EVP 500FP0025 Polaris RZR Surge Tank Kit Instruction Manual
- October 30, 2023
- EVP
Table of Contents
EVP 500FP0025 Polaris RZR Surge Tank Kit Instruction Manual
Polaris RZR Surge Tank Kit
SKU(s): 500FP0025 (XP Turbo/S), 500FP0026 (Pro XP & Turbo R)
INCLUDED PARTS
- (1) EVP Surge Tank Assembly
- (1) 20amp Mini Fuse
- (1) 13.3mm Pinch Clamp
- (1) 2” Heat Shrink
- (1) 12v Connector Pigtail
REQUIRED TOOLS
- EVP Fuel Pump Tool
- Knife
- Solder Gun
- Heat Gun
- Pinch Clamp Tool
Step 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).
Step 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.
Step 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.
Step 4: Remove the positive and ground wire from the pump. You can now
remove the OEM fuel hat assembly from the fuel pump.
Step 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.
Step 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.
Step 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 heatedinstall 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!
Installing the EVP Surge Tank Assembly
Step 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 ho
Step 4: Locate your fuse box (underneath steering wheel). Remove the fuel
pump fuse and install supplied 20amp fuse.
Thank you for choosing Evolution Powersports products. If you require further assistance, please call our Tech Support @ (715) 247-3862
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 noiseregulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.
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