POLARIS RZR 1000 - kraftwerksusa.com

RZR SUPERCHARGER KITINSTALLATION INSTRUCTIONS

POLARIS RZR 1000SUPERCHARGER KIT

1 of 36FOR TECHNICAL SUPPORT:

[email protected] or 951.808.9888 REV002


346

1218233334

NOTE: UPGRADED CLUTCH COMPONENTS

MAY BE REQUIRED PRIOR TO INSTALLSpecifications will vary due to Tire Size, Elevation, 2dr/4dr, Environment (sand, dirt, mud, etc.)

Paint Pen

Masking Tape

3" Hole Saw

Tin Snips

Adjustable Crescent Wrench

Plier Set

Razor Blade

Dremel Tool

3/16" Drill Bit

Small Funnel

Metric Allen Wrench Set

Torque Wrench

Supercharger Oil Cooler Kit

Intercooler / Charge Pipe / Bypass Valve

Supercharger Run-In / Final Checks

Warranty Information

Screw Driver Set

Blue Threadlocker

Impact Gun

Cordless Drill

Grease

Pre-Installation / Removal

Supercharger Assembly / Hose Kit

POLARIS RZR 1000 SUPERCHARGER KIT

Part Number(s): 150-17-1000

Introduction / Pre-Installation Instructions

C.A.D. Drawings Hose Cutters

RTV Silicone

TOOLS REQUIRED

Metric Wrench Set

Metric Socket Set

Metric Allen Socket Set

TABLE OF CONTENTS

Wire Cutters


[email protected] or 951.808.9888


INTRODUCTION

GENERAL

The Kraftwerks Polaris RZR 1000 Supercharger Kit was designed for easy installation. Competent mechanics with the appropriate tools will find the process to be relatively simple. This is a GENERAL installation guide; each installation, components and test vehicle may vary slightly. Some pictures may show assembly on anengine stand for clarity.

PLEASE BE AWARE THAT SOME PARTS MAY COME PRE-ASSEMBLED BUT ARE NOT TORQUED DOWN

- Review ENTIRE installation before beginning install. If you have any questions about your ability to performthe installation, take your vehicle to a qualified performance shop for installation (Please ask your dealer orKraftwerks representative for installers within your area).

- Disconnect BOTH Battery Terminals before install.

- Remove Gas Cap to relieve fuel tank vapor pressure.

- A minimal amount of work underneath the vehicle may be required. If you do not have access to a lift, thena Floor Jack and Jack Stands may be required. NEVER WORK UNDER A VEHICLE WITHOUT APPROPRIATEJACK STANDS.

- Always wear Safety Glasses when working on your vehicle.

DISCLAIMER

- WARNING: Engine Rev Limiter must be set below 8500 RPM. Any higher RPM will OVER-SPIN the RotrexSupercharger headunit which WILL void its warranty.

- Kraftwerks Supercharger Kits do not require break-in or warm-up periods. However, always warm yourengine up properly before operating at full boost.

- If an engine Oil and Filter change has not been performed recently, do so now using high quality, Syntheticoil.- A minimum of 91 OCTANE, premium-grade fuel must be used

ROTREX COMPONENTS DISCLAIMER

- Only use genuine Rotrex SX150 Traction Oil for supercharger lubrication. The proprietary traction formulaprotects the supercharger where other oils would fail, and is what allows its high-RPM operating levels. Useof Non-Genuine Rotrex SX150 Traction Oil WILL void the warranty of the Rotrex Supercharger.

- Important: Keep all Pipes and Hoses sealed and clean until installation. The Rotrex Supercharger operatesat speeds as high as 100,000 RPM on the RZR 1000. ANY debris that inadvertently enters the inlet pipes orbecomes stuck to the silicone hoses can enter the Rotrex Supercharger and will damage its compressorblades. Compressor blade damage is NOT covered by the Rotrex Two-Year warranty.

- NEVER rotate the Rotrex Supercharger counter-clockwise.


[email protected] or 951.808.9888 REV 1.19.21







C097-0001-01 Bypass Valve, Standard (Picture may vary)


PART 1: REMOVAL/PRE-ASSEMBLY

1.3

Remove Driver Side Clutch Assembly Cover (#36) and Vent Tube (#10).

(Note: Diagram courtesy of Polaris)

1.2

- Remove OEM Intake ManifoldAssembly (#19) and Piping (#14).

- Remove Factory Throttle BodyCouplers (#23) as they will be re-used later in the installationprocess.

- Remove the Passenger Side AirIntake Box Tube (#2)

(Note: Diagram courtesy of Polaris)

1.1

- Jack up vehicle and place onJack Stands or use a lift (aspictured). Make sure that therear suspension is not underload and that the suspensionis hanging freely.- Disconnect Battery- Remove the Passenger SideRear Tire.- Unbolt the Rear PassengerShock/Spring Assembly fromthe bottom and swing it upout of the way and properlysecure it with a strap (pictured).




1.4

How Driver Side Engine shouldlook after removal of OEM Air Intake Assembly and Clutch Cover Assembly.

1.5

Cut off a 6x6 section of theengine heat shield located above the engine.

1.6

How the Heat Shield shouldlook after modification.




1.8

- Use a Razor Blade and scrapeoff ANY excess gasket that mayremains to ensure that there areno leaks later in the buildprocess.

- Locate the Main CrankshaftBolt.

1.9

Use an Impact Gun and 19mmImpact Socket to removeCrankshaft Bolt.

1.7

- Place some foil and oil pan (orother type of oil drainage catch)under the engine.

- Remove the Passenger SideEngine Cover as shown.




PART 2: FUEL INJECTORS

2.1

Locate the GRAMS Performance550cc Fuel Injectors

2.2

- Disconnect the Fuel Injectorplugs.- Relieve the fuel systempressure using the pressurerelief valve (Arrow)

CAUTIONGasoline is an extremely flammable liquidand its vapors are potentially explosive aswell. Ensure that you are working in a well

ventilated area and that a fire extinguisher is always within reach.

2.3

- Pull back the green retainingclip of the fuel rail feed line.

- Place rags under fitting andslowly slide the connector pieceoff (Fuel WILL spill out so beready for it).

2.4

Locate the Fuel Rail mountingbolts and remove them from theThrottle Body Assemblies.

NOTE:You do NOT need to remove the actual Throttle Body Assemblies as pictured; itwas just to better showcase the location of the bolts themselves.




2.5

Remove the Fuel Rail Assemblyand the retaining clips as shown.

2.6

- Remove the OEM Fuel Injectorsby slowly pulling them out.

- Lube the O-Rings of the newGRAMS 550cc Fuel Injectors andinstall them.

-Repeat the process in reverseorder to re-install the Fuel Railwith new GRAMS 550cc FuelInjectors

END SECTION




PART 3: SUPERCHARGER DRIVE ASSEMBLY / HOSE KIT

3.2

Locate the Main S/C DriveAssembly with the mountedRotrex Head Unit.

3.1

Locate the Supercharger DriveAssembly Kit as shown.

3.3

- Remove OEM Stater Assemblyand install onto Main S/CBracket Assembly.

- Install OEM Wire HarnessBracket and Rubber Bushing.




3.4

How the Main S/C BracketAssembly should look at thispoint in the installation.

3.6

- Locate the QTY 2 Long SiliconeHoses with Angled ends.

- Cutting from the STRAIGHT end,cut off 24" of one hose and then10" off the other.

3.5

Locate the Hose Kit and removethe QTY 2 Long Silicone HoseAssemblies, Silicone Coupler,Breather and Aluminum Ring.




3.7

- Attach the hoses from the priorstep to the Brass Fittings attachedto the S/C Main BracketAssembly.

- The short hose attaches to thebottom fitting and the long hoseattached to the top fitting.

- Use included Clamps to secure.

3.9

Gently insert a Pry Bar intothe Driver Side Clutch PackAssembly as shown (This is tokeep the engine from turningover so you can properly installthe pullies in the next step).

3.8

Install the supplied Gasket byDABBING some RTV Silicone tohelp seat the gasket for easierinstallation.

SHORT LONG




3.11

- Locate Crankshaft PulleyAssembly and New CrankshaftBolt.

- Oil the Hub Section.

- Use Red Threadlocker on Bolt.

- Add Silicone to the FLANGE sideof the bolt (to ensure there areno leaks).

3.10

- Install Main S/C BracketAssembly.

- Torque M6 bolts to 8 ft/lbs.

3.12

- Torque new Crankshaft Bolt to95 ft/lbs (Do NOT use an impactgun).

- Torque the smaller M6 PulleyBolts to 84 INCH/lbs.




3.13

Locate S/C Drive Belt.

3.15

- Remove the Tensioner PulleyAssembly (The Top One) beforeinstalling belt.

- Place belt on both S/C Pulleyand Crank Pulley (Make sure thebelt is seated on the groovesCLOSEST to the Mounting Plate).

- Re-Install Tensioner PulleyAssembly (This will take someforce to push the belt down).

3.14

Belt Routing Guide.




3.16

Locate the Belt TensionerAdjustment Tool Kit as shown.

3.17

Install the Belt TensionerAdjustment Tool using theprovided M6 Allen Bolts (Only hand tighten these bolts asthese will be removed later).

3.18

- Download the "GATES CarbonDrive" App for Android or IOS.

- YouTube Links on how to usethe Gates Carbon Drive App:

IOS: https://youtu.be/ujfRnqfVoUY

Android:https://youtu.be/QejZD_wT1Gc

TensionAdjustment

Bolt

XXX Hz




3.20

Locate the S/C Belt Cover Plate,Gasket, and QTY 13 M6 x 1.0 x 10mm Allen Bolts.

3.21

Install S/C Belt Cover Plate withGasket using the M6x10 AllenBolts (Recommend DABBING RTV Silicone to help seat the gasket properly and for ease ofinstallation).

3.19

- Before tensioning the belt, besure that the Tensioner PulleyBolt is not torqued down.- Using a 10mm Wrench, adjustthe tension by turning the boltCLOCKWISE until you get to

140-145 Hz (flick theLONGEST belt section as shown)- Torque down the Belt TensionerPulley Assembly Bolt to36 ft/lbs.- Remove the Belt TensioningTool and M6 Allen Bolts.

TensionerPulley Bolt




3.22

Re-Install Crank Trigger Sensor.

3.24

- Route the longer SiliconeBreather Hose (From Step 3.7)towards the top and place theSmall Breather Assembly in thesmall factory hole as shown.

- Tighten Hose Clamp

3.23

Locate the Silicone Coupler andBreather Assemblies from theHose Kit.




END SECTION

3.25

Route the LOWER Fitting Hoseto the Coupler Fitting and routethe UPPER Fitting Hose to theBreather.

Secure all hoses with includedWorm Gear Clamps.




PART 4: INTERCOOLER / CHARGE PIPE / BYPASS VALVE

O

E

M

C

A

G

E

A

F

T

E

R

M

A

R

K

E

T

4.1

Locate Intercooler Kit as shown.

4.2

Based on the Roll Cage of yourRZR, mount the IntercoolerBracket to the Intercooler asshown.

4.3

OEM CAGE MOUNTIf you have an OEM Roll Cage,mount the Intercooler Assemblyto the Roll Cage as shown usingthe included C-Bracket (Note:the picture shows Pre-production pieces).




4.4

AFTERMARKET CAGE MOUNTIf you have an Aftermarket Cagethe mounting point may vary.

NOTE: In this picture Spacers andSilicone Hose (Both NOT included) were used to mountthe Intercooler Assembly to theCustom Roll Cage.

4.6

Locate the Passenger SideIntercooler Charge Pipe Assembly.

4.5

Locate Charge Pipe Kit.

To Passenger Side Intercooler Inlet

Connects to S/C Outlet Pipe




4.7

- Using a 3" HOLE SAW, cut a holefor the Charge Pipe Assembly. Besure to double Charge Pipelocation BEFORE cutting hole.

Mount Passenger Side Intercooler Charge Pipe Assembly.

4.8

Locate the Driver Side Intercooler Charge Pipe Assembly.

4.9

- As on the Passenger Side, use a3" HOLE SAW and cut a hole.Be sure to double check theCharge Pipe location BEFOREcutting hole.

- Install Driver Side IntercoolerCharge Pipe Assembly.

To Driver Side Intercooler Outlet

Connects to Intake Manifold Pipe




4.10

How the Intercooler Assemblyand Charge Pipes should look like up to this point.

4.11

Locate the Rotrex S/C OUTLETCharge Pipe Assembly.

4.12

Install the S/C Outlet Charge Pipe by attaching one end to theRotrex S/C Outlet and the otherend to the Passenger SideIntercooler Charge PipeAssembly.

To S/C Outlet

To Passenger Side Intercooler Inlet Pipe




4.13

Locate the NEW Intake ManifoldAssembly and attach the FactoryThrottle Body Couplers fromstep 1.2 as shown.

4.13

Remove the Bushing and Sleeve from the OEM Air IntakeAssembly.

4.14

Install the Custom IntakeManifold to the OEM ThrottleBodies

4.12

- Locate the Intake ManifoldBracket Support as shown.

- Insert the OEM Bushing andSleeve from the prior step intoBracket.




4.17

POWER VISION CX KITS ONLY:

Install the Intake ManifoldBlock Off Plate with O-Ringand Allen Bolt as shown.

4.15

- Locate the Intake ManifoldBracket Assembly from 4.12.

- Secure to the Engine Mount asshown.

4.16

POWER COMMANDER 5 TUNING

KITS ONLY:

Attach the included new Upgraded MAP Sensor to the Custom Intake Manifold as shown here.




4.18

Locate the S/C Intake Charge Pipe Assembly as shown.

4.19

Attach one end with transition section to the Rotrex S/C Inlet.

4.20

Attach the other end of to theFactory Air Box Outlet asshown.

To S/C Inlet

To Factory Air Intake Box




4.23

Locate the Blow Off Valve Assembly and attach the long 1"ID x 20" Length Heater Hose as shown. (Note: Actual blow off valve may vary than picture shown)

4.21

Locate the Intake ManifoldInlet Charge Pipe Assembly.

4.22

Attach one end to the IntakeManifold Assembly and theother end to the Driver SideIntercooler Charge Pipe Assembly.

To Intake Manifold Inlet

To Driver Side Intercooler Outlet Pipe




4.26

Locate the Vacuum Assembly.

4.24

Attach the short end of theBlow-Off Valve Assembly to theIntake Manifold Charge PipeAssembly.

4.25

Attach the longer end of theBlow-Off Valve Assembly to theRotrex S/C Intake Charge PipeAssembly as shown.




END SECTION

4.27

- Install the Vacuum Assemblywhere the PRIMARY MAP Sensoris on the Throttle Body asshown.

NOTE:DYNOJET POWER COMMANDER 5the Factory MAP Sensor will beinstalled here as pictured.

DYNOJECT POWER VISION CXthe included Upgraded MAPSensor will be installed here

4.28

Attach the other end of the Vacuum Hose to the top of the Bypass Valve Assembly and secure using an included Zip Tie.(Note: Actual blow off valve may vary than picture shown)




PART 5: OIL COOLER ASSEMBLY

5.2

Rotrex Oil Line RoutingAt-A-Glance.

5.1

Locate the Oil Cooler Kit as shown.

5.3

Locate the Oil Cooler and Universal Oil Cooler InstallationKit as shown.




5.4

Install the RUBBER washers ontoeach Strap Tie as shown.

5.5

Carefully push each Strap Tiethrough the Oil Cooler. Locatethe FOAM Cushion pieces andremove the adhesive backing.Slide the Foam Cushion piecesso that the STICKY SIDE IS DOWNand pushed onto the Oil Cooleras shown.

5.6

- Mount Oil Cooler to the BACKof the Intercooler by pushingeach Tie Strap through as shown.

- Make sure the fittings arefacing UPWARD as shown.

5.7

As in the prior step, install the RUBBER washers ontoeach Strap Tie as shown.




5.9

Locate Rotrex Oil ReservoirAssembly.

5.10

Remove Center Console andRemove Driver Side Seat BeltBolt closest to the Middle.

5.8

Finish off mounting the OilCooler by installing theLock Discs firmly and then trimoff the excess lengths as shown.




5.11

Bolt the Rotrex Oil ReservoirAssembly to the Seat BeltBolt with RED Threadlocker.

5.12

Locate the Bulk Oil Hose andSpring Clamps as shown.

5.13

Place a Spring Clamp on oneend of the Oil Hose FIRST, andthen insert the Banjo Fitting.Slide the Spring Clamp to securethe Banjo Fitting and then secure with Banjo Bolt and Copper Washers.

5.14

- You will need to drill a 5/8"Hole in the bed for BOTH RotrexOil Lines to pass through ascircled.- Run the Oil Line from theprevious step UP and attach it tothe DRIVER side Oil CoolerFitting and cut to proper length.- Attach the remaining Oil Hoseto the PASSENGER side fittingand then run it down DOWNthrough the newly drilled hole.

TO FITTINGS

FROM OILRESERVOIR

TO ROTREXOIL OUT




END SECTION

5.15

- Run the Oil Cooler Line fromthe previous step down to theOIL OUT port of the Rotrex S/CHead Unit and cut to length.- Place a Spring Clamp on theOil Hose end FIRST, and thenonto Banjo Fitting. Slide theSpring Clamp back up to secure.- Tighten the Banjo Bolt

5.16

Cut a 5" Hose Length and a 24"Hose Length. Attach the 5" Hoseto the Oil Filter INLET and thenattach the 24" to the OUTLET.Place Spring Clamps on Hose asshown.

5.17

- Locate the Banjo Bolt Kit.- Insert the Banjo Fitting andattach it to the short section ofthe Oil Filter Assembly andsecure it with a Spring Clamp.- Attach the 5" Hose section tothe BOTTOM of the Oil Reservoiras shown.

5.18

Attach the other end of the Oil Filter Assembly with the 24" OilHose to the OIL IN Port of theRotrex S/C Head Unit. Once hoseis on fitting, slide Spring Clampand secure.




PART 6: START-UP (RUN-IN) / FINAL CHECK

Use a small Funnel and carefully fill the Rotrex Oil Reservoir with Rotrex SX 150 Traction Fluid upto about 2/3 Full.

Start up Engine and let IDLE.

Periodically rev engine to no more than 3,000 RPM.

Monitor the Traction Fluid andpour in more as needed untilthe Traction Fluid has cycledthrough the system (About 5min).

DO NOT ALLOW RESERVOIR TOGO DRY OR ELSE THE ROTREXUNIT WILL OVERHEAT AND FAIL.

Check Fluid level on the Dipstickand make sure it is to the MAXlevel but DO NOT overfill.

END SECTION




LIMITED WARRANTYKraftwerks USA offers a 12 MONTH limited warranty against defects in materials, components, and workmanship unless specified otherwise. The warranty period starts on the ORIGINAL date of retail purchase directly from Kraftwerks or from your local dealer (Warranty of the Rotrex Supercharger Head Unit is ONE YEAR from date of manufacture). This limited warranty is only offered to the ORIGINAL OWNER (receipt will be required for verification). Furthermore, the warranty excludes any electronic components manufactured by other companies. IF THE KRAFTWERKS SUPERCHARGER KIT IS ALTERED FROM THE FACTORY SETTINGS, THE WARRANTY MAY BE VOID.This includes but is not limited to the following:- Over spinning of the Rotrex supercharger head unit- Use of non-approved or custom hubs/pulleys- Alteration of brackets, pulleys, and other drive components- Modification or re-routing of any charge piping or intake system that is included in the "FULL" Kits

Kraftwerks will honor a warranty claim at its sole discretion after the component in question is inspected at the Kraftwerks facility and/or the Rotrex A/S facility located in Denmark. NO WARRANTY CLAIM WILL BE ACCEPTED IF THE COMPONENT IS FOUND TO HAVE BEEN TAMPERED, MISINSTALLED, MISUSED, OR MISHANDLED (I.E. DROPPED) IN ANY WAY. Furthermore, disassembly of the Rotrex Supercharger Head Unit voids ALL warranty claims. No Kraftwerks dealer is authorized to make any warranty claims, repair, or modification. Any claims for freight / shipping damages will need to be directed towards the freight / shipping company.

- If the component in question is covered under the Kraftwerks USA limited warranty, the product will berepaired or replaced at the discretion of Kraftwerks USA.- If the component in question is not covered by the Kraftwerks USA limited warranty, our Kraftwerks staff willadvise you on the specific reason, the cost of replacement / repair, and estimated time it will take.

TO PROCEED WITH A WARRANTY CLAIM YOU MUST DO THE FOLLOWING:- Contact Kraftwerks USA directly at (951) 808-9888- A Kraftwerks USA team member will direct you to send the following to [email protected]:

1. Copy of original receipt or invoice (PayPal verifications alone are not accepted)2. Pictures and description of issue (Limit 1-2 Pictures per email or Compress Images)3. Contact information- Name, address, and contact number4. Vehicle description- Year, make, model, and any additional/supporting modifications

- Once all of the above have been received and the warranty claim has been INITIALLY approved by aKraftwerks team member (The component still needs to be inspected), you will be contacted with a ReturnMerchandise Authorization (RMA) number .- Once an RMA number has been given, you will then be directed to package the component(s) in question,write the RMA number in BOLD on the outside of the box, and then a call tag will be issued to pick up thepackage from your location.- Once the package arrives at the Kraftwerks facility, the Kraftwerks team members and engineers willdetermine if the component is covered under the limited warranty.

OTHER NOTES: Kraftwerks USA is located in California. Please be aware that warranty claims will be shipping GROUND (Faster shipping available at added cost) so please allow enough lead time for us to inspect the component(s). Please package components securely as any damage to components due to improper packaging will NOT be covered by the limited warranty. Also, if a Rotrex supercharger head unit is being warrantied, the lead time will be longer due to the fact that only Rotrex A/S located in Denmark can approve or deny claims of the superchargers themselves (If this is the case and time is limited, we do offer CORE CHARGE options. Please contact a KraftwerksUSA representative for more information).

KRAFTWERKS USA is also NOT liable for the following:- Voiding of Factory Warranty and/or components



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