Application Notes

This Kit fits the 2022 PRO R and PRO R 4

The vehicle shown in this document is a modified 2022 Polaris RZR Pro R. Your vehicle could have parts that may or may not be present in the pictures. The images are meant to be a reference.
If you have any questions regarding your installation, contact us at support@injectordynamics.com

Item List

Fuel Rail + Regulator Kit (Return Style Kit)

Remove Fuel Pump Module

1. Follow the manufacturer’s instructions to gain access to the fuel pump module.
2. Remove the firewall panels located behind the seats.
3. Disconnect the power connector and crank the engine to bleed fuel pressure. Disconnect battery once the pressure has bled.
4. Disconnect fuel line from the pump module. There will still be some fuel left in the fuel line.
5. Remove the fuel pump ring and lift the module out of the tank (drain as much fuel back into the tank as possible).


Figure 1: OEM Reference

Modify Fuel Pump Module for Return Line and Install Regulator Plug

1. Place the 7/16” washer on the underside of the Top Hat and using a marker place a mark in the center of the washer. Use figure 2 as a reference for the return line location.
   

   Figure 2: Return Line Placement reference

2. Start by drilling a 1/8” pilot hole on the mark that was made in the last step.
3. From the top side of the top hat, drill a 7/16” hole. A Unibit is recommended but it is also possible to start with a smaller drill bit and step up to a 7/16” bit.
4. Install the -4 bulkhead fitting using the stat-o-seal on the top of the top hat and the 7/16” washer on the bottom side. Use figure 3 as a reference for the orientation of the bulkhead fitting.
   

   Figure 3: Return Line reference

5. Remove the metal clip that is retaining the factor regulator. Make note of the wire being held in place. Use figure 4 as reference.
   

   Figure 4: Metal Clip Reference.

6. Use needle nose pliers to remove factory regulator.
7. Press the supplied regulator plug into the housing.
8. Reinstall metal clip making sure the clip is in contact with the bare wire.
9. Clearance between the return line fitting and body panel is extremely tight. In order to help prevent the chance of rubbing, it is recommended that a portion of the body panel is removed. Use figures 5 and 6 for reference.
   

   Figure 5: Body Panel Reference (Before)

   

   Figure 6: Body Panel Reference (After)

10. Reinstall the fuel pump module into the fuel tank. Use figure 7 as a reference for all connections.
    

    Figure 7: Fitting Reference

Install Fuel Rail, Injectors and Regulator

1. Remove the engine cover to gain access to the top of the engine.
   

   Figure 8: OEM Fuel Rail Reference

2. Disconnect injector electrical connectors.
3. Disconnect fuel line from the rail. There will be fuel left in the fuel line.
4. Remove the (4) clips retaining the wire harness and (4) bolts to uninstall the fuel rail.
5. Outside the vehicle, install the supplied fittings into the rail and regulator.
   1. Install the -06 ORB to 3/8” EFI on the inlet of the rail (towards the front of the car).
   2. Install the -06 ORB swivel fitting (non adjustable side) on the outlet port of the rail.
   3. Install the -06 ORB to -04 AN fitting into the bottom of the regulator housing.
   4. Thread on the regulator housing to the swivel fitting until the threads bottom out, then back out one turn. Do not tighten the lock nut.
   5. Install ID injectors into the fuel rail. (Apply some grease on all O-rings).
6. Install fuel rail and injectors onto the manifold ensuring both injectors are properly seated (Take care, not to over tighten bolts).
7. Orientate the fuel pressure regulator as seen in figure 9.
   

   Figure 9: ID Fuel Rail Reference

8. Locate the PCV fitting and hose on the bottom of the intake manifold. Use figure 10 as a reference.
   

   Figure 10: PCV Location Reference

9. Remove the hose from the vehicle by releasing the clips on both ends.
10. Cut the hose 1.625in from the end with the green clip.
11. Join the hoses back together using the supplied brass tee. Use figure 11 as a reference.
    

    Figure 11: Brass Tee Assembly Reference

12. Reinstall the hose onto the vehicle. Orientate the tee so that it is pointing up. Use figure 12 as a reference.
13. Install the supplied 4mm hose onto the tee. Route the hose up and towards the regulator. Use figure 13 as a reference.
14. Install the hose onto the regulator’s refence port. Secure the hose using the supplied cable ties.
    

    Figure 12: Brass Tee Orientation Reference

    

    Figure 13: Brass Tee Orientation Reference

Install Return Line

1. Install the 90° fitting of the -4 return hose onto the outlet of the pressure regulator.
2. Route the return line along the rail and the factory feed line. Use figure 14 as a reference

.



Figure 14: Return line routing reference.

3. Connect the straight end to the bulkhead fitting on the pump module.
4. Use supplied 11” cable ties to attach the return line to the feed line. Use figures 15 as a reference.
   

   Figure 15: Return line routing reference

5. Reconnect battery and prime the fuel system to check for leaks. Do not start the vehicle.

Flash ECU

1. Generate ECU data by using the online generator and follow the directions to make the changes in the calibration.

HP Tuners Polaris Pro R Data Generator

2. Once the ECU flash is complete, start the vehicle ensuring that there are no leaks in the fuel system (Always have a fire extinguisher close by).

Reinstall All Remaining Parts

1. Once you have ensured there are no leaks, reinstall all body panels and seats in the reverse order of removal.

Fuel Rail + Pulsation Damper Kit (Returnless Style Kit)

Install Fuel Rail, Injectors and Pulsation Damper.

1. Remove engine cover to gain access to the top of the engine.
   

   Figure 1: OEM Fuel Line Reference

2. Disconnect injector electrical connectors.
3. Disconnect the fuel line from the rail. There will be fuel left in the fuel line.
4. Remove the (4) clips retaining the wire harness and (4) bolts to uninstall the fuel rail.
5. Outside the vehicle, install the supplied fittings into the rail and pulsation damper.
   1. Install the -06 ORB to 3/8” EFI on the inlet of the rail (towards the front of the car).
   2. Install the -06 ORB swivel fitting (non adjustable side) on the outlet port of the rail.
   3. Install the -06 ORB plug into the bottom of the pulsation damper housing.
   4. Thread on the damper housing to the swivel fitting until the threads bottom out, then back out one turn. Do not tighten the lock nut.
   5. Install ID injectors into the fuel rail. (Apply some grease on all O-rings).
6. Install fuel rail and injectors onto the manifold ensuring both injectors are properly seated. (Take care, not to over tighten bolts).
7. Orientate the pulsation damper as seen in figure 2. NOTE: Pulsation Damper will be plugged.


Figure 2: ID Fuel Rail Reference (pulsation damper outlet will be plugged)

Flash ECU

1. Generate ECU data by using the online generator and follow the directions to make the changes in the calibration.

HP Tuners Polaris Pro R Data Generator

2. Once the ECU flash is complete, start the vehicle ensuring that there are no leaks in the fuel system (Always have a fire extinguisher close by).

Reinstall All Remaining Parts

1. Once you have ensured there are no leaks, reinstall all body panels.

Fuel Rail Upgrade Kit

Install Fuel Rail and Injectors

1. Remove the engine cover to gain access to the top of the engine.
   

   Figure 1: OEM Fuel Line Reference

2. Disconnect injector electrical connectors.
3. Disconnect the fuel line from the rail. There will be fuel left in the fuel line.
4. Remove the (4) clips retaining the wire harness and (4) bolts to uninstall the fuel rail.
5. Outside the vehicle, install the supplied fittings into the rail.
   1. Install the -06 ORB to 3/8” EFI on the inlet of the rail (towards the front of the car)
   2. Install the -06 ORB plug into the outlet port on the rail (towards the rear of the car).
   3. Install OEM injectors into the fuel rail. (Apply some grease on all O-rings).
6. Install fuel rail and injectors onto the manifold ensuring both injectors are properly seated. (Take care, not to over tighten bolts).
7. Connect the injector electrical connectors.

Reinstall All Remaining Parts

1. Once you have ensured there are no leaks, reinstall all body panels.