Polaris 2021 Pro XP High Pressure Fuel Pump Kit

Remove passenger seat and access cover by lifting on tab, to access fuel pump. With a damp rag or shop vacuum, clean the top of the fuel tank where the fuel pump nut ring is located. Failure to do so may result in foreign debris dropping into the tank, causing premature failure of the AEM High Flow Fuel Pump.

Put your safety glasses and rubber gloves on at this point. Unplug 4 pin sending unit and disconnect fuel line. Slide the blue clip towards the passenger side of the vehicle to release the fuel line. You can then pull fuel line off.

Unscrew the fuel pump nut ring. We recommend buying the Polaris Tool, so no damage is done to the fuel pump nut ring.

Genteelly remove the entire fuel pump assembly. Turning the pump at a 90-degree angle will help not damage the float and pre pump filter while removing.

Once the fuel pump assembly is removed, place it on a clean dry surface. Next step is pushing in the two black tabs on the pump, letting the pump pull out of the white cylinder housing.

Once the pump is released unplug both the Red (+) and Black (-) electrical terminals on the fuel pump. Note that both terminals are different sizes so they cannot be installed on the AEM pump incorrectly. With a razor blade, cut the hose down the ribs of the OEM fuel pump fitting. Do the same on the assembly side. Remove the hose completely and discharge. Remove the pre filter by prying on the plastic ring with a small screwdriver.

Now it is just the pump and black housing standing alone. Pull the stock fuel pump out of the black housing. Remove the bottom white plastic spacer off the bottom of the fuel pump. Remove the brass fitting from the black housing. Underneath the brass fitting is a 23mm spring, remove that.

Install the new AEM fuel pump into the black housing. You should feel it seat to the brass fitting. Next grab your 152.4mm corrugated hose and heat up one end of it with a heat gun. Once it becomes warm, slide it onto the green inlet of the fuel pump. Tighten the clamp.

Heat up the other end of the corrugated hose and slide it onto the fuel discharge fitting on the bottom of the sending unit. Tighen clamp. At this time you can install the AEM pre pump filter on the bottom of the AEM fuel pump.

Place pump and pre pump filter back into the white cylinder housing, you should hear both black tabs click. Connect both the Red (+) and Black (-) electrical terminals on the fuel pump. The fuel pump assembly is ready to be installed back into the fuel tank.

Start by holding the fuel pump assembly at a 90-degree angle. Place the float and filter in the tank first.

Slide the rest of the assembly into the tank. Make sure the O-ring is sitting flush on top of the fuel tank. Place fuel pump nut ring on the fuel tank threads and torque to 70 ft/lbs. Verify that the fuel line connections are free of debris. Connect the fuel line onto the pump module. Slide the blue clip towards the driver’s side of the vehicle to lock it into place. Re-connect the 4-pin sending unit.

Underneath the dash, remove the fuse box cover. On the back of the fuse box, you will see a diagram showing a 10AMP fuse in the fuel spot. Switch this fuse out with a 20amp fuse.

Test the fuel pump by turning on the key and listen for the pump to activate. Do this several times to prime the fuel system. Check for leaks. If there are no leaks, re-install the access cover and passenger seat.