP/Turbo R you will flip the fuel hat orientation 180-degrees. This will allow your float to read properly. You may need to clock your fuel line in the OEM holder.
Polaris RZR installation
4
Locate your fuse box (underneath steering wheel). Remove the fuel pump fuse and install supplied 20amp fuse.
Polaris RZR installation
Polaris RZR installation
Polaris RZR 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.