AEM Polaris 20142015 RZR XP 1000 303811 User Manual
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P/N 3 0-3 811
2 014-2 015 P ola ris R ZR X P 1 000
A EM In fin it y
P lu g a n d P la y H arn ess
AEM P erfo rm ance E le ctr o nic s
A EM P erfo rm ance E le ctr o nic s, 2 205 1 26th S tr e et U nit A , H aw th orn e, C A 9 0250
P hone: ( 3 10) 4 84-2 322 F a x: ( 3 10) 4 84-0 152
h ttp ://w ww.a em ele ctr o nic s.c om
I n str u ctio n P art N um ber: 1 0-3 811
D ocum ent B uild 1 0/2 7/2 015
I
n str u ctio n
M an ual
W ARNIN G : T his in sta lla tio n is n ot fo r th e tu nin g n ovic e ! U se th is s y ste m w ith E X TR EM E c a utio n! T he A EM
I n fin ity P ro gra m mable E M S a llo w s fo r to ta l fle xib ility in e ngin e tu nin g. M is u se o r im pro per tu nin g o f th is
p ro duct c a n d estr o y y o ur e ngin e! If y o u a re n ot w ell v e rs e d in e ngin e d yn am ic s a nd th e tu nin g o f e ngin e
m anagem ent s y ste m s D O N O T a tte m pt th e in sta lla tio n. R efe r th e in sta lla tio n to a n A EM -tr a in ed tu nin g
s h op o r c a ll 8 00-4 23-0 046 fo r te ch nic a l a ssis ta nce .
N O TE: A ll s u pplie d A EM c a lib ra tio ns, W iz a rd s a nd o th er tu nin g in fo rm atio n a re o ffe re d a s p ote ntia l
s ta rtin g p oin ts o nly . IT IS T H E R ES PO NSIB IL IT Y O F T H E E N G IN E T U NER T O U LTIM ATELY C O NFIR M IF T H E
C ALIB RATIO N IS S AFE F O R IT S IN TEN DED U SE. A EM h old s n o r e sp onsib ility fo r a ny e ngin e d am age th at
r e su lts fr o m th e m is u se o r m is tu nin g o f th is p ro duct!
STO P!
T HIS P RO DUC T H AS L E G AL R ESTRIC TIO NS.
R EAD T HIS B EFO RE IN STALLIN G /U SIN G !
T H IS P R O DUCT M AY B E U SED S O LELY
O N V EH IC LES U SED IN S A NCTIO NED C O MPETIT IO N W HIC H M AY N EV ER B E U SED U PO N A
P U BLIC R O AD O R H IG HW AY, U NLES S P ER M IT TED B Y S PEC IF IC R EG ULA TO RY E X EM PTIO N. ( V IS IT T H E “ E M IS SIO NS” P A GE A T H TTP://
W WW.S EM ASA N.C O M/E M IS SIO NS
F O R S TA TE B Y S TA TE D ETA IL S .)
I T IS T H E R ES PO NSIB IL IT Y O F T H E IN STA LLER A ND/O R U SER O F T H IS P R O DUCT T O E N SURE T H A T IT IS U SED IN C O MPLIA NCE W IT H
A LL A PPLIC A BLE L A W S A ND R EG ULA TIO NS. IF T H IS P R O DUCT W AS P U RCHA SED IN E R RO R, D O N O T
IN STA LL A ND/O R U SE IT . T H E
P U RCHA SER M UST
A RRA NG E T O R ETU RN T H E P R O DUCT F O R A F U LL R EFU ND.
T H IS P O LIC Y O NLY A PPLIE S T O IN STA LLER S A ND/O R U SER S W HO A RE L O CA TED IN T H E U NIT ED S TA TES ; H O W EV ER C USTO MER S
W HO R ES ID E IN O TH ER C O UNTR IE S S HO ULD A CT IN A CCO RDA NCE W IT H T H EIR L O CA L L A W S A ND R EG ULA TIO NS.
P/N 3 0-3 811 2 © 2 015 A EM P erfo rm ance E le ctr o nic s OVE R VIE W T he 3 0-3 811 A EM In fin it y P nP H arn ess w as d esig ned to ru n th e 2 014-2 015* P ola ris R ZR X P 1 000. T his is a tru e s ta ndalo ne s yste m th at e lim in ate s th e u se o f th e P ola ris E CU. T he u se o f th is h arn ess m akes th e k it “p lu g a nd p la y” s o n o c uttin g o r s plic in g w ir e s is n ecessary . T he b ase c onfig ura tio n file s a va ila ble fo r th e In fin it y E M S a re s ta rtin g p oin ts o nly a nd w ill n eed to b e m odifie d fo r e ve ry s pecific a pplic atio n. * 2 015 m odels h ave E CU-c ontro lle d b ra ke lig hts th at c an b e c ontro lle d b y th e In fin it y E CU, w it h m in or a ddit io nal w ir in g re quir e d. T he a ppro pria te In fin it y E CU p art n um ber fo r th is a dapte r k it is : · 30-7 112 IN FIN IT Y -8 H , P O W ERSPO RTS P le ase r e ad th is d ocu m ent in its e ntir e ty b efo re a tte m ptin g to s ta rt o r r u n a n e ngin e. GETTIN G S TA RTE D R efe r to th e 1 0-7 100 fo r E M S 3 0-7 100 In fin ity Q uic k S ta rt G uid e fo r a ddit io nal in fo rm atio n o n g ettin g t h e e ngin e s ta rte d w it h th e In fin it y E M S. T he P ola ris R ZR X P 1 000 b ase s essio n is lo cate d in C :\D ocum ents \A EM \ In fin it y T uner\S essio ns\B ase S essio ns. DO W NLO ADABLE F IL E S F ile s c an b e d ow nlo aded fr o m w ww.a em in fin it y .c om . A n e xperie nced tu ner m ust b e a va ila ble to c onfig ure a nd m anip ula te th e d ata b efo re d riv in g c an c om mence. T he Q uic k S ta rt G uid e a nd F ull M anual d escrib e t h e s te ps fo r lo ggin g in a nd re gis te rin g a t w ww.a em in fin it y .c om . T hese d ocum ents a re a va ila ble fo r d ow nlo ad h ere : h ttp ://w ww.a em ele ctr o nic s.c o m /p ro ducts /s u pport Kit C onte n ts Dia g ra m AEM P /N Descrip tio n Qty A 35-3 811 AEM In fin it y P nP H arn ess 1 B 35-2 843 Ig nit o r, 3 -C hannel w it h T herm al P aste 1 C 35-2 001 Bosch L S U 4 .2 W id eband U EG O S ensor 1 D 35-2 130-5 0 3.5 B ar M AP S ensor 1 E 35-2 150 1/8 N PT to -4 M ale A dapte r 1 F 35-2 151 1/8 N PT to 3 /1 6 B arb A dapte r 1 G 1062-2 0-0 122 Socket, A ux C onnecto r 12 H 1-3 069 Scre w , S elf- T appin g # 8 x 5 /8 6 I 1-3 070 Scre w , S elf- T appin g # 8 x 3 /4 2 J 1-1 17 Zip T ie , 4 6 K 8-1 15 Vacuum H ose, 3 /1 6 72 L 1-3 071 Cushio n C la m p, 7 /8 2 10-3 811 In stru ctio n S heet, 3 0-3 811 1
Kit C onte nts 3 © 2 015 A EM P erfo rm ance E le ctr o nic s Im porta n t A pplic atio n N ote s T he 3 0-3 811 A EM In fin it y P nP H arn ess a llo w s fo r a p lu g a nd p la y in sta lla tio n o f a n A EM In fin it y -8 H P ow ers ports E CU to a 2 014-2 015* P ola ris R ZR X P 1 000. T his k it c om ple te ly re pla ces th e s to ck E CU a nd o ffe rs fu ll c ontro l o f s equentia l fu el in je ctio n, ig nit io n tim in g a dva nce, a nd d riv e b y w ir e (D BW ) e le ctro nic th ro ttle c ontro l. T he In fin it y E CU a ls o s upports th e fa cto ry P ola ris d ash d is pla y fu nctio ns, a s w ell a s th e A W D H ub C ontro l. * 2 015 m odels h ave E CU-c ontro lle d b ra ke lig hts th at c an b e c ontro lle d b y th e In fin it y E CU, w it h m in or a ddit io nal w ir in g re quir e d. F uel In je cto rs T he O EM P ola ris R ZR X P 1 000 fu el in je cto rs flo w 3 30 c c/m in . T hese in je cto rs h ave b een c hara cte riz ed b y A EM a nd a re a va ila ble fo r s ele ctio n th ro ugh th e S etu p W iz ard . T he S etu p W iz ard a ls o in clu des in je cto r d ata fo r m any p opula r a ft e rm ark et fu el in je cto rs . T he In fin it y -8 H P ow ers ports E CU w ill d riv e u p to 8 h ig h im pedance in je cto rs . L ow i m pedance o r p eak a nd h old ty pe in je cto rs a re n ot s upporte d. If a ft e rm ark et in je cto rs a re u tiliz ed, th ey m ust b e o f t h e h ig h im pedance o r s atu ra te d ty pe. I g nit io n C oils T he O EM P ola ris tw o-w ir e ig nit io n c oils a re c ontro lle d b y th e A EM In fin it y E CU, b ut th ey a re n ot d riv e n d ir e ctly . T his k it in clu des th e A EM 3 -C hannel C oil D riv e r re quir e d to d riv e th ese c oils in te gra te d in to th e P nP h arn ess. D riv e b y W ir e ( D BW ) T hro ttle C ontr o l T he b ase s essio n p ro vid ed b y A EM is c onfig ure d to w ork w it h th e O EM P ola ris e le ctro nic th ro ttle b ody a nd a ccele ra to r p edal p osit io n s ensor. W hen th e s yste m is in sta lle d fo r th e fir s t tim e, th e D BW T unin g s ectio n o f th e S etu p W iz ard s hould b e ru n to C alib ra te S ensor D ata O nly . T his w ill c alib ra te th e E CU to y our s pecific v e hic le s s ensors . S peed D en sit y F uelin g T he A EM In fin it y E CU w ill ru n th e e ngin e w it h a s peed d ensit y fu elin g c alc ula tio n. T he O EM P ola ris A ir In ta ke T em pera tu re (A IT ) s ensor is lo cate d in sid e o f th e M anifo ld A ir Q ualit y S ensor (M AQ S). T his A IT s ensor h as b een c hara cte riz ed b y A EM a nd is p re -s ele cte d in th e S etu p W iz ard o f th e b ase s essio n. T he A EM 3 .5 B ar M AP s ensor (in clu ded in th is k it ) n eeds to b e p lu m bed to a v a cuum s ourc e th at s am ple s fr o m b oth in ta ke ru nners . T he p re ssure s ensor in sid e o f th e M AQ S s am ple s fr o m o nly o ne ru nner o nly a nd is n ot s uit a ble fo r u se in th e s peed d ensit y fu el c alc ula tio n. T he fa cto ry C oola nt T em pera tu re (C LT) s ensor h as b een c hara cte riz ed b y A EM a nd is a ls o p re -s ele cte d in th e S etu p W iz ard o f th e b ase s essio n. U EG O W id eb an d O xyg en S en so r T he A EM In fin it y E CU in clu des o n b oard c ontro l fo r o ne U EG O w id eband o xygen s ensor. T he B osch L S U 4 .2 s ensor (in clu ded in th is k it ) p lu gs in d ir e ctly to th e A EM In fin it y P nP H arn ess. A n o xygen s ensor b ung (a va ila ble s epara te ly ) s hould b e w eld ed in to th e e xhaust s yste m a ft e r th e m erg e c olle cto r (s o th at b oth c ylin ders a re s am ple d). If a n a ft e rm ark et tu rb o k it is in sta lle d, th e o xygen s ensor b ung s hould b e in sta lle d in to th e d ow npip e, p ost-tu rb o. O xygen s ensor b ungs a nd re pla cem ent s ensors a re a va ila ble fr o m A EM . 3 5-4 005 O2 S enso r B ung, M ild S te el 3 5-4 008 O2 S enso r B ung, T all S ta in le ss S te el 3 0-2 001 Bosc h L S U 4 .2 W id eband U EG O R epla ce m ent S enso r
P/N 3 0-3 811 4 © 2 015 A EM P erfo rm ance E le ctr o nic s IN FIN IT Y A DAPTE R H A RNESS T he c ore o f th e A EM In fin it y P nP H arn ess K it is th e m ain h arn ess th at c onnects b etw een th e P ola ris e ngin e h arn ess (re pla cin g th e O EM E CU) a nd th e A EM In fin it y E CU. T he h arn ess c onnectio ns fo r th e v a rio us p ow er, s ensors , a nd a uxilia ry o ptio ns a re d escrib ed h ere . C onnectio ns L am bda - T his 6 -w ay te rm in ate d c onnecto r p lu gs d ir e ctly in to th e in clu ded w id eband o xygen U EG O s ensor, A EM P /N 3 0-2 001. R efe r to U EG O S ensor s ectio n fo r m ountin g r e quir e m ents . A UX - T his 1 2-w ay c onnecto r is u sed to a dapt m any c om mon a ncilla ry in puts a nd o utp uts e asily . In clu ded in th is k it a re a 1 2- w ay m atin g c onnecto r, 1 2 te rm in als , a nd a c onnecto r w edgelo ck. T hese c om ponents w ill n eed to b e te rm in ate d b y th e in sta lle r w it h 1 6-2 2ga w ir e . N ote : th e p in n um berin g is m old ed in to th e w ir e s id e o f th e c onnecto r. S ee P in outs s ectio n fo r d eta ils o f th is c onnecto rs p in s.
IN FIN IT Y A DAPTER H ARNES S 5 © 2 015 A EM P erfo rm ance E le ctr o nic s C oil - T his c onnecto r s hould b e p lu gged in to t h e 3 -C hannel Ig nit o r, p ro vid ed in th is k it . S ee 3 -C hannel C oil D riv e r s ectio n fo r m ountin g r e quir e m ents . F la sh - T his 2 -w ay c onnecto r is u sed fo r s econdary h ard w are fla shin g. T his c onnecto r i s n orm ally p ro te cte d w it h a d ust c ap. T he i n clu ded s hunt c onnecto r ju m ps th e tw o w ir e s to geth er w hen re quir e d. O nce in it ia lly f la shed, th e E M S is n orm ally u pgra ded in th e s oft w are , n ot re quir in g th is c onnecto r. S ig nal - T his is a s eale d, s elf- c onta in ed s ig nal c ondit io ner. T his p lu g w ill c om e p re - t e rm in ate d a nd s hould b e s ecure d o ut o f th e w ay o f h ot o r m ovin g p arts . M AP - T his 3 -w ay c onnecto r p lu gs in to th e 3 .5 bar M AP s ensor, in clu ded in th is k it . T he M AP s ensor s hould b e p lu m bed to a c om mon v a cuum s ourc e th at s am ple s fr o m b oth in ta ke ru nners . B ATTER Y (+ ) - T he re d fly in g le ad rin g te rm in al s hould b e c onnecte d to th e b atte ry p osit iv e te rm in al. T his p ro vid es p erm anent p ow er to th e E CU. T he fu se h old er c onta in s a 5 A fu se. A lw ays re pla ce w it h a fu se o f th e s am e ra tin g. E C U C 1 - T his 8 0-w ay c onnecto r s hould b e p lu gged d ir e ctly in to th e A EM In fin it y E CU.
P/N 3 0-3 811 6 © 2 015 A EM P erfo rm ance E le ctr o nic s IN C LU D ED H A RDW ARE 3 -C han nel C oil D riv er I t is c rit ic al th at th is d riv e r m odule b e m ounte d to a fla t m eta llic s urfa ce a nd th at th e s upplie d th erm ally c onductiv e g re ase is a pplie d b etw een th e m odule a nd it s m ountin g s urfa ce. T his is r e quir e d to a llo w th e h eat g enera te d to b e c onducte d a w ay. F ailu re to m ount th e d riv e r in th is m anner w ill c ause a p re m atu re fa ilu re a nd w ill v o id th e w arra nty . U EG O S en so r A n M 18x1.5 o xygen s ensor b oss n eeds to b e w eld ed in to th e e xhaust s yste m fo r in sta lla tio n. T his s ensor s hould b e m ounte d in th e e xhaust c olle cto r w here it w ill s am ple fr o m b oth e ngin e c ylin ders . O n tu rb ocharg ed e ngin es th e U EG O s ensor m ust b e in sta lle d a ft e r th e tu rb ocharg er, if n ot, th e p re ssure d iffe re ntia l w ill g re atly a ffe ct th e a ccura cy o f th e s ensor. T o p re ve nt c olle ctio n o f liq uid s b etw een th e s ensor h ousin g a nd s ensor e le m ent d urin g th e c old s ta rt p hase, th e i n sta lla tio n a ngle s hould b e in clin ed a t le ast 1 0° fr o m h oriz onta l w it h th e e le ctric al c onnectio n u pw ard s, s ee d ia gra m M AP S en so r T w o a dapte rs a re in clu ded w it h th e 3 .5 bar M AP s ensor- a 3 /1 6 h ose b arb a nd a -4 A N m ale fit tin g. T he d esir e d fit tin g s hould b e in sta lle d to th e M AP s ensors 1 /8 N PT th re ad w it h T eflo n th re ad s ealin g p aste . T he M AP s ensor s hould b e s ecure ly m ounte d w it h a c ushio ned c la m p a nd p lu m bed to a g ood v a cuum s ourc e. T he v a cuum s ourc e s hould p ull fr o m a v o lu m e c om mon to b oth e ngin e c ylin ders , a m anifo ld v a cuum r e fe re nce fr o m a s in gle in ta ke ru nner is n ot s uit a ble .
IN STA LLA TIO N 7 © 2 015 A EM P erfo rm ance E le ctr o nic s IN STA LLA TIO N 1 ) R em ove th e d riv e rs s id e s eat (re ar s eat in X P 4 fo ur-s eate r m odels ) to g ain a ccess to th e E CU c om partm ent. R em ove th e a ccess c ove r. 2 ) R em ove th e tw o s cre w s s ecurin g th e E CU to t h e b ody p anel. P ull th e E CU o ut to g ain a ccess t o th e c onnecto rs . U nla tc h th e c onnecto rs a nd r e m ove th e E CU fr o m th e v e hic le .
P/N 3 0-3 811 8 © 2 015 A EM P erfo rm ance E le ctr o nic s 3 ) C onnect th e tw o E CU c onnecto rs to th e A EM a dapte r h arn ess in sid e th e E CU c om partm ent. R oute th e U EG O s ensor c onnecto r th ro ugh th e h ole , a lo ng th e p ath o f th e O EM w ir e h arn ess. T he s ensor w ill n eed to b e in sta lle d in a n M 18x1.5 th re aded b ung (A EM p /n 3 0-4 008, s old s epara te ly ). T his b ung is n orm ally in clu ded in t h e d ow npip e o f a n a ft e rm ark et tu rb o k it , b ut m ay b e w eld ed in to th e s to ck e xhaust p ip e in a n atu ra lly a spir a te d a pplic atio n. M ark a nd trim th e p la stic a ccess c ove r to th e p ass th e A EM h arn ess th ro ugh th e b otto m . 4 ) R epla ce th e p la stic a ccess c ove r a nd ro ute t h e A EM h arn ess d ow n to w ard s th e fu se b ox, b elo w th e s eat b ra cket. S ecure th e h arn ess to t h e p la stic b ody p anel u sin g th e s upplie d c ushio n c la m p a nd # 8 x 5 /8 s elf- ta ppin g s cre w .
IN STA LLA TIO N 9 © 2 015 A EM P erfo rm ance E le ctr o nic s 5 ) F in d th e s to ra ge b in lo cate d b elo w th e s eat. P la ce th e A EM In fin it y E CU a gain st th e fr o nt w all o f th e c om partm ent (o pposit e th e fu se b ox) a nd s ecure in p la ce w it h fo ur o f th e s upplie d # 8 x 5 /8 s elf- ta ppin g s cre w s. N ote th e o rie nta tio n o f t h e E CU in th e p hoto - th e la rg e b lu e c onnecto r s hould b e to w ard th e b otto m o f th e c om partm ent, w it h th e tw o U SB c onnecto rs n ear t h e to p. 6 ) M ount th e A EM 3 -C hannel C oil D riv e r to th e d riv e rs s id e o f th e s am e c om partm ent w it h th e t w o s upplie d (lo nger) # 8 x 3 /4 s elf- ta pin g s cre w s.
P/N 3 0-3 811 1 0 © 2 015 A EM P erfo rm ance E le ctr o nic s 7 ) In sta ll th e b arb ed h ose fit tin g to th e A EM 3 .5 bar M AP s ensor. U se T eflo n ta pe o r th re ad s ealin g p aste o n th e th re ads. M ount th e M AP s ensor to th e p la stic p anel a dja cent to th e fu se b ox u sin g th e s upplie d c ushio n c la m p a nd # 8 x 5 /8 s elf- ta ppin g s cre w . C onnect th e 3 /1 6 v a cuum h ose o n to th e b arb fit tin g a nd s ecure w it h a z ip tie . N O TE : T he s econd s ensor s how n i n th is p ic tu re is p art o f a n u nre la te d b oost g auge i n sta ll, a nd w as te ed in to th e M AP s ensors v a cuum lin e. T his s econd s ensor is n ot p art o f t h e A EM In fin it y in sta lla tio n. 8 ) R oute th e v a cuum h ose a ro und th e fu se b ox a nd u nder th e s eat m ountin g b ra cket. E nsure t h e h ose is n ot a ble to b e p in ched w hen th e s eat i s re in sta lle d. P ass th e h ose th ro ugh th e h ole in t h e p la stic b ody p anel lo cate d b eneath th e s eat b ra cket. T he h ose w ill c om e o ut o n th e o uts id e o f th e b ody, a dja cent to th e O EM v o lt a ge r e gula to r. R oute th e v a cuum h ose a lo ng th e w ir e h arn ess u p th e c lu tc h c ove r to w ard s th e in ta ke m anifo ld . S ecure w it h s upplie d z ip tie s.