AEM Polaris RZR XP Turbo 303822 User Manual
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P/N 3 0-3 822
2 016 P ola ris R ZR X P T urb o
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 0-3 822
D ocum ent B uild 7 /2 7/2 016
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 0-3 822 2 © 2 016 A EM P erfo rm ance E le ctr o nic s OVE R VIE W T he 3 0-3 822 A EM In fin it y P nP H arn ess w as d esig ned to ru n th e 2 016 P ola ris R ZR X P T urb o. 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 s to ck 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. 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 5 08, 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 Y our In fin it y E M S w ill b e p ackaged w it h fo ur im porta nt d ocum ents : U sage L egalit y D is cla im er, S oft w are D ow nlo ad N otic e, S ecurit y C ode N otic e, a nd a n In fin it y Q uic k S ta rt G uid e. F ir s t, re ad a nd a cknow le dge th e U sage L egalit y D is cla im er. S econd, re fe r to th e In fin it y Q uic k S ta rt G uid e (Q SG ). T hir d , fo llo w th e S oft w are D ow nlo ad N otic e a nd d ow nlo ad th e In fin it y T uner s oft w are fr o m th e A EM E le ctro nic s w eb s it e . F ourth , v is it w ww.a em in fin it y .c om to re gis te r y our E M S (S ee A ccount R egis tra tio n in Q SG ). O nce th e r e gis tra tio n p ro cess is c om ple te , y oul l b e a ble to d ow nlo ad th e la te st fir m ware fo r y our E M S*. T he fin al s etu p p ro cess is to o pen th e In fin it y T uner s oft w are a nd c onnect to y our E M S to u pdate th e fir m ware (S ee F ir m ware U pdate in Q SG . T his c an b e d one o nce th e E M S is in sta lle d in to y our v e hic le - s ee In sta lla tio n s ectio n. O nce th e In fin it y is in sta lle d in to y our v e hic le a nd it h as b een lo aded w it h th e la te st fir m ware , s etu p a nd tu nin g m ay c om mence. R efe r to th e Q SG fo r a ddit io nal in fo rm atio n o n g ettin g th e e ngin e re ady fo r tu nin g w it h th e In fin it y E M S. A ddit io nally , th e fu ll In fin it y U ser M anual c an b e re fe re nced fo r m ore in -d epth in fo rm atio n p erta in in g to th e i n sta ll, s etu p, a nd u sage o f th e In fin it y E M S. * B e s ure to d ow nlo ad In f-5 08 P ola ris R ZR X P T urb o fir m ware . D o N O T d ow nlo ad th e In f- 5 08 P ola ris R ZR 900/ R ZR 1000 fir m ware .
GETTIN G S TA RTED 3 © 2 016 A EM P erfo rm ance E le ctr o nic s IM PO RTA NT A PPLIC ATIO N N O TE S T he 3 0-3 822 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 5 08 P ow ers ports E CU to a 2 016 P ola ris R ZR T urb o. 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 fu el i n 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. F uel In je cto rs T he s to ck R ZR T urb o fu el in je cto rs flo w 4 50 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 in th e S etu p W iz ard b ut te stin g h as s how n th at th e s to ck in je cto rs o pera te n ear 1 00% d uty c ycle w hen ra n a t th e fa cto ry ra te d p ow er/b oost le ve l. It s s uggeste d th at la rg er in je cto rs b e in sta lle d in o rd er to s upport h ig her th an s to ck p ow er/b oost le ve ls . T he S etu p W iz ard 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 . P le ase n ote th at th e In fin it y 5 08 P ow ers ports E CU c an o nly d riv e h ig h im pedance i n je cto rs a nd lo w im pedance o r p eak a nd h old in je cto rs a re n ot s upporte d. 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 s to ck 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 riv e B y W ir e S etu p W iz ard s hould b e ru n w it h C alib ra te S ensor D ata O nly s ele cte d to c alib ra te th e In fin it y to y our s pecific v e hic le s s ensors . S en so rs a n d S peed D en sit y F uelin g T he In fin it y w ill ru n th e e ngin e w it h a s peed d ensit y fu elin g c ontro l u sin g th e s to ck P ola ris M anifo ld A ir P re ssure ( M AP), In ta ke A ir T em pera tu re (IA T) a nd C oola nt T em pera tu re (C LT) s ensors . T he s to ck M AP s ensor re ads u p to 3 00kpa. T he In fin it y a ls o re fe re nces th e s to ck a ir b ox/b aro m etric p re ssure s ensor. U EG O W id eb an d O xyg en S en so r a n d m ountin g b ung T he In fin it y 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. T he in clu ded o xygen s ensor b ung s hould b e w eld ed in to th e e xhaust s yste m a ft e r th e tu rb o b ut b efo re th e c ata ly tic c onve rte r (if s till e quip ped). 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 0-3 822 4 © 2 016 A EM P erfo rm ance E le ctr o nic s KIT C O NTE NTS AEM P /N Descrip tio n Qty 35-3 822 AEM In fin it y P nP H arn ess 1 35-2 843 Ig nit o r, 3 -C hannel w it h T herm al P aste 1 35-2 001 Bosch L S U 4 .2 W id eband U EG O S ensor 1 35-4 005 Oxygen s ensor b ung 1 1-3 071 Cushio n C la m p, 7 /8 1 1-3 069 Scre w , S elf- T appin g # 8 x 5 /8 5 1-3 070 Scre w , S elf- T appin g # 8 x 3 /4 2 1062-2 0-0 122 Socket, A ux C onnecto r w it h te rm in als 12 10-3 822 In stru ctio n S heet, 3 0-3 822 1 IN FIN IT Y C O NNEC TO RS T he A EM In fin it y E M S u ses th e M X123 S eale d C onnectio n S yste m fr o m M ole x. A EM s tro ngly re com mends th at u sers b ecom e fa m ilia r w it h th e p ro per to ols a nd p ro cedure s b efo re a tte m ptin g a ny m odific atio ns. T he e ntir e u ser m anual c an b e d ow nlo aded d ir e ct fr o m M ole x a t: h ttp ://w ww.m ole x.c om /m x_uplo ad/fa m ily //M X123U serM anual. p df * *N O TE** D UE T O E X PO SURE T O D IR T A ND M UD, T H E F O LLO W IN G C LEA NIN G P RO CED URE M UST B E F O LLO W ED IN O RDER T O P REV EN T D AM AG E T O T H E M AIN W IR IN G H ARNES S C O NNEC TO R. D O N O T A TTEM PT T O U NLA TC H A ND R EM OVE T H E M AIN C O NNEC TO R IF IT S D IR TY P RIO R T O C LEA NIN G !! D AM AG E T O T H E M AIN H ARNES S C O NNEC TO R D UE T O L A CK O F O R IM PRO PER C LEA NIN G IS N O T C O VER ED U NDER W ARRANTY!!
IN FIN IT Y C O NNEC TO RS 5 © 2 016 A EM P erfo rm ance E le ctr o nic s C le anin g In stru ctio ns - D O N O T A TTEM PT T O U NLA TC H O R R EM OVE T H E C O NNEC TO R U NTIL S TEP 3 . Note d ir t a n d g rit b uilt u p a ro und la tc h lo ck a n d in c o nnecto r s lid es. A ll d ebris m ust b e r e m ove d b efo re a tte m ptin g t o u nla tc h a n d r e m ove c o nnecto r. 1 . W it h th e c onnecto r s till in p la ce a nd la tc hed, u se a s quir t b ottle to s quir t w ate r lib era lly a nd d ir e ctly o nto th e c onnecto r s lid es a nd a ro und a ll e xposed s urfa ces to l o osen a nd re m ove d ir t, g rit a nd s m all ro cks. R epeat a s n ecessary . Squir t w ate r lib era lly t o t h e a re as in dic ate d 2 . W it h th e c onnecto r s till in p la ce a nd la tc hed, u se h ig h p re ssure a ir to re m ove lo osened d ebris . D ir e ct a ir s tre am a ro und c onnecto r s lid es a nd a ll e xposed s urfa ces. R epeat a s n ecessary .
P/N 3 0-3 822 6 © 2 016 A EM P erfo rm ance E le ctr o nic s 3 . R ele ase la tc h lo ck a nd g ently a tte m pt to lift th e la tc h t o d ete rm in e if th ere is e xcessiv e re sis ta nce. If la tc h b in ds o r re sis ta nce is fe lt , s to p a nd m ove to S te p 4 . 4 . If re sis ta nce is fe lt w hile u nla tc hin g th e c onnecto r, c ontin ue c le anin g th e c onnecto r w it h th e la tc h ra is ed to t h e p oin t o f re sis ta nce. C ycle th e la tc h b ack a nd fo rth t o h elp lo osen a ddit io nal d ebris . Contin ue t o c le an o ut d ebris b y s quir tin g w ate r in to c o nnecto r s lid es
IN FIN IT Y C O NNEC TO RS 7 © 2 016 A EM P erfo rm ance E le ctr o nic s 5 . R epeat p re vio us s te ps u ntil th e c onnecto r s lid es a re c om ple te ly fr e e o f d ir t a nd d ebris a nd th e c onnecto r c an b e fu lly u nla tc hed a nd re m ove d w it h lit tle re sis ta nce. Cle an c o nnecto r s lid es 6 . O nce c onnecto r is re m ove d, c heck th e s lid es fo r a ny d ebris . U se a c le an d am p p aper to w el o r ra g to re m ove d ebris fr o m th e o uts id es o f th e c onnecto r. U se c autio n w hen w ip in g n ear th e te rm in al o penin gs. Cle an o uts id e o f c o nnecto r h ousin g - a vo id t e rm in al o penin gs 8 . U se a c le an d am p p aper to w el o r ra g to re m ove d ebris fr o m th e o uts id e o f th e h eader c onnecto r. U se c autio n to a vo id g ettin g d ebris in to c onnecto r.
P/N 3 0-3 822 8 © 2 016 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 s to ck E CU) a nd th e A EM In fin it y E M S. 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 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 t h 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 t h 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. E C U H eader - P lu gs in to c ars s to ck w ir in g h arn ess. 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. T he in clu ded M 18x1.5 o xygen s ensor b ung 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 he 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 f r o m b oth e ngin e c ylin ders . O n tu rb ocharg ed e ngin es t h e U EG O s ensor m ust b e in sta lle d a ft e r th e t u 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 in 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 t h e e le ctric al c onnectio n u pw ard s.
IN FIN IT Y A DAPTER H ARNES S 9 © 2 016 A EM P erfo rm ance E le ctr o nic s 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 -te 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 . D o N O T re m ove . C oil - T his c onnecto r s hould b e p lu gged in to th e i n clu ded 3 -C hannel Ig nit o r a s s how n. A EM net - A EM net is a n o pen a rc hit e ctu re b ased o n C AN 2 .0 w hic h p ro vid es th e a bilit y fo r m ult ip le e nable d d evic es, s uch a s ra ce d ashes, d ata lo ggers , e tc ., to e asily c om mum ic ate w it h o ne a noth er th ro ugh tw o t w is te d c able s (C AN+/C AN-). 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 is n orm ally p ro te cte d w it h a d ust c ap. T he in clu ded s hunt c onnecto r ju m ps t h 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. B atte ry (+ ) - 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 r a tin g. E C U C 1 - P lu gs in to In fin it y E M S.
P/N 3 0-3 822 1 0 © 2 016 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 th e b ody p anel. P ull th e E CU o ut to g ain a ccess to th e c onnecto rs . U nla tc h th e c onnecto rs a nd re m ove th e E CU f r o m th e v e hic le . 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 to th e U EG O s ensor l o catio 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 .