Two Brothers Racing Polaris RZR 800 Coil Kit - Manual

2009 Polaris Ranger RZR and RZR-S 800 EFI
Dynatek Coil Kit DCK9-3
Congratulations on your purchase of a Dynatek Ignition Coil Kit. Please take a moment to read these instructions
completely before installing the ignition coil. The installation will take about 1 hour.
This kit includes: (1) Mini-Coil, 0.5ohm dual output
(1) Mounting bracket
(1) 48” Carbon core spark plug wire, 135° boots at both ends (1) ¼-20 x 3/4 bolt
(2) Spark plug wire terminals (2) ¼-20 x 1-3/4 bolts
(1) Stub harness (1) Lock washer
(2) Coil spacers (3) Flat washers
(2) ¼-20 lock nuts
This is a complete kit, and includes everything needed to install the ignition coil.
Note: The stock sparkplug boots and protective sleeves will be reused in this application.
Note: Route all wires carefully. Secure wires in factory loops or use cable ties to ensure electrical wires do not chafe or
touch anything hot. Pay close attention to the wiring detail and wire crimping, successful installation depends on this.
Tools Required:
Fractional socket/ wrench set Grease tub
Screw driver set Diagonal cutters
Wire crimping tool for spark plug terminals Pliers
Wire cutter/stripper
Installation
1)
Remove seats, engine access panel, and transmission air duct (2 push-pins and hose clamp).
2) Disconnect battery ground. Bed removal is not necessary, but it makes access to spark plugs easier.
3) The coil is located in front of engine, near driver side.
4) Unplug the 3-wire connector from the coil. Wire colors are Yellow, Red, and Green. Unplug both sparkplug
boots from the sparkplugs. Remove the mounting bolt and the coil.
5) Use grease. With fingers or q-tip, push grease in between rubber boot and wire. Hold the stock sparkplug wire
near the boot and pull the wire out of the rubber sparkplug boot. Pull wire out of protective sleeve. Do this for
both wires. The original boots and sleeves will be used with the Dyna spark plug wires.
6) Cut single 48 inch sparkplug wire in half. So there are 2 lengths of 24 inch sparkplug wire. Put wire thru
protective sleeve. Push wire thru original sparkplug boot. Use grease on wire and boot. Do this for both wires.
(see pictures 1-6)
7) Pull wire several inches thru boot. Wipe grease from wire, so boot no longer slides. Strip ¾ inch of insulation
from spark plug wire. Take care not to knick or damage the carbon center. Bend carbon center back over
insulation. Place sparkplug wire in terminal as shown. Carbon center should extend slightly beyond rear of
terminal. Use pliers to gently squeeze sides of terminal, until wire is held in place. Use crimping tool to crimp
terminal properly onto wire. (see pictures 7-14)
8) Press first wire terminal onto #1 spark plug. Make sure terminal clicks into place. Slide boot down wire until
spark plug #1 is covered completely. Press second wire terminal onto #2 spark plug. Make sure terminal clicks
into place. Slide boot down wire until spark plug #2 is covered completely. (see pictures 15-18)
9) Put long bolts thru Dyna bracket from the back side. Put ½” spacers over bolts. Then fasten bracket to vehicle
using short bolt with flat and lock washer. (see picture 19)
10) Mount Dyna coil on bracket as shown. (see picture 21) Place coil on spacers, then flat washers. Hold bolt head
with closed end wrench and tighten locknuts with socket.
11) Plug stub harness into three wire connector of main harness.
12) Red wire connects coil terminal (with red dot).
13) Yellow wire connects coil terminal (without red dot).
14) Press wires from spark plugs #1 and #2 onto either coil tower. Make sure wire snaps into place.
DYNATEK 164 S. Valencia St., Glendora, CA 91741 800-928-3962 www.dynaonline.com 2801398B
15) Tighten all bolts securely so Dyna coil and bracket is not loose. (Medium strength thread lock is recommended)