Polaris RZR XP1000/Turbo Pump Installation
Our XP1000/Turbo fuel cell is designed to utilize the shock fuel pump module for either the XP 1000 or the XP1000 Turbo with minimal modifications. Depending on which vehicle you have, please read the instructions below. (Note: It is recommended to take several photos of the pump before it is disassembled to ensure reassembly is correct.)
1. XP 1000 (non-turbo):
The stock fuel pump module for the XP1000 must be shortened in order to comfortably fit inside your new fuel cell without damaging the inner components of the safety bladder. This is done quickly by removing the spring that compresses the fuel pump to the bottom of the stock tank. This can be done via two methods:
- By un-soldering the pump and sending unit wires connected to the top of the module, then separating the bottom module (with the pump still in it and line attached) from the top. THERE IS NO NEED TO CUT THE FUEL LINE BETWEEN THE PUMP AND TOP MODULE OUTLET. Once the two are separated (but with the fuel line still connected) the spring can be removed and the module can be put back together.
- With some units the wiring is long enough to simply pull apart the units without having to un-solder the wires from their terminals; simply separate the unit, remove the spring, and reassemble. The tension from the fuel line withhold the pump against the bottom of the fuel cell without causing excessive wear on the safety bladder.
2. XP1000 Turbo:
The stock fuel pump module for the XP1000 Turbo is a fixed-length module, and so it is necessary to extend the length to fit into the new tank. Failure to do so may result in an inability to get all the fuel out of the tank. To do this, each XP1000/Turbo fuel cell comes with three clear tubes that will replace the ones connecting the bottom module and the top. Using a knife, cut each of the three tubes and remove them from the modules (NOTE: that the kit comes with two (2) tubes that are 2.625" in length and one (1) that is 3.375" in length). Once removed, connect the longer tube between the fuel pump outlet and the fuel outlet on the top of the module. Once done, connect the other two support tubes to the bottom and top of the module. From there, use the included clamps to secure the tube connecting the fuel pump and fuel outlet on the top module. BE SURE NOT TO CRIMP THE TUBES DURING INSTALLATION AS THIS MAY CAUSE A CRACK IN THE LINE AND MALFUNCTION OF THE MODULE.
Additional Installation Instructions
For a complete break down of installing one of these units into a vehicle please review the link below: