Polaris 2020-2022 Pro XP, 2022 Turbo R Install Instructions

Application Notes

This Kit fits the following models

1. 2022 Turbo R and Turbo R 4, all trims (includes EVAP).
2. 2020+ Pro XP and Pro XP 4, all trims (includes EVAP).

The vehicle shown in this document is a modified 2021 Polaris RZR Pro XP. 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. For two seat vehicles, remove both seats. For four seat vehicles, remove both rear seats.
2. Remove the firewall panels located behind the seats to gain access to the fuel pump
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).

Modify Fuel Pump Module for Return Line and Install Regulator Plug

1. Place the bulkhead nut on the underside of the Top Hat and using a marker. Mark the center as a reference for a drill. Use figure 1 as a reference for the return line location.
   

   Figure 1: 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” serrated washer on the bottom side. Use figure 2 as a reference for the orientation of the bulkhead fitting.
   

   Figure 2: 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 3 as reference.
   

   Figure 3: 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. Reinstall the fuel pump module into the fuel tank. Use figure 4 as a reference for all connections.
   

   Figure 4: Fitting Reference

Install Fuel Rail, Injectors and Regulator

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

   Figure 5: OEM Fuel Line Reference

2. Disconnect injector electrical connectors.
3. Disconnect fuel line from the rail. There will be fuel left in the fuel line.
4. Remove (2) 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 5/16” EFI on the inlet of the rail (driver’s side).
   2. Install the -06 ORB swivel fitting (non adjustable side) on the center port of the rail.
   3. Install the -06 ORB plug into the remaining port on the rail (passenger side).
   4. Install the -06 ORB to -04 AN fitting into the bottom of the regulator housing.
   5. 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.
   6. 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 6.
8. Connect the injector connectors using supplied electrical adapters.
   

   Figure 6: ID Fuel Rail Reference

9. Connect vacuum hoses for manifold pressure reference:
   1. Cut the factory vacuum line as shown in figure 7. 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 3” cable tie onto all hose ends.


Figure 7: Vacuum Line Reference

Install Return Line

1. Install the straight fitting of the -04 return hose onto the outlet of the pressure regulator.
2. Route return line along the factory feed line. Insert the return hose into the available slot of the routing slip at the firewall (non EVAP vehicles). Use figure 8 as a reference.
   

   Figure 8: Return line routing reference.

3. Connect the 90° 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 figure 9 as a reference.
   

   Figure 9: 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.

Dynojet PV3 Polaris Data Generator
HP Tuners Polaris 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 (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 (2) 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 5/16” EFI on the inlet of the rail (driver’s side ).
   2. Install the -06 ORB swivel fitting (non adjustable side) on the center port of the rail.
   3. Install a -06 ORB plug into the remaining port on the rail (passenger side).
   4. Install a -06 ORB plug into the bottom of the pulsation damper housing.
   5. Thread on the pulsation damper housing to the swivel fitting until the threads bottom out, then back out one turn. Do not tighten the lock nut.
   6. 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.
8. Connect the injector connectors using supplied electrical adapters.
   

   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.

Dynojet PV3 Polaris Data Generator
HP Tuners Polaris 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 (2) bolts to uninstall the fuel rail.
5. Outside the vehicle, install the supplied fittings into the rail. Use figure 2 as a reference.
   1. Install the -06 ORB to 5/16” EFI on the inlet of the rail (driver’s side)
   2. Install the two -06 ORB plugs into the remaining ports on the rail (passenger side and center).
   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.
   

   Figure 2: Fitting reference

Reinstall All Remaining Parts

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