Polaris RZR XP Turbo System


Overview

FEATURES

  • 53 Series Aerocharger
  • Air-Water Intercooler
  • High-Flow Exhaust
  • Donaldson Air Filter
  • Tuned Air Box
  • Clutch Upgrade
  • E85 Fuel Option
  • Boost & AFR Guages

OVERVIEW

Aerocharger’s first RZR turbo kit was originally developed in 2008 to be a demo on proper turbo system engineering, but quickly become a best-selling product for the UTV market. Our RZR systems have been rigorously tested and proven every year since then, and our Aerocharger RZR system was completely reworked for the release of the XP 900. The 53 Series Aerocharger is a substantial innovation over conventional turbocharger technology, making it ideal for use with the Polaris ProStar 900 engine. A much-requested E85 fuel option is also available for this turbo kit, which provides a performance upgrade and higher boost levels over normal fuels. The Aerocharger Polaris RZR XP turbo system was built to prioritize horsepower-generating efficiency, and this equals an ultra-responsive, ridable system that excels at high altitude and on technical terrain.

ABOUT AEROCHARGER

Aerocharger Turbo Systems is a 3rd generation engineering company and the manufacturer of the Aerocharger, a specialized Variable Vane Turbo. Aerocharger also directly researches and develops turbo kits using the fully optimized Aerocharger for UTV, snowmobile, motorcycle and automotive applications. Aerocharger’s engineers have expert technical backgrounds in fuel management and thermal dynamics, and Aerocharger systems are carefully designed to prioritize efficiency, power and response.

System Specs


Performance Gains

RZR XP’s are capable of around 60hp stock at the wheel. After the Aerocharger system is installed, at-the-wheel dyno results show the RZR XP will do 96 hp at 5.5 psi on pump gas, and 130 hp at 10psi on race fuel.

Fueling

The Aerocharger RZR XP turbo system can be shipped from us set up for either 91+octane pump gas, or E85 fuel – just let us know which version you want when ordering. Once an Aerocharged RZR XP has been set up for a specific fuel, other fuels cannot not be used.

E85 Fuel Option

E85 is an inexpensive race fuel that typically costs much less than high octane pump gas, and is readily available at many gas stations including rural areas. Using E85 safely allows running higher boost psi. This fuel also creates a chemical intercooling reaction for the air charge from the turbo. This effect will reduce charge temperatures and increase horsepower output. An Aerocharged RZR XP that is set up for E85 will burn around 30% more fuel, but the cost savings and power gains will make sense for many RZR owners. The combined effect of alcohol-based fuel and additional fuel volume will reduce engine coolant temperatures as well, and you might notice slightly lower engine heat.

It should be noted that the E85 fuel blend available at the pump is changed for the winter, and the winter blend is less than ideal for turbocharged use. Summer blend E85 can be found all year long in certain areas, but will be a little harder to start in cold weather. The Aerocharger E85 system provides larger injectors and a specialized fuel map, and other fuels cannot be used in an Aerocharged RZR XP once it is set up for E85 fuel.

Click the Video tab to view a feature on E85 Aerocharged RZR XPs.

Boost Levels

Max boost level is mechanically set by a pre-loaded spring inside the Aerocharger’s integrated boost controller, and aftermarket boost controllers can also be used for additional boost control. See the Aerocharger page for additional information.

Intercooler

An Air-to-Water intercooler comes standard with the Aerocharger RZR XP 900 package. This intercooler is built into the airbox, and comes complete with an auxiliary radiator to provide a consistent, dense air charge.

Big Bore/Compression Mods

The Aerocharger RZR XP 900 System is compatible with engine mods such as big bore kits or lower/higher compression.

No Spark Arrestor Required

Unlike all other UTV turbo systems, the unique design of the Aerocharger means a spark arrestor is not required to meet US Forest Service regulations. The Aerocharger utilizes 100% of exhaust gasses, serving as it’s own spark arrestor.

Reliability & Support

Aerocharger has a well-tested, strong-running and reliable turbo system. The Aerocharger doesn’t require any more care or maintenance than any other turbocharger, and when properly installed your Aerocharger should outlast the life of your vehicle. We will make sure you have the support you need – for any questions, troubleshooting or maintenance, don’t hesitate to directly contact Aerocharger’s engineers or your nearest Aerocharger dealer.

Installation

The Aerocharger RZR XP 900 system is completely comprehensive, and was designed for easy installation with little modification from stock. The XP 900 system fits cleanly under the bed for a stealthy look that doesn’t block views or limit storage or accessory space. Aerocharger systems are designed so they can be installed at home by a rider with moderate mechanical ability and common garage tools, but many Aerocharger customers prefer to have their turbo system installed at a dealership or performance shop.

Contact Aerocharger for information about dealers in your area.

Components

AEROCHARGER RZR ESSENTIALS SYSTEM

Aerocharger RZR XP Turbo Kits are fully comprehensive and ship with all required parts. Here are featured components that showcase the superior quality and finish of this Aerocharger Turbo System.

Aerocharger 53 Series

VATN Technology

Aerocharger’s powerful variable geometry tech optimizes turbine size, producing lag-free boost. Excellent performance for high altitude and technical riding. The ideal turbo for 2-strokes.

Independent Oil Supply

The Aerocharger contains it’s own oil supply allowing for clean and simple installation, and reduced risk of complications when riding.

Non-Flooded Bearings

Innovative oil misting system allows for drag free bearing performance and ultra-fast spooling. A major performance increase over conventional journal bearings.

Fuel Management

Exclusive Fuel Programming

The Aerocharger system is managed by a pre-tuned fuel controller. The program was built by Aerocharger’s EFI engineer and has been rigorously tested at different altitudes and environments. AFR and Boost Guages are supplied with the kit.

Adjustability Options

The Aerocommander includes on-the-fly fine-tune settings for different boost levels and altitudes.

Air Box with integrated Air-to-Water Intercooler

Durably Built

Robust design allows for best air flow from the turbo.

Intercooled Power Advantage

An Air-to-Water intercooler comes standard with the Aerocharger RZR XP 900 package. This intercooler is built into the airbox, and comes complete with an auxiliary radiator to provide a consistent, dense air charge.

Donaldson Air Filter

Industrial Filtration

The Aerocharger is fed by a heavy duty Donaldson Air Filter- the same one used in mining and industrial machinery. An oversized filter element provides long-lasting clean air flow, accomodating extremely dusty riding conditions.

Stainless Exhaust

High-Flow

The muffler is high flow in order to reduce back pressure. It has a slightly louder operating volume, but the noise level isn’t bothersome and remains compliant with noise ordinances.

No Spark Arrestor Required

Unlike all other UTV turbo systems, the unique design of the Aerocharger means a spark arrestor is not required to meet US Forest Service regulations. The Aerocharger utilizes 100% of exhaust gasses, serving as it’s own spark arrestor.

Custom Headers

TIG Welded

Durable construction by skilled production welders.

Heat Wrapped

Pipes are heat wrapped to maintain thermal energy and lower engine bay temperatures.

Race Clutch

Performance Upgrade

Aerocharger developed this Race Helix during development of the RZR XP 900 Turbo System, and it has been found through rigorous testing to be the helix for the best driving Aerocharged vehicle. Utilizing the adjustable weights provided with the kit, the Race Clutch upgrade package creates smoother shifting and less aggressive engine braking during backshift, resulting in a substantially smoother ride.

Also Included

rzr_boostguage

Boost Gauge

Boost gauge included for easy reference.

rzr_afrguage

AFR Gauge

Color display for on-the-fly readability.

rzr_airtube

Intake Tube

Connects to Intake Flange and feeds the Donaldson filter.

rzr_clutchweights

Clutch Weights

Comes with setting recommendations based on Aerocharger testing.

rzr_lines

Lines and Wiring

Boost reference lines and wiring.

rzr_hose

Coolant Hoses

Extra length included for precise fitment.

rzr_hardware

Hardware

Kit ships with all necessary mounting hardware.

rzr_fillerneck

Radiator Fillneck

Allows turbo coolant to be added quickly.

rzr_radiator

Radiator

Fits over stock radiator to rapidly cool turbo charge.

rzr_waterpump

Water Pump

Automotive-grade Bosch water pump assembly.

rzr_injectors

Fuel Injectors

Fuel injectors for pump gas or optional E85 Fueling.

rzr_heatshield

Turbo Heat Shield

Helps manage engine compartment heat.

rzr_oilbreatherfilter

Oil Breather Filter

High quality K&N Oil Breather Filter is included.

rzr_manual

Reference Materials

Manual, quick start guide, turbo guide, templates and stickers are included for simple installation.

E85 Fuel Conversion


E85 Fuel Setup – $150

rzr-xp-turbo-e85Fuel System Conversion

An E85 conversion setup is available for Aerocharger systems currently set for standard fuels. The conversion includes E85 injectors and a fuel controller reflash, and will allow E85 fuels to be ran in your Aerocharged RZR XP. E85 is an inexpensive race fuel that typically costs much less than high octane pump gas, and is readily available at many gas stations including rural areas. Using E85 safely allows running higher boost psi. This fuel also creates a chemical intercooling reaction for the air charge from the turbo. This effect will reduce charge temperatures and increase horsepower output. An Aerocharged RZR XP that is set up for E85 will burn around 30% more fuel, but the cost savings and power gains will make sense for many RZR owners. The combined effect of alcohol-based fuel and additional fuel volume will reduce engine coolant temperatures as well, and you might notice slightly lower engine heat.

It should be noted that the E85 fuel blend available at the pump is changed for the winter, and the winter blend is less than ideal for turbocharged use. Summer blend E85 can be found all year long in certain areas, but will be a little harder to start in cold weather. The Aerocharger E85 system provides larger injectors and a specialized fuel map, and other fuels cannot be used in an Aerocharged RZR XP once it is set up for E85 fuel.

This 2-part video provides an overview of E85 fuel for RZR XPs and documents the development of this setup.


Downloads


Videos


Supplementary Turbo Installation Video: 2013 RZR XP 900


E85 Part 1: Fuel Map Development

Follow along with Aerocharger engineer Andrew Dey as he develops a fuel map for an E85 RZR XP Jagged X turbo.

E85 Part 2: High Altitude Dune Testing

The Aerocharger crew meets up with Brook and Calvin at Felker Motorsports to install an Aerocharger E85 turbo kit on Brook’s new RZR XP4. Then it’s off to the dunes to prove out the fuel map at high altitude and roost some sand.

RZR XP 900 | Aerocharger Ride-Along

Black Aerocharged RZR XP in Devils’ Tub at Rally on the Rocks 2013 in Moab

Turbo RZRs in Little Sahara, OK

RZR XP 900 | Aerocharger Ride-Along

Aerocharger RZR XP Turbo Trail Riding

Aerocharger RZR XP Turbo vs RZR 800 Turbo