RPM Powersports RZR Turbo Verti-Flow Big Core Billet Intercooler
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The RPM Powersports Verti-Flow big core billet intercooler replaces the factory Polaris RZR Turbo intercooler, a known failure point, with a TIG-welded, CNC-refaced aluminum unit that made 172.33 HP on RPM's dyno, 3.7 HP over stock and 7.65 HP over the leading competitor. It drops into the factory plenum with no cutting and no retuning.
A rzr intercooler failure can leak coolant into the intake, causing white exhaust smoke, misfires, low coolant and possible engine damage. This rzr turbo intercooler uses a massive vertical-flow core with carefully chosen fins per inch for fast heat transfer without restriction, an external top-mounted reservoir with an integrated bleeder for easy burping, and a finned top that acts as an extra heat sink.
After welding, every unit is CNC refaced so it seals flat to the factory plenum with the OEM gasket, and EPDM-sealed end tanks keep charge air from bypassing the core. As a rzr turbo s intercooler, rzr turbo s 4 intercooler, rzr pro xp intercooler and rzr turbo r intercooler, it is a direct polaris rzr intercooler replacement and a true rzr intercooler upgrade. This rzr big core intercooler is a billet intercooler built by RPM, so the rpm rzr intercooler is as at home on a stock engine as on a big-turbo build.
Key Features
- Big core vertical-flow design for lower intake air temps under load
- Optimized FPI core selection balances heat transfer and airflow
- Dyno result: 172.33 HP, +3.7 HP over stock and +7.65 HP over the leading competitor
- External top-mounted reservoir with integrated air bleeder screw
- Finned top housing acts as an added heat sink
- Fully TIG-welded, then CNC refaced for a flat OEM gasket seal
- EPDM-sealed vertical end tanks prevent charge air bypass
- -8 ORB to -10 barb fittings, convertible to -AN lines
- Direct drop-in: no cutting, modifications or ECU retuning
Built To Solve: Failing Factory Polaris RZR Turbo Intercoolers
- Factory intercoolers that crack and leak coolant into the intake
- White exhaust smoke, misfires and unexplained coolant loss
- Heat soak and rising intake temps on hot days or tuned engines
- Air pockets and messy burping during coolant service
- Look-alike intercoolers that lose power versus stock
Best For: RZR Turbo, Turbo S, Pro XP and Turbo R Owners
- Owners replacing a failed or leaking factory intercooler
- Tuned and big-turbo builds that need cooling headroom
- Desert and dune riders who see high ambient temperatures
- Owners who want a drop-in part with no retune
- Builders planning -AN coolant lines
Specifications
- Brand: RPM Powersports
- Construction: aluminum, TIG-welded, post-weld CNC refaced
- Core: vertical-flow big core
- Dyno: 172.33 HP vs. 168.63 HP stock (RPM testing)
- Fittings: (2) -8 ORB to -10 barb
- Included: intercooler, integrated top reservoir with bleeder valve, (2) fittings, serrated stainless hardware
- Manufacturer Part Number: INK-PO-2-PL
Fitment
Fits Polaris RZR turbo models that use the factory liquid-to-air intercooler in the plenum, including the RZR Turbo S and Turbo S Velocity (2- and 4-seat), RZR Pro XP, Pro XP 4, Pro S, Pro S 4, Turbo R and Turbo R 4. Fitment is not guaranteed on applications not listed here; confirm your model before ordering.
FAQ
Why do factory RZR Turbo intercoolers fail?
RPM describes the factory unit as a notorious weak point that can crack internally, leaking coolant into the intake and causing white smoke, misfires and low coolant.
How much power does the RPM intercooler make?
On RPM's dyno it made 172.33 HP, 3.7 HP more than stock and 7.65 HP more than the leading competitor.
Do I need a tune after installing it?
No. It is a direct drop-in replacement with no modifications or ECU retuning required.
How do I bleed air from the system?
The external top-mounted reservoir has an integrated bleeder screw that makes burping the system simple and mess free.
Can I run -AN coolant lines?
Yes. The -8 ORB to -10 barb fittings replace factory hoses directly and can be swapped for -AN threaded fittings.
Which RZR models does it fit?
It fits RZR turbo models with the factory plenum intercooler, including the Turbo S, Pro XP, Pro S and Turbo R families.
Why RPM Powersports
RPM Powersports engineers its intercoolers in-house and publishes dyno and temperature data against stock and competitor parts so riders can see the result before they buy.
Replace Your RZR Turbo Intercooler
Order the RPM Verti-Flow big core intercooler from Dunes 2 Dezert SXS before a factory failure takes your RZR off the trail. Contact us with fitment questions.
