Evolution Powersports Maverick R Billet Fuel Rail Installation Instructions

Product Details

Maverick R Billet Fuel Rail

SKU(s): 501FC0016 (OEM), 501FC0017 (-8AN)

Included Parts

• (1) Maverick R Fuel Rail, Black
• (3) Injector Clip
• (3) 1/4-28 x 3/8 Socket Cap Screw
• (1) 8an ORB Plug
• (1) 8an ORB to 3/8 Quick Connect or 8an ORB to 8an Male Fitting

Required Tools

• 8, 10mm Socket
• T-30 Socket
• 8an Wrench
• Brake Cleaner & Dielectric Grease

Installation Steps

1. Step 1: Remove wind dam. (2) push darts and (2) T-30 screws. Pop the front grill out of (4) grommets.

   Figure 1 shows the front of the vehicle with the wind dam. Figure 2 shows the front grill assembly.

2. Step 2: Remove the driver side foam insert. (4) 10mm screws, (1) T-30, push out the intake duct.

   Figure 3 illustrates the driver's side interior, highlighting the foam insert and the locations of four 10mm screws and one T-30 screw to be removed, along with the intake duct.

3. Step 3: Remove the passenger side foam insert. (3) 10mm screws, (1) T-30.

   Figure 4 shows the passenger's side interior, indicating the foam insert and the locations of three 10mm screws and one T-30 screw to be removed.

4. Step 4: Remove the charge tubes from the intercooler.

   Figure 5 shows the front of the vehicle with the intercooler exposed. Figures 6 and 7 provide close-ups of the intercooler charge tubes that need to be disconnected.

5. Step 5: Remove (1) 10mm screw holding the coolant reservoir to the intercooler tray. Pull the reservoir back from the firewall, out of the clip. Strap the reservoir up.

   Figures 8 and 9 show the coolant reservoir, indicating the 10mm screw securing it and demonstrating how to pull it away from the firewall and secure it.

6. Step 6: Disconnect both intercooler fans from the OEM harness.

   Figure 10 displays the intercooler fans and their connection to the OEM harness, showing where to disconnect them.

7. Step 7: Remove (6) 10mm screws on the intercooler tray. Behind the seats, remove (4) rubber plugs and access (4) 10mm screw. Total of 10 screws.

   Figure 11 shows the intercooler tray with six 10mm screws highlighted. Figure 12 provides a closer view of the area behind the seats, indicating four rubber plugs and the location of four additional 10mm screws for removal.

8. Step 8: Remove the intercooler.

   Figure 13 shows the vehicle's engine bay after the intercooler has been removed.

9. Step 9: Remove the upper plastic cover on the plenum. (1) 8mm screw.

   Figure 14 shows the engine plenum with the upper plastic cover, highlighting the single 8mm screw that secures it.

10. Step 10: Remove the coolant hose, transmission hose, and EVAP hose if your model is equipped. Remove the lower plastic tray by removing (5) 8mm screws.

    Figure 15 illustrates the area where coolant, transmission, and EVAP hoses are located, and shows the lower plastic tray secured by five 8mm screws.

11. Step 11: Spray all injector ports and plenum with brake cleaner and compressed air. You do NOT want anything falling into the injector ports. Remove (2) 8mm screws.

    Figure 16 shows the engine's fuel rail and injector ports, indicating the two 8mm screws to be removed after cleaning the ports.

12. Step 12: Carefully push down and remove the blue safety clip on the fuel quick connector. DON'T BREAK IT. Press down on the top black connector and remove the fuel hose from the fuel rail.

    Figure 17 shows a close-up of the fuel rail's quick connector, highlighting the blue safety clip and the black connector for fuel hose removal.

13. Step 13: Remove the fuel rail with injectors attached. Flip the fuel rail 180 degrees. Unclip all injector electrical connectors.

    Figure 18 depicts the fuel rail with injectors attached, showing the process of flipping it and unclipping the electrical connectors from each injector.

14. Step 14: Remove all (6) injector clips. Remove injectors and clean O-rings.

    Figure 19 shows the fuel rail with injectors removed, illustrating the injector clips and the injectors themselves.

15. Step 15: Install the 3/8 quick connect fitting (or -8an) and 8an plug. Make sure the O-rings are seated and not pinched. Use dielectric grease on all injector O-rings. Install the injector clips into the small cut outs on the injectors. They will sit flush. Tighten down with supplied socket cap screws.

    Figures 20 and 21 show the new billet fuel rail being prepared. Figure 20 displays the 3/8 quick connect fitting and 8an plug. Figure 21 shows injectors being installed into the billet fuel rail with clips and socket cap screws.

16. Step 16: Reinstall all (6) injector electrical connectors. Make sure they click into place.

    Figure 22 illustrates the process of reconnecting the electrical connectors to the injectors on the fuel rail, ensuring they click securely.

17. Step 17: Reinstall the quick connect fuel line to the fuel rail. Reinstall the blue safety clip. Mount the fuel rail using (2) OEM screws. Cycle the key a few times and check for leaks.

    Figure 23 shows the fuel rail reinstalled in the vehicle, with the fuel line reconnected and the blue safety clip in place, ready for leak checking.

18. Step 18: Reinstall the plastic hose supports if you prefer. You can also install the billet hose supports, reusing OEM hardware.

    Figure 24 shows the fuel rail installed, with an example of reinstalling plastic or billet hose supports using OEM hardware.

19. Step 19: Reinstall all other parts in reverse order.

    General instruction for final assembly.

Important Notes and Support

Thank you for choosing Evolution Powersports products. If you require further assistance, please call our Tech Support @ (715) 247-3862.

Note: This product is exempt from the emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code§§ 27156 and 38391]. This product is sold only for use in connection with EPA certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/that purchase this product represent and warrant that the product is purchased only in connection with EPA -certified, emission-regulations-exempt and noise-regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.

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