Polaris Pro R & Turbo R Auxiliary Fuel Tank Kit

What's in the Box

Included parts

Pro R Auxiliary Fuel Tank Qty 1

Assembly

Auxiliary Tank Filler Adaptor Qty 1

Kit

Auxiliary Tank Install Kit Qty 1

Required tools

Flat Blade/ Phillips Screwdriver

T-25, T-40 Socket

21/64” Drill Bit

13mm Open End Wrench

5mm Allen Socket

Measuring Tape & Cutting Tool

Installation

Remove the plastic shroud around the glovebox. Remove (3) T-40 screws.

Remove (4) T25 screws holding the glovebox in. Slide the glovebox underneath the dash and remove.

Remove (4) Philip screws from the glovebox door. Remove the door.

Remove the speaker faceplate, (2) T-40 screws. Remove (4) T-20 screws holding the speaker in.

Remove (2) T-20 screws holding the rear of the speaker to the front firewall. Unplug the speaker electrical connector through the glove box access panel.

Remove the front passenger fender/panel. (11) T-40 screws and (3) push darts.

Remove the upper hood. (2) T-40 screws. Remove the lower hood (1) T-40 screw.

Remove the passenger side hood panel. (3) T-40 screws and (1) push dart.

Remove the 10mm nut holding the antenna through the dash. Remove (1) T-40 screw and (1) push dart. Can remove passenger side hood.

Slide the rubber A-pillar boot up the cage rail. Unplug the tweeter speaker connector. Remove (1) T-40 screw holding the upper passenger dash on.

Cut/Grind the (4) plastic tabs off on the front firewall located underneath the dash.

Install fuel tank and loosely install the two hose clamps on upper dash tube. Push up on bottom of tank and drill the 3 holes using the 21/64 drill bit.

Install the (3) 8mm bolts with locknuts and tighten. Bolt head on outside of firewall. Tighten the hose clamps.

Remove passenger seat and rear firewall. Locate the filler neck, remove both hose clamps. Make a mark in the middle of the tube, cut off 1/2" on both sides of the tube.

Install the aluminum filler in the middle of the rubber filler neck. Tighten with supplied hose clamps. Make sure the barbs are facing down and orientation is correct. Reinstall to tank. Install one end of each 112” fuel hose to the barbs and use supplied pinch clamp to tighten.

Route both fuel hoses underneath the cab, through the frame up to the fuel cell. Zip tie where needed.

Continued:

If you have excess hose (2-seater), trim both hoses to length and install onto the (2) barbs located on the fuel hat. Use supplied 13.3mm pinch clamps to secure. Orientation does not matter, both hoses run to the same adaptor. Install the one-way check valve in line on the fuel outlet hose. Use supplied 13.3mm pinch clamps to fasten down.

Connect the relay harness to the fuel cell connector. Plug the other end into the bus bar.

Install the auxiliary rocker switch into a blank location on the dash.

Fill the fuel cell and transfer fuel. Check for leaks.

Reinstall all plastic except the inner glove box tray or subwoofer.

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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 Pro R & Turbo R Auxiliary Fuel Tank Kit — Install Guide

Polaris · Pro R (RZR) · SKU 500RP0062

What's in the Box

Installation