What's in the Box
Installation
1
Remove both passenger and driver captain’s chairs.
2
Remove the rear firewall access panel to the turbo.
3
Remove the center console by removing (4) push darts and (3) T-40 Torx. Push the shifter and seat belt rubber boots down into the center console. They will stay with the vehicle. (Figure 1).
4
Remove the center console, you will have to finesse the shifter around to fully remove the console. Place the console in the driver’s side floorboard.
5
On the front of the vehicle, you will find a hood, remove the hood and locate the Diagnostic port. The diagnostic port will be an 8-pin port with a purple internal clip. On the firewall you will see (2) rubber gromets, pop the smaller gromet out on the left. (See figure 2).
6
Locate the glove box, we will need to drill a 1 1/4" hole. To keep the wires and harness’s hidden, we drilled our hole towards the left rear of the glove box. (See figures 3-4).
7
Grab the supplied diagnostic triple Indy wiring harness, feed the Polaris male (2 ft end) from the glove box through the front firewall and rubber gromet. Plug it into the vehicle diagnostic port. The triple Indy part of the plug will stay in the glove box.
8
Grab the supplied 02 sensor and put anti seize on the threads. NOTE: Do not put anything on the tip of the sensor. (Figure 5).
9
With a 19mm wrench, remove the auxiliary 02 sensor bung plug. Install the 02 sensor into the bung, tighten down with a 22mm wrench.
10
Grab the supplied AFR wiring harness and plug it into the tail of the 02 sensor. Route the wiring harness away from any heat source, rotating parts, and so it wont snag onto anything while riding. Run it through the rear firewall, underneath the center counsil supports, next to the shifter, and through the front firewall following the coolant lines. Run it up the front firewall, through the rubber gromet where the diagnostic Figure 5 port is, and down into the cab. Feed it into the glove box. Once complete, start strapping it with zip ties from the rear to the front. You can keep the access length up front, under the hood. (Figure 6-7).
11
Plug the AFR wiring harness into the AFR module in the glovebox. From the AFR module plug in the grey adaptor to the triple Indy harness (the first or second grey plug). Cut the proper length Velcro and mount the module on the side of the glovebox.
1
If you have not already installed the AFR module, please see step 1-7 above underneath AFR Module. This is the same seven steps it takes to disassemble the car.
2
Now that the center console is out, glove box is drilled out, and the Polaris diagnostic harness is plugged in, we can continue.
3
First thing we need to mount the Belt Temperature sensor. Don’t mount the sensor on the clutch cover, otherwise you need to remove it every time you need to maintenance your clutches. The RZR Turbo has a shelf in the middle of the clutch box, which makes the 12 o’clock position not very suitable for mounting. We mounted our Belt Temperature sensor in the 10 o’clock position. (See Figure 7) 12 O’clock Position.
4
With a hole punch or small diameter drill bit, start an indent on the clutch casing. NOTE: Make sure the belt sensor is directly in the middle of the belt. Once your indent is in the correct location, grab a 1/2” drill bit and drill the hole out. (Figure 8-9).
5
Blow the debris away with compressed air and make sure inside the belt box is clean.
6
Grab the belt temperature sensor take both nuts off, apply a small amount of Teflon tape (since we are mount the sensor directly to the casting of the clutch box) place one nut on the backside and slide it through the hole. Apply a small amount of Loctite to the threads inside the clutch box. Tighten the second nut on, keep the nut and sensor flush with each other. You do not want the sensor protruding into the clutch box. Take (2) 14mm wrenches and tighten. (Figure 11).
7
Connect the Belt Temperature wiring harness to the pig tail on the sensor, route the harness through the rear firewall, down center console by the shifter, through the front firewall following the coolant lines. Run it up the firewall and through the same rubber gromet where the diagnostic plug and AFR wiring harness did. Push it through the firewall into the cab and into the glovebox. (Figure 12-13).
8
With zip ties, start in the rear of the vehicle and strap the Belt Temperature wiring harness to the frame of the car, keeping the wiring harness away from heat sources and rotating parts.
9
Connect the Belt Temperature module to the belt wiring harness in the glovebox. From the Belt Temperature module, plug in the grey adaptor to the triple Indy harness (the first or second grey plug). Cut the proper length Velcro and mount the module on the side of the glovebox. Belt Temperature module. AFR module.
10
If you would like to keep your glove box sealed, purchase a 1 1/4" rubber gromet and cut one end from the outside to the middle. Wrap the cables to the inside of the gromet and push it from the bottom of the glovebox in. Once the rubber gromet is seated, run a bead of clear silicone around the outside and middle of the gromet. This will help seal the glovebox.
1
Reassemble the center console, pull the seat belt boots and shifter boot till they are seated. Secure the center console with (3) T-40 Torx bolts and (4) push darts.
2
Reassemble the turbo access panel on the rear of the firewall.
3
Reassemble both driver and passenger seats.
4
Reassemble the clutch cover.
5
Zip tie any access wire underneath the front hood, reassemble the front hood.
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.