C

A

BC

© 2014 SuperATV.com®. All Rights Reserved. Rev IN-PS-SPT-380 9/18/2014

INSTALLATION INSTRUCTIONS

Thank You For Choosing

Item Description Qty

A ECU Mount 1B Motor Mount 1C Mounting Tabs 2D Lower Shaft 1

(Kit contents continue on following page)

D

2753 Michigan Road • Madison, Indiana 47250 • 855-743-3427

Power Steering Kitfor Polaris Sportsman®

(Sportsman 570 installation shown)

Read instructions and view illustrations before beginning.Need help with your installation?

www.superatv.com

8:00am - 9:00pm EST M-Th8:00am - 7:00pm EST Friday9:00am - 2:00pm EST Saturday

sales@superatv.com

1-855-743-3427

2IN-PS-SPT-380

E

(Kit contents continued) Item DescriptionE Upper ShaftF Wire HarnessG MotorH ECU

M8 x 20mm Lg. FHCSQty (6)

M8 x 25mm Lg. FHCSQty (4)

M8 Nylock NutQty (6)

G* H*

F*

*Connections- Before installing, ensure that all Gaskets in

electrical connections are properly seated.- If Gaskets are not seated use a Flathead

Screwdriver to seat.

(extra hardware may be present after installation; discard)

M10 x 25mm Lg. FHCSQty (3)

3IN-PS-SPT-380

220 Motor

to Rack and Pinion

380 / 400 Motor

to Rack and Pinion

4IN-PS-SPT-380

For reference, photographing of removal process is highly recommended due to amount of components being removed from machine.

(removal illustrations on following pages)

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.

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. PowerSteeringBenefitswillbenoticedassoonasmachineismoving.2. Handlebarwillhavemorenoticeabledeflectionwhileatrest.Asaresultofspeedsensitive

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.

5IN-PS-SPT-380

Fig. 1Remove Seat

Fig. 2 Remove Headlight Pod

Remove HeadlightFig. 3

Remove Front Cab

Fig. 5

Removal Reference

Remove Side Panels

Fig. 4

(removal illustrations)

6IN-PS-SPT-380

Fig. 7

Remove Gas Tank

Remove Steering Bushing

Fig. 6

Remove Handlebar Block

Pod Mounting Bracket

(removal illustrations continued)

7IN-PS-SPT-380

(Front)

Fig. 8

(Right Side)

Remove

Disconnect Tie RodsUnbolt Lower Steering Post Assembly

(removal illustrations continued)

8IN-PS-SPT-380(Installation illustrations on following pages)

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 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”.

10. Reverse steps taken during “Removal” and reinstall necessary components with stock hardware.

11. Tighten all hardware completely.

Handlebar and Tie Rods to be inline before tightening hardware. Remove Upper Shaft (E) from Motor (G) and realign if necessary.

When connecting positive (+), negative (-), and 12V source wires, 570 models will use “Wiring Details” on page 14. Models that are not 570, will use page 13.

9IN-PS-SPT-380

Motor Mount

Motor

570/800 Models

400 Model

Motor Orientation, Fig. 1

When installing to Frame ensure that there is no interference with any components.

M10 x 25mm Lg. FHCS

Secure with:Qty. (3)

Output Shaft

Output Shaft

10IN-PS-SPT-380

D

(Front)

(Right)

G

Fig. 3

provided hardware

(Right)

Fig. 2

(Left)

(Front)

C

D

(Right)(Left)

(Front)stock location

M8

x 20

mm

Lg.

FH

CS Qty. (2)

M8 Nut

Qty. (2)

Install Lower Shaft (C) and Tie Rods with stock hardware

Fig. 4

M8 Nut

Qty. (4)

M8

x 20

mm

Lg.

FH

CS Qty. (4)

CG

(Left)

11IN-PS-SPT-380

Fig. 5

G

provided hardware

(Left)

(Front)

(Right)E

(Front)

Fig. 5a

G

(Right)

D

E

Estock components

Apply grease when reinstalling Steering Bushing

Fig. 6

(Right)

12IN-PS-SPT-380

Remove stock screws

Splash Guard

(Front)

(Right)

Fig. 7

(Front)

H

A

(Right)

Fig. 8

Item Description Qty

A ECU Mount 1B Motor Mount 1C Mounting Tabs 2D Lower Shaft 1E Upper Shaft 1F Wire Harness 1G Motor 1H ECU 1

PARTS REFERENCE

M8

x 25

mm

Lg.

FH

CS Qty. (4)

When connecting positive (+), negative (-), and 12V source wires, 570 models will use “Wiring Details” on page 14. Models that are not 570, will use page 13.

13IN-PS-SPT-380

Non 570 Wiring Details

(Wiring Details continue on following pages)

(Left)

(Front)

Battery

Black - To Negative (-)

Red - To Positive (+) F

Route Wiring Harness (F) along Frame; secure with wire ties. Power and Ground Connections

(Left)

(Front)

(Right)

stock Orange w/White Stripe Wires

White Wire, Switched 12V Source from Wire Harness (F)

Switched 12V Source(Key-On Power)

14IN-PS-SPT-380

(Left Side)

(Front)

(Left)

(Front)

Orange w/White Stripe Wires

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.

FSwitched 12V Source

(Key-On Power)

Black - To Negative (-)

Red - To Positive (+) F

(Front)

Positive (+)

Negative (-)

Terminal Block

(Left Side)

Power and Ground Connections

570 only Wiring Details

15IN-PS-SPT-380

D

A B

C

Plug Function

A MotorB Main Power and GroundC Non-Contact Torque SensorD Key-On Power, Speed Sensor Wire, and LED

ECU Functions

When activated, LED Diagnostic Light will flashonceforabout1secondbeforeturningoff indicating proper function. Should different patterns occur, contact SuperATV.

LED Diagnostic Light

F

Secure in a visible location

16IN-PS-SPT-380

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.

Blue Wire, Speed Sensor from Wire Harness (F) F

Fig. B

Fig. A Right Rear

Stock Harness

Front

Green with Red Stripe Wire

Scotch Lock or solder connection.

Fig. C

Depending on model year, Speed Sensor Connection will vary. See following pagesUse this connection if machine has a Wire Harness present on right side of Gearcase.

Speed Sensor Connection continue on following page

Speed Sensor Connections(Disregard for 570 Models; not used)

17IN-PS-SPT-380

Fig. C

Speedometer

Unplug

Fig. A

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.

Blue Wire, Speed Sensor from Wire Harness (F)

*Fig. Bsolder together

* Depending on year, wire may be White or Green with Red Stripe.

Use this connection if machine has a Wire Harness present on right front Wheel.

Speed Sensor Connections

18IN-PS-SPT-380

Liability StatementSuperATV’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.Installing, adding, modifying, or fabricating any factory or aftermarket product to your ATV/UTV may violate certain local, state, and federal laws. Be advised that laws vary depending on town, city, county, state, etc. Use of certain products on public streets, roads, or highways may be in violation law. The Buyer is solely and exclusively legally and personally responsible for any violation of the law by the installation or use of the product. You must abide by all local, state, and federal laws, including but not limited to vehicle safety, traffic laws, and ordinances. It is your responsibility to know the laws and how they apply to you. The Buyer is responsible to fully understand the capability and limitations of his/her vehicle according to manufacturer specifications, warnings and instructions and agrees to hold SuperATV® harmless from any damage resulting from failure to adhere to such specifications, warnings and/ or instructions. The Buyer is also responsible to obey all applicable federal, state, and local laws and ordinances when operating his/her vehicle while using this product, and the Buyer agrees to hold SuperATV® harmless from any violation thereof.