Manual

ManualsBrandsS&S Cycle ManualsFor motorcyclesIntake Kit, PN106-5012 For 2008 – Up Polaris Ranger RZR and RZRs

S&S

Cycle, Inc.

14025 Cty Hwy G

Viola, Wisconsin 54664



Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com • www.ss-offroad.com

Installation Instructions: S&S® Intake Kit,

PN106-5012 For 2008 – Up Polaris® Ranger RZR® and RZRs®

IMPORTANT NOTICE:





WARNING

Means there is the possibility of injury to yourself or others.

CAUTION

Means there is the possibility of damage to the part or vehicle.

NOTE

Other information of particular importance has been placed in italic type.



WARRANTY:

            

          















 

            

      













ADDITIONAL WARRANTY PROVISIONS:











           

  





  



SAFE INSTALLATION AND OPERATION RULES:







 





    





 





         

      







          

   



        



          



 

         

         



 



DISCLAIMER:

         

          











         







             



Instruction 106-5164

5-4-09



 





Summary of content (12 pages)

PAGE 1
5-4-09 S&S Cycle, Inc Copyright © 2009 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 Instruction 106-5164 All rights reserved. Printed in the U.S.A. ® . 14025 Cty Hwy G Viola, Wisconsin 54664 Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.com • www.ss-offroad.
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Tool requirements: •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• T-27 Torx® drive socket 5/16” Flat blade screwdriver #3 Phillips screwdriver #2 Phillips screwdriver RZRs models 1/2” Socket wrench 1/2” Combination wrenches 3/8” Combination wrench Pliers Saber saw with fine tooth scroll blade Masking tape Silicone sealer Scissors Thread sealer Tape measure Pencil WARNING The safety of vehicle occupants is dependent on proper installation of this product.
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6- Remove four bolts (A) (1/2” hex) from bed and four screws (B) (T27 torx®) from the rear of the bed. A B Picture 4 7- Remove four screws (T27 Torx®) from front of bed. Picture 5 8- Remove bed from vehicle. NOTE: This may require an assistant. Stock air box can removal: Note: Before removing air intake box, cover belt intake duct with a rag or tape to avoid dropping something into the tube. 1- Remove two plastic push rivets that hold the air intake box to the frame.
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2- Remove engine breather hose at valve cover and air can. Save hose clamps as they will be reused. Note: The stock breather hose has a slit in it put there by the factory to prevent cold weather freeze-ups. We feel this can be a place for dirt to enter the engine so this hose should be replaced with new hose supplied in kit. We have done testing down to -10 degrees Fahrenheit without the slit and noticed no adverse effects. Picture 7 3- Disconnect wire from intake air temperature sensor.
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6- Remove air box can from vehicle. Gently pull air intake boot off of throttle body being careful not to damage rubber air intake manifold. 7- On RZRs, remove the air intake duct (three number 2 Phillips screws). Picture 10 Bed Preparation: Cutting Hole In Bed For Air Box 1- Clean bed area where template will be mounted. 2- Cut template where indicated by the scissors mark on the template. 3- Put masking tape over area where cutout will be made. Mark center line of bed with pencil.
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5- Drill hole in waste area of cutout to allow for a starting place for saber saw blade. Picture 14 6- With a good fine tooth scrolling blade in the saw carefully cut out the access hole for the air box. Picture 15 7- Remove pattern and tape. Deburr sawn edges of plastic. Intake installation: 1- Cut supplied tape strip into three 10” pieces and two 2½” pieces. 2- Install foam tape on primary air box as shown in Pictures 16 and 17.
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3- Install 90 degree hose fitting in intake runner. (A) Note: Use a good quality thread sealer on fitting threads. 4- Remove air temperature sensor from stock intake boot with 3/8” wrench and reinstall in intake runner. (B) Note: Use dish soap or motor oil on o-ring so fitting will slide into runner easier. 5678- Slide 31/2" x 21/2" intake adaptor boot (C) over intake runner. The hose clamps should be oriented as shown in Picture 18.
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10- Install the oval-shaped gasket over the inlet duct as shown in Picture 20. Now, gently pull peel-back liner up while pressing gasket into place as you go. See Picture 21. Picture 20 Picture 21 11- Insert intake runner down through the bed rail support so that it lines up with the throttle body. Route all wires to the front side of the intake runner away from the exhaust heat. Use the supplied wire ties to organize the wires. 12- Put a bead of silicone around the top of the oval gasket.
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NoteS: •• You must reuse stock boot to throttle body hose clamp. •• Boots sliding off of stock RZR’s not equipped with the barbed end on the throttle body has been an issue. If your vehicle has the barbless throttle body, installation of this hose clamp is critical to making sure the intake stays on the throttle body. We have chosen a silicone boot for this installation. Because of the sticky nature of the silicone it is much less apt to slide off of the throttle body.
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7- Install prefilter and end cap on secondary air box with four 5/8” oval head #3 Phillips drive screws. 8- Peel backer off of primary to secondary air box seal and adhere to air box scoop. Picture 28 9- Attach secondary air box to primary air box with four ¼” 20 x 1” #3 Phillips panhead machine screws and four ¼” x 5/8” washers provided. See Picture 29. Picture 30 Picture 29 Replacement Parts for Polaris® Ranger RZR® 800 and RZRs® intake Intake Kit, 2008-Up Polaris® Ranger RZR® 800....................
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Continued...
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