Power Steering Kit

Power Steering Kit
INSTALLATION INSTRUCTIONS
Power Steering Kit
for Polaris Sportsman®
740B Clifty Drive • Madison, Indiana 47250 • 812-574-7777
(Sportsman 570 installation shown)
A
Item
Description
Qty
A
ECU Mount
1
B
Motor Mount
1
C
Mounting Tabs
2
D
Lower Shaft
1
C
B
C
D
(Kit contents continue on following page)
Read instructions and view illustrations before beginning.
Need help with your installation?
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www.superatv.com
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Liability Statement
SuperATV’s® products are designed to best fit user’s 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.
© 2014 SuperATV.com®. All Rights Reserved.
Rev IN-PS-SPT-380 9/18/2014
(Kit contents continued)
Item Description
E
E
Upper Shaft
F
Wire Harness
G
Motor
H
ECU
(extra hardware may be present after installation; discard)
Qty (6)
M8 x 20mm Lg. FHCS
Qty (6)
M8 x 25mm Lg. FHCS Qty (3)
Qty (4)
M8 Nylock Nut
M10 x 25mm Lg. FHCS
H*
G*
*Connections
F*
- Before installing, ensure that all Gaskets in
electrical connections are properly seated.
- If Gaskets are not seated use a Flathead
Screwdriver to seat.
IN-PS-SPT-380
2
Power Steering will provide multiple improvements to your machine. After installation, it is highly
recommend to take time and learn your machines new handling characteristics and feel.
Key Recommendations:
1. Power Steering Benefits will be noticed as soon as machine is moving.
2. Handlebar will have more noticeable deflection while at rest. As a result of speed sensitive
operation, this is normal.
3. Check steering sensitivity at multiple speeds to best understand new handling characteristics
and feel.
4. Without Throttle input, turning Handlebar back and forth unnecessarily is not recommended.
This action is very hard on remaining stock steering components, Tie Rod Ends, and Power
Steering unit.
Like all SuperATV products, Power Steering kits were designed with riders in mind.
For reference, photographing of removal process is highly recommended
due to amount of components being removed from machine.
Removal: Keep all components removed from machine.
1. Remove Seat. See Fig. 1.
2. Remove Headlight Pod. See Fig. 2.
- Unplug Wire Harness’
3. Remove Headlight. See Fig. 3.
4. Remove Side Panels. See Fig. 4.
5. Remove Front Cab. See Fig. 5.
6. Remove Steering Bushing, Handlebar Block, and Pod Mounting Bracket. See Fig. 6.
7. Remove Gas Tank; unplug Wire Harness and Fitting. Use a rag to catch any spilled fuel. See Fig. 7.
8. Remove Tie Rods from Lower Steering Post Assembly. See Fig. 8.
9. Unbolt stock Lower Steering Post Assembly. See Fig. 8.
10.Remove Steering Shaft. Lay Handlebar out of way. See Fig. 8.
(removal illustrations on following pages)
IN-PS-SPT-380
3
(removal illustrations)
Fig. 1
Fig. 4
Remove Seat
Remove Side Panels
Fig. 2
Remove Headlight Pod
Fig. 5
Remove Front Cab
Fig. 3
Remove Headlight
Removal Reference
IN-PS-SPT-380
4
(removal illustrations continued)
Fig. 6
Remove Handlebar Block
Pod Mounting Bracket
Remove Steering Bushing
Fig. 7
Remove Gas Tank
IN-PS-SPT-380
5
(removal illustrations continued)
Fig. 8
Remove
(Front)
(Right Side)
Disconnect Tie Rods
Unbolt Lower Steering Post Assembly
IN-PS-SPT-380
6
Installation: Do not tighten hardware unless noted.
1. Install Motor Mount (B) to Motor (G) with M10-1.50 x 25mm Lg. FHCS. See Motor Orientation, Fig. 1.
2. Install Mounting Tabs (C) to Frame with M8-1.25 x 20mm Lg. FHCS and M8-1.25 Nylock Nuts. See
Fig. 2.
3. Install Lower Shaft (D) to stock location with stock hardware. See Fig. 2.
4. Reinstall Tie Rods to Lower Shaft (D) with stock hardware. See Fig. 2.
5. Install Motor (G) onto Lower Shaft (D). Secure with provided hardware. See Motor Shafts Detail and
Fig. 3.
6. Secure Motor Mount (B) to Mounting Tabs (C) with M8-1.25 x 20mm Lg. FHCS and M8-1.25 Nylock
Nuts. See Fig. 4.
7. Install Upper Shaft (E) to Motor (G) with provided hardware. See Motor Shafts Detail and Figs. 5 - 5a.
8. Apply grease and install stock Steering Bushing to Upper Shaft (E). See Fig. 6.
- Secure Steering Bushing to Frame with stock hardware. See Fig. 6.
9. Remove hardware from Right Side Splash Guard. See Fig. 7.
- Install ECU (H) to ECU Mount (A) with M8-1.25 x 25mm Lg. FHCS. See Fig. 8.
- Install ECU Mount (A) to Frame/ Right Side Splash Guard with stock hardware. See Fig. 8. Plug in
Wire Harness (F) and plugs from Motor (G). Ensure wires have clearance between all components.
Secure as needed.
- Proceed to “Wire Details”.
When connecting positive (+), negative (-), and 12V source wires,
570 models will use “Wiring Details” on page 13. Models that are
not 570, will use page 12.
10.Reverse steps taken during “Removal” and reinstall necessary components with stock hardware.
Handlebar and Tie Rods to be inline before tightening hardware. Remove Upper Shaft (E)
from Motor (G) and realign if necessary.
11.Tighten all hardware completely.
Motor Shafts Detail
To Upper Shaft
To Lower Shaft
(Installation illustrations on following pages)
IN-PS-SPT-380
7
Output Shaft
Motor Orientation, Fig. 1
570/800 Models
When installing to Frame ensure that there is
no interference with any components.
Secure with:
Qty. (3)
Motor Mount
M10 x 25mm Lg. FHCS
Output Shaft
400 Model
Motor
IN-PS-SPT-380
8
stock location
(Front)
Fig. 2
(Front)
(Left)
(Right)
C
(Left)
(Right)
Install Lower Shaft (C) and Tie Rods
with stock hardware
M8 x 20mm Lg. FHCS
D
Qty. (2)
Qty. (2)
Fig. 3
G
M8 Nut
(Front)
D
(Right)
Fig. 4
C
G
M8 x 20mm Lg. FHCS
provided hardware
Qty. (4)
Qty. (4)
(Left)
M8 Nut
IN-PS-SPT-380
9
Fig. 5
(Front)
(Left)
(Right)
E
provided hardware
G
Fig. 5a
(Right)
E
G
(Front)
D
Fig. 6
E
stock components
(Right)
Apply grease when reinstalling Steering Bushing
IN-PS-SPT-380
10
Fig. 7
(Right)
Splash Guard
Remove stock screws
(Front)
M8 x 25mm Lg. FHCS
Fig. 8
Qty. (4)
(Front)
A
H
(Right)
PARTS REFERENCE
Item
Description
Qty
A
ECU Mount
1
B
Motor Mount
1
C
Mounting Tabs
2
D
Lower Shaft
1
E
Upper Shaft
1
F
Wire Harness
1
G
Motor
1
H
ECU
1
When connecting positive (+), negative (-), and 12V source wires,
570 models will use “Wiring Details” on page 13. Models that are
not 570, will use page 12.
IN-PS-SPT-380
11
Non 570 Wiring Details
(Right)
(Left)
(Front)
Switched 12V Source
(Key-On Power)
stock Orange w/White Stripe Wires
White Wire, Switched 12V
Source from Wire Harness (F)
Route Wiring Harness (F) along Frame; secure with wire ties.
Battery
Power and Ground
Connections
(Front)
Black - To Negative (-)
F
Red - To Positive (+)
(Left)
(Wiring Details continue on following pages)
IN-PS-SPT-380
12
(Front)
570 only Wiring Details
Orange w/White Stripe Wires
Switched 12V Source
(Key-On Power)
F
1. Locate stock Orange with White Stripe wires.
2. Connect White Wire (Switched 12V Source)
from Wiring Harness (F) to (1) stock Orange
with White Stripe Wire.
(Left)
(Front)
(Left Side)
Positive (+)
Power and Ground
Connections
Black - To Negative (-)
Terminal Block
F
Red - To Positive (+)
(Front)
(Left Side)
Negative (-)
IN-PS-SPT-380
13
ECU Functions
B
A
D
C
Plug Function
A
Motor
B
Main Power and Ground
C
Non-Contact Torque Sensor
D
Key-On Power, Speed Sensor Wire, and LED
When activated, LED Diagnostic Light will
flash once for about 1 second before turning
off indicating proper function. Should different
patterns occur, contact SuperATV.
LED Diagnostic Light
F
Secure in a visible location
IN-PS-SPT-380
14
Speed Sensor Connections
(Disregard for 570 Models; not used)
Depending on model year, Speed Sensor Connection will vary. See following pages
Use this connection if machine has a Wire Harness present on right side of Gearcase.
Soldering connection is recommended however, installer may use other forms of connecting.
1. Remove Right Rear Tire and locate stock harness containing Red with Green Stripe Wire.
See Fig. A.
2. Solder Blue Wire (Speed Sensor) from Wire Harness (F) to Red with Green Stripe Wire.
See Figs. B - C.
3. Wrap connection with electrical tape and secure Wire Harness (F) to Frame. Ensure that
no interference occurs with Suspension, Drive Shaft, etc.
Front
Stock Harness
Fig. A
Right Rear
Blue Wire, Speed Sensor
from Wire Harness (F)
Scotch Lock or
solder connection.
F
Green with Red
Stripe Wire
Fig. B
Fig. C
Speed Sensor Connection continue on following page
IN-PS-SPT-380
15
Speed Sensor Connections
Use this connection if machine has a Wire Harness present on right front Wheel.
Soldering connection is recommended however, installer may use other forms of connecting.
1. Unplug harness from Speedometer. See Fig. A.
2. Strip away approximately 1” of appropriate wire. See Figs. B - C.
3. Solder Blue Wire (Speed Sensor) from Wire Harness (F) to appropriate wire. See Figs. B - C.
4. Wrap connection with electrical tape and reconnect.
Speedometer
Unplug
Fig. A
Fig. B
solder together
*
Blue Wire, Speed Sensor from
Wire Harness (F)
*
Depending on year, wire may be
White or Green with Red Stripe.
Fig. C
IN-PS-SPT-380
16
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