Contents

Kawasaki Teryx KRX 1000 - Install Instructions

1Fuel Rail + Regulator Kit (Return Style)
  1. Remove Fuel Pump Module
  2. Modify Module for Return Line & Regulator Plug
  3. Install Fuel Rail, Injectors & Regulator
  4. Install Return Line
  5. Flash ECU
  6. Reinstall All Remaining Parts
2Fuel Rail + Pulsation Damper Kit (Returnless)
  1. Install Fuel Rail, Injectors & Pulsation Damper
  2. Flash ECU
  3. Reinstall All Remaining Parts
3Fuel Rail Upgrade Kit
  1. Install Fuel Rail & Injectors
  2. Reinstall All Remaining Parts

Application Notes

Supported Models : 2020-2021 Kawasaki Teryx KRX 1000

Note: The vehicle shown in this document is a modified 2021 Kawasaki Teryx KRX 1000. Your vehicle could have parts that may or may not be present in the pictures. The images are meant to be a reference only. If you have any questions regarding your installation please contact us at offroad@yawpower.com

Item List

Item No. Description Qty. Fuel Rail + Regulator Kit (Return Style Kit) Fuel Rail + Pulsation Damper Kit (Returnless Style Kit) Fuel Rail Upgrade Kit
1 KRX Fuel Rail 1
2 3 Bar Regulator Pressure / Pulsation Damper ASY 1
3 KRX Return Backing Plate 1
4 KRX Pilot Hole Bushing 1
5 KRX OEM Injector Adapter 2
6 Stock Fuel Pressure Regulator Plug 1
7 06 ORB Male to 5/16" EFI Male (Incl. O Ring) 1
8 06 ORB Plug 1
9 06 ORB to 04AN Male 1
10 06 ORB to 06 ORB Coupler 1
11 04AN E85 Rated Hose (65"), 45° / 45° Crimp Fittings 1
12 04AN 90° Bulkhead 1
13 04AN Bulkhead Nut 1
14 04AN Stat-O-Seal 1
15 4mm Wye Hose Barb 1
16 4mm Black Silicone Hose (5") 1
17 11" Cable Tie 5
18 3" Miniature Cable Ties 4

Fuel Rail + Regulator Kit (Return Style Kit)

1. Remove Fuel Pump Module

  1. Remove the passenger seat by unfastening (4) bolts securing the seat rail.
  2. Remove the plastic cover shown in figure 1.
    image_1

    Figure 1: Pump access panel reference.

  3. Disconnect the power connector and crank the engine to bleed fuel pressure. Disconnect battery once the pressure has bled.
  4. Disconnect fuel line from the pump module. There will be some fuel left in the fuel line.
  5. Remove the fuel pump locking ring by removing (6) bolts and lifting the fuel pump module out of the tank (drain fuel back into the tank).
    image_2

    Figure 2: Pump connections reference.

2. Modify Fuel Pump Module for Return Line and Regulator Plug Installation

  1. Uninstall the pump top hat by disconnecting (2) electrical connectors and lifting on (4) clips shown in figure 3.
    image_3

    Figure 3: Top hat clips reference.

  2. Using side cutters, cut the center webbing shown in figure 4.
    image_4

    Figure 4: Top hat web reference.

  3. Insert the backing plate into the webbing of the top hat. Next, insert the pilot hole bushing as shown in figure 5.
    image_5

    Figure 5: Backing plate and bushing reference.

  4. Drill a 1/8” hole using the center hole of the bushing. Remove the bushing and backing plate.
  5. From the top side of the top hat, drill a 7/16” hole. A Unibit is recommended but it is also possible to start with a smaller drill bit and step up to a 7/16” bit.
  6. Install the -04 90° bulkhead fitting using the stat-o-seal on the top of the top hat. Use figure 6 as a reference for the orientation of the bulkhead fitting.
    image_6

    Figure 6: Return line orientation reference.

  7. Remove the bottom half of the fuel pump module by lifting on the clips shown in figure 7. Make sure not to lose the O-ring that sits on the pump outlet.
    image_7

    Figure 7: Clip reference.

  8. Remove the factory fuel pressure regulator.
  9. Insert the supplied regulator plug into the fuel pump module.
    image_8

    Figure 8: Installed regulator plug.

  10. Reassemble the fuel pump module.
  11. Reinstall the fuel pump module into the fuel tank. Use figure 2 as a reference for all connections.

3. Install Fuel Rail, Injectors and Regulator

  1. Remove the trunk panel to gain access to the top of the engine.
  2. Disconnect injector electrical connectors.
  3. Disconnect the fuel line from rail. There will be fuel left in the fuel line.
  4. Remove (2) Phillips head bolts to uninstall the fuel rail.
  5. Install the supplied fittings on the rail and regulator.
    1. Install the -06 ORB to 5/16” EFI fitting on the inlet of the rail (driver’s side).
    2. Install the -06 ORB swivel fitting (non adjustable side) on the outlet of the rail (passenger’s side).
    3. Install the -06 ORB to -04 AN fitting into the bottom of the regulator housing.
    4. Thread on the regulator housing to the swivel fitting until the threads bottom out, then back out one turn. Do not tighten the lock nut.
    5. Install ID injectors into the fuel rail (Apply grease on all O-rings).
  6. Install fuel rail and injectors onto the throttle body ensuring both injectors are firmly seated (Take care, not to over tighten bolts).
  7. Orientate the fuel pressure regulator as seen in figure 9.
    image_9

    Figure 9: Pressure regulator orientation reference.

  8. Reconnect the factory fuel line.
  9. Reconnect injector connectors using the supplied electrical adapters.
  10. Connect the vacuum hoses for manifold pressure reference:
    1. Cut the factory vacuum line 2 inches away from the T shown in figure 10 and push on the supplied Wye fitting onto both ends of the cut line.
    2. Insert the supplied 4mm vacuum hose onto the last leg of the Wye fitting.
    3. Trim any excess length of the vacuum hose and push onto the pressure regulator barb.
    4. Secure a zip tie onto all hose ends.
image_10

Figure 10: Vacuum line reference.

4. Install Return Line

  1. Pass the return line through the firewall alongside the feed line and tighten the fitting at the pump first. Pull all slack towards the rear of the car.
  2. Tighten the fitting to the fuel pressure regulator.
  3. Secure the return line to the feed line using zip ties. Use figure 11 as a reference.
    image_11

    Figure 11: Return line routing reference.

  4. Reconnect battery and prime the fuel system to check for leaks. Do not start the vehicle.

5. Flash ECU

  1. Generate ECU data by using the online generator at the link below and follow the directions to change the calibration.
    Dynojet PV3 Kawasaki Data Generator
  2. Once the ECU flash is complete, start the vehicle ensuring that there are no leaks in the fuel system (Caution: It is best to have a fire extinguisher within reach).

6. Reinstall All Remaining Parts

  1. Once you have ensured there are no leaks, reinstall all body panels and seats in the reverse order of removal.

Fuel Rail + Pulsation Damper Kit (Returnless Style Kit)

1. Install Fuel Rail, Injectors and Pulsation Damper

  1. Remove the trunk panel to gain access to the top of the engine.
  2. Disconnect injector electrical connectors.
  3. Disconnect the fuel line from rail. There will be fuel left in the fuel line.
  4. Remove (2) Phillips head bolts to uninstall the fuel rail.
  5. Install the supplied fittings on the rail and pulsation damper.
    1. Install the -06 ORB to 5/16” EFI fitting on the inlet of the rail (driver’s side).
    2. Install the -06 ORB swivel fitting (non adjustable side) on the outlet of the rail (passenger’s side).
    3. Install the -06 ORB plug fitting into the bottom of the pulsation damper housing.
    4. Thread on the pulsation damper housing to the swivel fitting until the threads bottom out, then back out one turn. Do not tighten the lock nut.
    5. Install ID injectors into the fuel rail (Apply grease on all O-rings).
  6. Install fuel rail and injectors onto the throttle body ensuring both injectors are firmly seated (Take care, not to over tighten bolts).
  7. Orientate the pulsation damper as seen in figure 1. NOTE: You will not have a return line connected to the pulsation damper.
    image_1

    Figure 1: Pulsation damper housing orientation reference.

  8. Reconnect factory fuel line.
  9. Reconnect injector connectors using the supplied electrical adapters.
  10. Reconnect battery and prime the fuel system to check for leaks. Do not start the vehicle.

2. Flash ECU

  1. Generate ECU data by using the online generator at the link below and follow the directions to change the calibration.
    Dynojet PV3 Kawasaki Data Generator
  2. Once the ECU flash is complete, start the vehicle ensuring that there are no leaks in the fuel system (Caution: It is best to have a fire extinguisher within reach).

3. Reinstall All Remaining Parts

  1. Once you have ensured there are no leaks, reinstall all body panels and seats in the reverse order of removal.

Fuel Rail Upgrade Kit

1. Install Fuel Rail and Injectors

  1. Remove the trunk panel to gain access to the top of the engine.
  2. Disconnect injector electrical connectors.
  3. Disconnect the fuel line from rail. There will be fuel left in the fuel line.
  4. Remove the (2) Phillips head bolts to uninstall the fuel rail.
  5. Install the supplied fittings on the rail.
    1. Install the -06 ORB to 5/16” EFI fitting on the inlet of the rail (driver’s side).
    2. Install the -06 ORB plug on the outlet of the rail (passenger’s side).
    3. Install the OEM injectors into the fuel rail using the supplied injector adapters (Apply grease on all O-rings).
  6. Install fuel rail and injectors onto the throttle body ensuring both injectors are firmly seated (Take care, not to over tighten bolts). Use figure 1 as a reference.
    image_11

    Figure 1: Rail reference.

  7. Reconnect the factory fuel line.
  8. Reconnect the injector connectors.
  9. Reconnect the battery and prime the fuel system to check for leaks. Do not start the vehicle.

2. Reinstall All Remaining Parts

  1. Once you have ensured there are no leaks, reinstall all body panels and seats in the reverse order of removal.