Polaris XP Turbo/S Big Injector Kit 850cc, Set of 2

This installation should be done OUTDOORS in a well-ventilated area with a cold engine and away from any potential spark or heat sources.

Disconnect the ground terminal off the battery.

Remove the box and back panel off the firewall.

Remove the electric connectors from the injectors – this is done by squeezing the wire clips towards the back of the vehicle and pulling the connectors off the injectors. See figure 1.

MAKE SURE TO WEAR SAFETY GLASSES IN THIS STEP. Disconnect the fuel line from the fuel rail by removing the GREEN clip– See figure 1.

Remove the two 8mm bolts holding the fuel rail to the manifold.

Push the fuel rail towards the back of the vehicle while lifting upwards. This will expose the tip of the injectors. With your sharpie and tape mark injector connecters 1 & 2. Starting with injector 1, push the plastic injector clip down (see figure 1.) This will release the injector from the fuel rail. Remove both the clip and injector. Repeat step 5 for injector 2.

Remove the bottom O-ring from the stock injectors and replace the bottom O-rings on the bottom of the new EVO 850 injectors.

The opening of the injector clips needs to be modified so the EVO 850 injectors fit into the retaining clip like the OEM injector.

Place the injector locating tab into a vice. Using a Dremel with a small de-burring bit, enlarge the opening as shown in figure 2. Enlarge the sides of the opening of the clip from the top to bottom. Make sure NOT to grind off the side or bottom locator tabs. See figures 2 & 3.

Put di-electric grease onto the top and bottom of each injectors O-rings.

Install the modified injector retaining clips onto the bottom of the fuel rail.

Install the injectors into the fuel rail. The slots in the clips slide onto the outer rings of the fuel rail. Push the injector up into the fuel rail until the slot on the injector lines up with the ribs and locating tab on the clip. Push the retaining clips up from the bottom until they lock in place. When the injector clips and fuel rail outer ring are lined up correctly, the retaining clip should slide in place easily and the injector should have no movement.

Tip the injector rail downward to get the injectors into the manifold. Push the fuel rail toward the manifold to seat the O-rings into manifold injectors seats. You should feel the O-rings click into place on the manifold side.

Reinstall the fuel rail 8mm bolts – use BLUE LOCTITE on the threads.

Reinstall the fuel line and fuel line clips.

(Only For 2016 Model) Install O2 sensor bypass plug into harness. Zip tie factory O2 sensor plug end to the frame.

Reconnect the ground terminal to the battery.

Switch key to the “ON” position and check for fuel leaks. If leaks are detected, go back to step 9.

If no leaks are detected, cycle the key 3 times and start the engine.

Re-check after 50 miles.