rpmsxs PRO R Rear Passenger Floor Fuel Tank Installation Guide
- August 9, 2024
- rpmsxs
Table of Contents
PRO R Rear Passenger Floor Fuel Tank
Installation Instructions
PRO R Rear Passenger Floor Fuel Tank
**this install on is the Passenger side, Drivers side is very similar.
Inspect tank and fittings for any damage before starting the install process.
Installation should be double checked after first use for any loose bolts or leaks. Proper installation is key to a successful installation. If you do not feel safe with the installation or the work you performed, we highly suggest having a UTV or performance shop install the kit. If you ever smell gasoline, immediately stop use of the machine and fuel system and locate and resolve the issue.
Notes:
When fueling, stop the filling at the last bar on the gauge to avoid
overfilling the factory tank.
It’s best to park the car on a slight downhill to fully drain the accessory
tank.
6AN Female cap is only used if you remove the system from the vehicle to cap the bulk head fitting on the fill neck.
#1 Remove the factory fuel tank fill neck. You will drill a 3/8″ hole into the rubber tube 2.5” from the bottom. This will be the hole for the bulkhead fitting. The fitting will be tough to push through the smaller hole but it is important that it is this way in order for the bulkhead washers to nut pull through when tightened.
#1.1 Use plentiful loctite on the bolk head threads when tightening the fitting. You are sandwiching rubber, do not overtighten! When you see the rubber begin to deform, this is a good stopping point.
NOTE** some machine have enough floor board room for the tank to drop into place without following #2 instructions. This is a snug fit, but can be done.
#2 You will need to remove the flippable seat bases. 13mm bolts circled in red. The factory bolts can be reached best by removing or at minimum loosening the bolts for the factory plastic panel that covers the factory gas tank. Plastic cover outlined in yellow.
#3 First the fuel pump and fuel pump fittings are to be installed on to the tank. You will thoroughly apply the loctite to the fittings. Never use loctite on the AN side of the fittings.
#4 Install the stainless bottom fitting aiming for the same orientation as pictured below. This can be adjusted as / if needed after installation. You can wire the harness to the fuel pump, and route the harness through the small PVC coated clamp. The PVC clamp will then be secured to the tank at the yellow circle.
#5 At this time you can drop the tank into place.
#6 Assemble the fuel fitting as pictured, applying loctite to the 1/8 NPT
fitting, orientate it as pictured.
#7 You can begin routing the fuel and vent lines as pictured. You will
cut the 6an fuel line to length.
#7.5 Using the supplied hose clamps to secure the lines to the body using
the factory torx screws ( circled in purple ). Apply zip ties every 4-6 inches
as needed.
#8 Using the two supplied strips of foam, remove the adhesive and install
them onto the tank in such a way that the seat bracket will press on them,
this prevents a rattle between the gas tank and seat bracket.
#9 Reinstall the seat base with the factory 13mm bolts Then using the
supplied 8mm bolts, secure the tank to the seat base ( circled in green )
using loctite. Once tightened, install the J-Hook clamp ( circled in red )
If you need to re-use the factory plastic seat bracket cover. You will need to secure it from the bottom up using flush allen bolts. Use washers under the 8mm supplied bolts to space the bracket upward. This prevents any bolts from rubbing the tank.
ADDING A ADDITIONAL TANK
Adding an additional tank ties into the existing fuel system by either using
the supplied -6an Y adapter for the fuel line, or by adding a “T” 6an and 4an
adapter to accommodate the additional fuel system.
The wiring for the second pump can be connected to the first essentially daisy
chaining off each other.
This is a universal wiring and plumbing kit and can be modified as needed.
Due to the many variations of fuel system options, there is no 1 set of
instructions that would work for every option. Depending on the route and
fittings used you will have extra fittings when finished with the installation
of any additional tank.