Install Instructions for 76-7013

Before you Begin

This installation requires the use of a powered electrical busbar found underneath the hood of the vehicle. The provided Wire Harness (17) is designed to work with these factory-installed electrical posts on the busbar and has the length of wire necessary to power the Particle Separator's scavenge fan anywhere on the vehicle. If the busbar in your vehicle is not connected to the vehicle's battery do not begin the installation of the Particle Separator. You will need to install both a power and a ground cable from the vehicle's battery to the busbar. Although not required, Polaris offers a busbar harness kit with complete instructions about how to do this.

Step 1

Remove the bed by removing the 4 screws securing it to the frame. Lift up on the handle and pull the bed out to the rear of the vehicle.

Tools Required: T40 Torx

Step 2

Remove the bolts and push in rivets securing the rear quarter panels to the body.

Tools Required: T40 Torx & Panel Popper

Step 3

Remove the push in rivet on the underside of the body panel to release it.

Tools Required: Panel Popper

 

Step 4

Remove the back half of both seats (Rear if 4 seater) by pressing the release button on the back of the headrest, then pull up and out.

 

Step 5 A

Remove the 3 bolts and one push in rivet securing the body panels from the inside of the vehicle.

Tools Required: T40 Torx & Panel Popper

 

Step 5 B

Step 5C

Step 6

Disconnect the rubber grommet holding the gas line to the body panel by pressing it back through the plastic.

Step 7

Remove the side body panel assembly. Note that there are two clip-in attachments at the bottom below the gas cap that will need to be pressed out while removing the body panels.

Step 8

Remove the rear brake light by disconnecting the power harness and removing the three screws holding it to the body.

Tools Required: T30 Torx

Step 9

Disconnect the intake tube from the Frogzskin side cover by loosening the hose clamp connected to the side cover and pulling down.

Tools Required: 5/16” driver

Step 10 A

Remove the two bolts securing the side cover to the vehicle.

Tools Required: 10mm socket

Step 10B

Step 11

Remove the side cover from the vehicle. Lifting up the rear plastic will make this much easier.

Step 12

Install the rear scoop bracket (23) onto the S&B Side cover scoop (21) using the supplied M6 screws (25) and washers (24). Only hand tighten for now, leaving slightly loose.

Step 13

Install the front scoop bracket (22) onto the S&B Side cover using the supplied M6 screws and washers, only hand tightening for now leaving it free to rotate. Make sure the side with the slotted hole is pointing toward the rear of the scoop. The side with the standard hole is screwed into the scoop.

Step 14

Remove the bolt securing the bed bracket to the chassis.

Tools Required: 10 mm Socket

Step 15 A

Install the S&B Side cover onto the vehicle. Reinstall the removed bolts from steps 11 and 15 to secure the scoop to the chassis.

Tools Required: 10mm socket

Step 15 B

Step 16

Attach the intake tube to the S&B side cover by sliding it over the bottom opening and tightening.

Tools Required: 5/16” Socket

Step 17

Install the Clamp Adapters (6) on the mounting bosses of the Particle Separator (1) with the supplied M6-1.0 x 18 screws (14) and M6 washers (15). Apply threadlocker (16) to the screw before tightening. You will do this on both sides of the Particle Separator unit.

Tools Required: 4mm hex key

Step 18 A

Remove the 4 rearmost bolts securing the roof to the roll cage. This will give you enough clearance to install the particle separator to the upper bar of the roll cage.

Tools Required: T40 Torx

Step 18 B

Step 19

Install the two Clamp Straps (1.75”) (9) onto the upper bar of the roll cage. Do not pull the ends of the straps open. Loosely wrap some plastic around the roll cage to prevent scratching, and push the straps onto the roll cage until they snap into place.

Step 20

Install the clamp pivot bodies (8) onto the clamp straps with the supplied M8-1.25 x 50 screws (11), M8 washers (10), and M8 locknuts (13). Do not fully tighten the screws and locknuts. Leave the straps loose for final adjustments later in the install. Tools Required: 5mm hex key, 13mm socket

Step 21

Install the L brackets (7) onto the clamp pivot bodies using the M8-1.25 X 22 screws (12) and M8 washers. Apply threadlocker to the screws before tightening.

Tools Required: 5mm hex key

Step 22

Install the particle separator unit onto the vehicle by fastening the L brackets to the adapters previously installed onto the unit. Determine the proper angle to mount the clamp L-brackets to the clamp adapters based on the desired location for the Particle Separator. Make sure the ribs in the clamp L-brackets are properly seated inside the grooves of the clamp adapters. Do not attempt to rotate these parts once assembled. They are designed to lock into place once seated. Once you're satisfied with the position of the clamp L-brackets, apply threadlocker to the M8-1.25 x 25 screws, install the M8 washers, and tighten. Ensure that the L-brackets on both sides are pointed in the same direction and are aligned with each other.

Tools Required: 5mm hex key

Step 23

Adjust the position of the particle separator unit so that everything sits as desired. Then tighten all of the screws and nuts associated with the roll cage clamps assembly so that the particle separator is completely fixed and does not move or rotate around the roll cage when shaken.

Tools Required: 5mm hex key, 4mm hex key, 13mm socket

Step 24 A

Insert one end of the flexible duct (2) onto the top outlet of the S&B side cover. Do not install the hose clamp #72 (4) or flex duct end cuff yet (3). Bring the other end up towards the round clean air outlet of the Particle Separator to simulate the desired length of ducting. Note the amount of duct that needs to be cut. We recommend adding at least an extra inch to the length of the duct needed. The duct can always be cut shorter if desired. Remove the duct from the adapter and Particle Separator.

Step 24 B

Step 25 A

Pierce the flexible duct using a razor blade, centered between the two-wire reinforcements. Cut all the way around, keeping the blade centered between the wire reinforcements the entire length of the cut. Use a mini-bolt or a heavy duty wire cutter to cut through the wire and duct. Use a pair of scissors to finish the cut and to even out any jagged edges.

Tools Required: wire cutter, scissors

Step 25 B

Step 26

Insert each end of the flexible duct fully into each of the flex duct end cuffs provided. Place the #72 hose clamps around each flex duct end cuffs, making sure that they are seated in the grooves. Leave the hose clamps loose.

Step 27 A

Install one end of the flexible duct onto the S&B side cover and the other end of the flexible duct onto the plenum outlet on the particle separator unit. Tighten each Hose Clamp #72. Make sure the hose clamp is seated in the groove of the Flex Duct End Cuff and check to make sure the duct will not pull off either of the openings.

Tools Required: 5/16” nut driver or flat head screwdriver

Step 27 B

Step 28

Secure the flex duct to the roll cage using the provided velcro strap (17).

Step 29

Locate the ignition sensor (19) and remove the top clip piece.

Tools Required: Phillips screwdriver

Step 30

Install the ignition Sensor onto the positive ignition coil wire placing it about 1” away from the connector. Make sure that the top clip piece touches the bottom clip piece on the inside. Use Zip ties (5) on each side of the connector to ensure it does not slide up or down the wire during use.

Tools Required: Phillips screwdriver

Step 30 B

Step 31

Route the sensor harness towards the front of the vehicle, under the airbox and pass the connector through the opening above the frame on the right side. Use zip ties to secure the harness to the frame away from engine components.

Step 32

Remove the front in-dash tray by using a pry tool or screw driver to pop out both sides under the handles, then pull up and out.

Step 33

Connect the pulse connector on the main wiring harness (18) to one of the plug-ins in the dash.

Step 34

Remove both of the rear access panels by turning each of the 6 quarter-turn fasteners counterclockwise and pulling out.

Step 35 A

Remove cupholders, both front and rear if applicable, by simply pulling up and out. This will allow for easier wire harness routing.

Step 35 B

Step 36

For 4-seater applications, remove the back center console panel by simply pulling out and away

Step 37 A

Remove the 6 screws securing the front passenger side center console panel so you are able to pull the bottom forward, but not fully remove. Make sure to remove the ones next to the seat as well.

Step 37 B

Step 37 C

Step 38 A

Route the 2pin connector end of the main wiring harness through the hole in the dash down through to the passenger side and pull enough through to route the rest of the harness.

Step 38 B

Step 39 A

Pull the center console side panel out from the bottom and insert the connector underneath it as shown. You can grab a hold of it from the cupholder opening. Once it is through, push the rest of the harness into the center console under the panel as wel

Step 39 B

Step 40 A

For 4-seater, route the harness back through the center console and out where you removed the back seat panel.

Step 40 B

Step 41

Pull the harness to the back, routing it over the frame and sway bar.

Step 42

Locate the control board harness (20) and familiarize yourself with it using the picture for this step. One side will have a single 3 pin connector that connects to the Particle Separator fans. The other end has two connectors: one square 4 pin connector that connects to the ignition sensor, and one flat 2 pin connector that connects to the main power harness.

Step 43

Plug the square 4 pin connector on the control board harness into the connector on the ignition sensor and the 2 pin connector on the control board harness into the connector on the main wiring harness.

Step 44

You are free to route the 3 pin fan connector on the other side of the control board harness to the Particle Separator however it is most convenient for you, however, we prefer to run the wiring up through the wheel well, along the roll cage parallel to the flex duct. This keeps the wiring out of sight and prevents it from becoming tangled with anything.

Step 45

Once the harness has been plugged into the particle separator, collect the slack from the harnesses next to the airbox. Using zip ties, secure the slack from the harnesses to the vertical roll cage bar to the left of the airbox (toward the passenger side). Be sure that all parts of the harness are out of the way from any hot or moving components.

Step 46

Reconnect the negative terminal on the battery and replace all panels that were removed in the installation process. Reinstall both of the seats that were removed to complete installation. 

Step 47

You have now completed the installation for your new Particle Separator. To ensure that everything is installed correctly and there are no problems with any part of the electrical system, we need to run a test to verify the function of the whisper quiet fan technology system. 

Test the particle separator with these steps:

1. Turn the ignition to the key on position. The fans on the particle separator should be at 20% speed and should barely be audible.
2. Turn the ignition on. The fans should be at 50% speed and barely be audible over the engine idle noise.
3. Rev the engine to a constant 4000 rpm for 5 seconds and then take your foot off of the gas. The fans should build to and stay at max speed during the 5 seconds, and decelerate back to 50% speed 2 seconds after you let your foot off of the gas.

If your particle behaves as these tests describe, the installation is complete. If the separator does not act as described, please watch our electrical system troubleshooting video to determine the cause of the misbehavior.