Supported Models

This kit fits the 2020+ Kawasaki Teryx KRX 1000

The vehicle shown in this document is a modified 2021 Kawasaki Teryx KRX 1000. Your vehicle could have parts that may or may not be present in the pictures. The images are meant to be a reference only. If you have any
questions regarding your installation please reach out at support@injectordynamics.com

Item List

Return Style Fuel System Installation
Instructions

Removing the Fuel Pump module

1. Remove the passenger seat by removing the four bolts securing the seat rail.
2. Remove the plastic cover shown in figure 1.

3. Disconnect the power connector and crank the engine to bleed fuel pressure. Disconnect the battery once the pressure has bled.
4. Disconnect the fuel line from the pump module. There will be some fuel left in the fuel line.
5. Remove the fuel pump locking ring by removing the six bolts and lifting the fuel pump module out of the tank (drain fuel back into the tank).

Modifying the Factory Fuel Pump Module for Return Line

1. Uninstall the pump top hat by disconnecting the two electrical connectors and lifting on the four clips shown in figure 3.

2. Using side cutters, cut the center webbing shown in figure 4.

3. Insert the backing plate into the webbing of the top hat. Next, insert the pilot hole bushing as shown in figure 5.

4. Drill a 1/8” hole using the center hole of the bushing. Remove the bushing and backing plate.
5. 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.
6. Install the -4 AN 90° bulkhead fitting using the stat-o-seal on the top of the top hat. Use figure 6 as a reference for the orientation of the bulkhead fitting.

7. Reinstall the fuel pump module into the fuel tank. Use figure 6 as a reference for all connections.

Fuel Rail, Injector, and Regulator Install

1. Remove the trunk panel to gain access to the top of the engine.
2. Disconnect injector electrical connectors.
3. Disconnect the fuel line from rail. There will be fuel left in the fuel line.
4. Remove the (2) Phillips head bolts to uninstall the fuel rail.
5. Install the supplied fittings on the rail and regulator.
   1. The -6 ORB to -6 AN needs to be installed on the inlet of the rail on the driver’s side of the car.
   2. The -6 ORB swivel fitting needs to be installed on the outlet of the rail on the passenger’s side of the car.
      The non-adjustable side of the swivel fitting needs to be installed into the rail.
   3. Install the -6 ORB to -6 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 the ID injectors into the fuel rail. (Apply grease on all O-rings).
6. Install fuel rail and injectors onto the throttle body ensuring both injectors are firmly seated (Take care, not to over tighten bolts).
7. Orientate the fuel pressure regulator as seen in figure 9.

8. Reconnect the injector connectors using the supplied electrical adapters.
9. Connect the vacuum hoses for manifold pressure reference:
   1. Cut the factory vacuum line 2 inches away from the T shown in figure 10 and push on the supplied Wye fitting onto both ends of the cut line.
   2. Insert the supplied 4mm vacuum hose onto the last leg of the Wye fitting.
   3. Trim any excess length of the vacuum hose and push onto the pressure regulator barb.
   4. Secure a zip tie onto all hose ends.

FDM Install

Mounting the FDM

1. Mount the FDM using figure 11 as a reference. Ensure that FDM isn’t contacting any other parts and rotated so that the tank is level vertically.

Routing and Securing Fuel Lines

1. Remove the factory fuel line from the vehicle. Do not remove retaining clips.
2. Install the supplied 6AN to 6 ORB adapters into the top of the FDM. Use figure 12 as a reference for FDM connections. Ensure hoses are not rubbing on adjacent fittings. Take caution to not rotate top cap while tightening adapters and fittings.
   • Port 1 – 6AN to 6 ORB. FDM feed to fuel rail (-6 hose with 90° fitting)
   • Port 2 – 6AN to 6 ORB. Return from regulator (-6 hose with 90° fitting)
   • Port 3 – 4AN to 6 ORB. FDM return to OEM fuel tank (-4 hose with 90° fitting)
   • Port 4 – 6AN to 6 ORB. Feed from OEM tank (-6 hose with 90° fitting)

3. NOTE: All four hoses will be routed along the horizontal tube against the firewall, behind the heat shield. Use figure 13 as reference. Ensure that hoses are secure and not rubbing on any sharp components.

4. Starting with the 58” -6 hose and the 58” -4 hose, route them through the firewall as shown in figure 14 and behind the heat shield. Connect the -6 hose to port 4 and the -4 hose to port 3 on the FDM.

5. Next, route the 77” -6 hose from port 1 on the FDM behind the heatshield to the right side of the vehicle. Run the hose where the factory fuel line was to the inlet of the fuel rail. Reuse the retaining clips that held the OEM fuel line.
6. Lastly, route the remaining 77” -6 hose behind the heatshield to the right side of the vehicle. Run it along the previously run hose to the bottom of the regulator. The 90° fitting will connect to port 2 on the FDM and the 45° fitting will connect to the bottom of the regulator. Use figure 15 and 16 as reference.

FDM Wiring

1. Connect the harness to the FDM and run the wires along the hoses behind the heatshield. Route the red and black wires to the battery and the two gray wires to the OEM fuel pump. Trim excess wire.
2. Cut the fuse holder’s wire loop to your desired leg lengths. Using the supplied blue butt splice, connect the red wire from the FDM to one leg of the fuse holder. Crimp a ring terminal to the other leg of the fuse holder.
3. Crimp the other ring terminal to the black wire from the FDM.
4. Using the metal butt splices and heat shrink, splice the two gray wires from the FDM into the OEM fuel pump power (white and red) and ground (black and yellow). It does not matter which gray wire is hooked to the OEM pump power or ground.
5. Connect the red and black wire’s ring terminals to the battery.
6. Secure all the wires with cable ties
7. With the electrical connector to the FDM unplugged, prime the fuel system to fill the FDM.
   1. Check for leaks.
8. Connect the FDM electrical connector and prime the fuel system. Listen for the pump to turn on and look for the blue LED on the underside of the FDM.
   1. Check for leaks.

Flash the ECU

1. Generate ECU data by using the online generator located on the Injector Dynamics website at http://injectordynamics.com/utv/ and follow the directions to make the changes in the calibration.
2. Once the ECU flash is complete, start the vehicle ensuring that there are no leaks in the fuel system (Caution: Ensure a fire extinguisher is within reach).

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.