This Stage 4 kit is the most complete turbo upgrade kit you'll find for your RZR XP Turbo and backed with the best tuning out there to make your RZR rip all day long. This kit combines absolutely everything you need to take your RZR to above and beyond the competition. It includes our exchange turbo mod, custom tuning, S3 complete clutching, our billet diverter/blow off valve, secondary clutch snap ring delete kit, pre-gapped spark plugs, performance slip-on exhaust, high flow intake tube, and high flow charge tube. Our turbo mod creates up to 255-260 crank horsepower! This complete turbo modification is just what you need for 25-27 PSI of boost! This is NOT just a simple billet wheel turbo mod, we are doing it all! We start off by modifying the compressor housing to accept the much larger, billet compressor wheel that will move some serious air. This gains turbo efficiency to push more air per RPM of the turbo. Boost temps will skyrocket quickly on the factory turbo, where as with our mod, they will be much lower... even at boost temps over 25 pounds! Now that we are moving air on the intake side, we need to get that air out. Our mod includes a high flow 9 blade exhaust turbine to create less back pressure and heat buildup in the motor. Heat buildup on the exhaust side is another HUGE issue with the factory turbo. What's essentially happening is you are running out of exhaust flow, and that makes more power very hard to produce. With this high flow turbine, we can increase boost and see a healthy increase in horsepower with our tuning on pump gas and race fuel. The factory wastegate is also a big problem as it's very weak, and as time goes on the spring only gets weaker. Building boost with a wimpy wastegate (like our competitors do) can produce varied results, hot temps, and turbo overheating. We install a high pressure actuator complete with a new bracket. This wastegate produces extremely consistent results, will hold a huge amount of boost, and is a key component in this turbo mod working so well. Each turbo is fully blueprinted and balanced with all new bearings from a professional turbocharger manufacturer. Our custom tuned Powervision ECU flash device will send the tunes directly to your ECU, allow you to change tunes within 3 minutes, and easily return to stock. It also has data logging capabilities, diagnostics, and is a great gauge allowing you to read boost, throttle position, RPM, and more. We then transfer the power to the ground MUCH better than the factory with our S3 complete clutch kit. Though we test mostly in the real world to get the best results, we did see a 7-10 RWHP increase from 20 MPH to 40 MPH on the wheel dyno with just the clutch kit. This kit also includes our high flow exhaust to get rid of the catalytic converter and restrictive stock muffler. This allows heat to escape much quicker, and allows us to tune more aggressively. Our exhaust features an EXCELLENT sound that is fully adjustable with our quiet core that blocks off one outlet. The diverter valve is an o-ringless tip design and is needed when increasing boost pressure to prevent factory valve failure. It also comes with a plug so you can have that classic blow off CHHHH sound when you want it. Our high flow intake and charge tube help to lower intake temps going into your motor which is HUGE when going with our Level 3 or higher tunes. For more detail on each product, see the individual listings.
Massive horsepower gains bundled into a simple package
Quicker throttle response and power delivery
Requires AA custom tunes built specifically for this turbo mod
ARP head studs are required for Level 4 or higher
Requires your turbo to be sent in for exchange or modification. We have some exchange turbos to speed up the process as all turbos are basically re-manufactured to brand new. If you have a stripped bolt hole or other turbo damage, please let us know ahead of time. If this is the case, we will need to fix the issue and will most likely have the mod done to your exact turbo and send that turbo back to you. Turbo mod turnaround time can vary from 0-3 weeks depending on core availability. Normally cores are kept in stock. If you would like the modification done to your own turbo, lead times are closer to the 3 week timeframe. Please call or e-mail for current availability if you are in a time crunch. Core charge available for $600 which will be refunded when a good usable core is sent back.
Looking to keep your factory turbo? Select the buy outright option for an extra $500
Stock like drivability!
On our dyno we saw 204 RWHP @ 27 PSI on 110 octane with some serious top end pull. Other customers on car wheel dynos have reported 215-220 RWHP. That's a calculated 255-260+ crank horsepower!
Gain another 10-15 RWHP on pump gas tunes over the factory turbo (19-20 PSI on 2017+ models, 18-19 PSI on 2016 models)
Big gains in low end performance and crazy high end gains on longer pulls (this mod does not fade off anywhere near as much as the factory setup)
Lower EGT (Exhaust temps) due to higher exhaust flow & lower intake temps before and after the intercooler
More efficient turbo all around which is easier on the turbo and motor even if you just want pump gas tuning (especially nice riding higher altitudes!)
Using the factory turbo, we are able to keep reliability, proper heat shielding, and proper mounting points. The factory turbo was designed for the off-road world of dirt and water. This made it hard to shy away from something so proven, but just needing a little more flow. Others may bore the exhaust side out, buyers beware! This is a fragile part of the turbo and we have seen various cores with a crack between the exhaust turbine and wastegate. Boring this would simply mean it would be much more likely to crack. Our goal is to give you the most horsepower possible while still having a reliable machine.
Mod includes: Machined compressor housing, billet compressor wheel, high flow exhaust turbine, high pressure wastegate actuator, new bearings, head to turbo gasket, fully blueprinted & balanced turbo. Turbo looks new and is basically brand new when returned. We re-use the turbo to exhaust gasket as it's metal.
Please package your turbo very carefully when sending it in, and be sure to insure for replacement cost ($500-800 rough used cost Ebay, or $2000 for a new one). We would recommend at least a 12x12x12 or larger box. Remove the mounting bracket, but leave the wastegate actuator installed (we re-use a few bolts and it's easier this way). If your core has something wrong with it, just let us know... it's easier that way and we will find a solution. If it's just bad bearings, that's no big deal as we replace them anyways.
Send your turbo to: Aftermarket Assassins, 2348 75th Ave, Osceola, WI 54020
All level tunes feature: Throttle by wire limiters disabled, Fan on/off temp lowered to 185 degrees Fahrenheit, Seat Belt limiter disabled, Speed limiter removed in low and high gears, Rev limit at a safe 9200 RPM, more throttle in low gear, better throttle response, and much more!
1 tune is included in the price. We would recommend going with 2 or more tunes as the factory tune will run the machine, but will go into overboost if trying to run wide open.
We start with the lowest tune, the Level 2 turbo upgrade tune is a very safe 16-17 PSI 91 octane tune, good to run on any 91 oxy/ethanol. This tune produces 150-155 RWHP peak (calculated 195 crank HP), but will pull much harder and keep that horsepower maintained much better than the stock turbo.
The Level 3 turbo upgrade tune offers 18-20 PSI and is also meant to run on 91-93 octane fuel. This produces 165-170 RWHP (calculated 215 crank HP) and comes on unbelievably strong, and keeps pulling. Those with 91 non ethanol, or 93 even with ethanol will be fine on straight gas. Those with oxygenated/ethanol 91 might want to add a little bit of race fuel or VP Octanium/boostane fuel additive.
The Level 4 turbo upgrade tune is for 96-100 octane fuel. This will produce 180-185 RWHP (calculated 235 crank HP) at 22-23 PSI and hauls the mail! Most will mix race fuel with pump fuel to get the 100 octane which is what we recommend. A can of Octanium/boostane to your tank will also work with this tune.
The Level 5 turbo upgrade tune is for 110 octane fuel and simply drops the hammer! You'll have everyone wondering what is done to your RZR with this bad ass tune. A huge 25-27 PSI of boost that comes on HARD. This tune produces 200-205+ RWHP (calculated 260 crank HP) on our dyno, and has shown 215-220 on customers car dynos. We normally run this tune on 110 leaded fuel. Leaded fuel is harder on O2 sensors but we have not had much of an issue. We would suggest picking up another O2 sensor, or an O2 block off to keep around.
The Level 6 E-85 turbo upgrade tune is simply unbelievable. Very similar to the 110 tune power, but runs on cheap corn fuel, or expensive VP corn fuel! This fuel makes the motor run cooler and it absolutely loves it. If using pump E-85, make sure you are between 70-85% ethanol for this tune. 25-27 PSI with a wicked timing curve that produces the same 200-205 RWHP. This tune requires our 1200cc injectors. The injectors are included in the price of the Level 6 tune. Selecting Level 6 will result in all tunes being built to run 1200cc injectors. You MUST run the 1200cc injectors with all tunes if selecting this option.
2016 Models will need our high pressure fuel pump for Level 2 and higher
Performance Helix 1031(aggressive holeshot):For 2 seat XPT 28-32" Tires / 28-32" paddles.For 2 Seat Turbo S running 30-33" Tires or Paddles. This helix works excellent for the listed setups and has a more aggressive shift angle from 0-25mph over the 1024 performance helix. This is best for holeshots and aggressive riders that are trail riding, dune riding racing, and drag racing. This setup will still crawl good when needed, but if your riding is more slow speed/crawling, we'd suggest the 1024 helix.
Performance Helix 1024: For2 or 4 seat XPT 28-32" Tires or paddles.For Turbo S 2 or 4 Seat with 30-33" tires or 30-32" paddles. The only difference over the 1031 performance helix is the shift angle from 0-25mph is slightly less aggressive. This makes it better for crawling and those slow speed situations, but it still pulls like crazy when needing to accelerate hard. **Keep in mind if you have a 2018+ 4 seat model they are geared higher. If your tires or paddles are 31-32" and heavy, you may want to go with the high load clutch kit**
High Load Helix:For 2 seat XPT 34-35" Tires. For 4 seat XPT 32-35" tires / 32" paddles.For2 or 4 seat Turbo S running 34-35" tires. If you are using very large/heavy tires, the high load helix might be the choice for you. The high load helix is recommended for those turning heavy 34-35" tires. This angle slows the shift down to help act like it's "gearing down" the secondary clutch. This helps not over shift and cause belt slip. **Keep in mind if you have a 2018+ 4 seat model they are geared higher. If your tires or paddles are 31-32" and heavy, you may want to go with the high load clutch kit**
For even more info on the products in this kit, see the individual product listings.