SuperATV Power Steering Kit Polaris RZR 800 09-14 | PS-P-RZR
INSTALLATION INSTRUCTIONS PS-P-RZR Polaris RZR Power Steering 2753 Michigan Road · Madison, Indiana 47250 · 812-574-7777 Item Description Qty A Motor Mount 1 B ECU Mount 1 C Support Bracket 1 D Lower Shaft 1 C E Upper Shaft 1 J Wiring Connectors Kit 1 B If kit includes (2) Plastic Bushings and/or a Steel A Spacer, discard. Not used for this application. D J E (kit contents continue on following page) Read instructions and view illustrations before beginning. Need help with your installation? sales@superatv.com www.superatv.com 1-812-574-7777 8:00am - 9:00pm EST M-Th 8:00am - 7:00pm EST Friday 9:00am - 2:00pm EST Saturday Thank You For Choosing © 2011 SuperATV.com. All Rights Reserved. Liability Statement SuperATV's products are designed to best fit users ATV/UTV under stock conditions. Adding, modifying, or fabricating any factory, or aftermarket, parts will void any warranty provided by SuperATV and is not recommended. SuperATV's products could interfere with other aftermarket accessories. If user has aftermarket products on machine, contact SuperATV to verify that they will work together. Although SuperATV has thousands of satisfied customers, user should be aware that installing lift kits, long travel, or suspension kits, tires, etc will change the ride of machine and may increase maintenance and part wear. Operating any off-road machine while, or after, consuming alcohol and/or drugs increases risk of bodily harm or death. No warranty or representation is made as to this product's ability to protect user from severe injury or death. SuperATV urges operators and occupants to wear a helmet and appropriate riding gear at all times. By purchasing and installing SuperATV products, user agrees that should damages occur, SuperATV will not be held responsible for loss of time, use, labor fees, replacement parts, or freight charges. SuperATV, nor any 3rd party, will not be held responsible for any direct, indirect, incidental, special, or consequential damages that result from any product purchased from SuperATV. The total liability of seller to user for all damages, losses, and causes of action, if any, shall not exceed the total purchase price paid for the product that gave rise to the claim. SuperATV will warranty only parts provided by SuperATV. Any damage or problems with OEM housings, bearings, seals, or other manufacturers products will not be covered by SuperATV. SuperATV parts and products are not warrantied if item was not installed properly, misused, or modified. REV IN-PS-P-RZR 1/28/2014 Item Description Qty F F ECU 1 G Motor 1 H Wire Harness 1 Qty (5) M6 x 20mm Lg. FHCS G Qty (3) M8 x 20mm Lg. FHCS Qty (1) M8 Flat Washer H Qty (5) M6 Flat Washer Qty (5) M6 Nylock Nuts Removal: Keep all components removed from machine. 1. Remove Steering Shaft Bolt on Steering Rack. See Fig. 1. 2. Remove Steering Wheel and Shaft. Hint: Removing Steering Column Bolt may ease removal. See Fig. 2. Fig. 1 Fig. 2 Rack and Pinion Remove stock Steering Shaft Remove Front (Driver Side) Remove Installation: Do not tighten hardware completely unless noted. 1. Install Lower Shaft (D) to Steering Rack with provided hardware. See Figs. 3 - 3a. Tighten completely. 2. Install Motor (G) to Lower Shaft (D) with provided hardware. See Motor Shafts Detail and Fig. 4. 3. Join Mounting Brackets (A)(C) with M6-1.0 x 20mm Lg. FHCS, M6 Flat Washers, and M6-1.0 Nylock Nuts. See Fig. 5. - Install to Motor (G) with M8-1.25 x 20mm Lg. FHCS. See Fig. 5. 4. Install Tab on Mounting Bracket (A) to Steering Column with stock hardware and M8 Flat Washer. See Figs. 6a - 6b. 5. Attach Upper Shaft (E) to Motor (G), tighten completely, and reinstall Steering Wheel; reuse stock Washers and Spacers. See Fig. 6a. 6. Locate (2) holes in Steering Frame underneath Dash. See Fig. 6. - Secure Mounting Bracket (C) with M6-1.0 x 20mm Lg. FHCS, M6 Flat Washers, and M6-1.0 Nylock Nuts. See Figs. 6a - 6b. -See "Connections" portion of instructions before installing ECU7. Install ECU (F) and ECU Mount (B) to Frame with M6-1.0 x 20mm Lg. FHCS. See Figs. 8 - 8b. Plug in Wire Harness (H). See Connections and Wiring Details. 8. Tighten all hardware completely. (illustrations continue on following pages) 3 When joining Shafts, scalloped area must be positioned so that Bolt cleanly engages Fig. 3 Insert through Firewall Fig. 3a D D Motor Shafts Detail To Rack & Pinion To Steering Shaft Line-up with notch on Steering Rack Fig. 4 D supplied G 4 Fig. 5 (Driver Side) Qty. (3) M8 x 20mm Lg. FHCS Front Qty. (2) M6 x 20mm Lg. FHCS Qty. (2) M6 Nut Qty. (2) C A M6 Flat Washer G (Passenger Side) provided hardware D 5 Reuse stock Washers and Spacers when reinstalling Steering Wheel. Fig. 6 Bracket Mounting Holes Fig. 6a Front E Frame Front of machine G (looking up from Driver Side under Dash) provided hardware C (Passenger Side) Qty. (2) A M8 Flat Washer Qty. (2) Tab M6 x 20mm Lg. FHCS Fig. 6b (Driver Side) M6 Nut Qty. (2) M6 Flat Washer A Stock hardware C Steering Column Tab 6 Fig. 8 Pivot Tube ECU (F) Mounting Location (Driver Side) Frame Tilt Adjustor Fig. 8a J Fig. 8 B J Frame B (Pivot Tube removed for clarity) (Driver Side) E Qty. (2) M6 x 20mm Lg. FHCS Tilt Adjustor (looking up from Driver Side) 7 Connections - Before installing, ensure that all waterproof connections are properly seated. - If Gaskets are not seated, as shown, use a Flathead Screwdriver to seat. Seat Seat Push in....... ........Seat 8 (White) (Black) Wiring Details To Switched 12V Source (See 12V Source Connection Details) Switched 12V Source Connection Details (Driver Side, 12V AUX Plug, under Dash) To Battery, Negative (-) (Red) To Battery, Positive (+) G F H F Orange w/White Stripe Wire (1) or (2) plugs may be present. Either plug is acceptable. Fig. A 1. Locate Orange with White Stripe wire underneath dash. See Fig. A. 2. Determine connector style to use. See Fig. B - C. SuperATV recommends use of Bullet Connector. 3. Make connection. See Fig.A. White Wire, Switched 12V Source from Wire Harness (L) Heat Shrink Tubing A D B C Plug Function A Torque Sensor B Switched 12V Source C Power D Motor Black - To Negative (-) Red - To Positive (+) Fig. B Bullet Connector Strip wire 1/2", push into Butt Connector, and apply heat to Heat Shrink Tubing. White Wire, Switched 12V Source from Wire Harness (L) Scotch Lock Fig. C Orange w/White Stripe Wire Remove Driver Side Seat to access Battery. When activated, Diagnostic Light will flash (1) time for about (1) second before turning off indicating proper function. Should different patterns occur, contact SuperATV. Secure Diagnostic Light in a visible location. Diagnostic Light 9Adobe PDF Library 10.0.1 Adobe InDesign CS6 (Windows)