Install Instructions for 76-2003

Before You Start

• Please read the entire installation manual before proceeding.

• Ensure all components listed on page 10 are present.

• If you are missing any of the components, call our customer support at (909) 947-0015.

• Do not work on the vehicle while the engine is hot.

• Make sure the engine is turned off, the vehicle is in Park and the Parking Brake is set.

Required Tools

  • 2.5mm, 4mm, 5mm Hex Key
  • 7mm, 10mm Wrench/Socket
  • 5/16 Nut Driver
  • T30 Torx
  • Wire Stripper
  • Phillips Screwdriver, Flat Blade Screwdriver, Razor Blade, and Wire Cutters

THREAD LOCKER USE

We have provided a small tube of thread locker in your kit. Whenever you see the symbol above on a step of the instructions, apply 1 small drop of the thread locker to the threads of the screws or bolts. This will keep your hardware from vibrating loose during rough driving. If the hardware ever needs to be removed, do so slowly to avoid having the inserts strip out from the plastic.


STEP 1

Use a T30 Torx and 10mm wrench to remove the six screws and lock nuts. Remove the rear rack and set it aside.


STEP 2

First, remove the three plastic rivets using a flat blade screwdriver or a push rivet removal tool. Remove the stock intake cover.


STEP 3

Use a T30 Torx to remove the two screws securing the bracket beneath the rear passenger side fender.


STEP 4

Use a screwdriver or a 7mm socket to loosen the hose clamp at the air intake and remove the tube assembly.


STEP 5

Install the Mounting Bracket (Q) onto the side of the Air Tube (N) using a 4mm Hex Key with the supplied Screw (D) and Washer (E).


STEP 6

Install the Silicone Coupler (M) and two Hose Clamp #36 (L) onto the stock airbox inlet. Due to the tight space make sure that the hose clamps are positioned in a way that you can reach and tighten the hose clamp easily. Tighten the hose clamp at the air inlet side first using a flat head screwdriver or a 5/16 socket. Leave the other hose clamp loose.


STEP 7

Insert the Air Tube (N) into the Coupler (M).


STEP 8

Align the Mounting Bracket (Q) with the holes on the side fender and secure the bracket with the supplied Screw (D) and Washer (E) using a 4mm Hex Key. Pinch the two Plastic Rivet (Y) and Washer (Z) together to plug up the hole that was not used.


STEP 9

Tighten Hose Clamp #36 (L). using a flat head screwdriver or a 5/16 socket.


STEP 10

Determine where on the roll cage you want to mount the Particle Separator (F). Make sure you have enough room to fit the clamps and particle separator on the roll cage without any interference. Planning ahead will save you time and frustration during the install. Our clamps are adaptable enough to work around any additional accessories you may have on the roll cage in addition to the particle separator.


STEP 10 (IMAGE 2)

STEP (IMAGE 3)

STEP 11

At the mounting locations determined previously, install the Strap (A) onto the roll cage. Loosely wrapping some plastic around the roll cage will help to slide the strap onto the roll cage easier and prevent scratches.


STEP 12

Install the Pivot Body (H) onto the Strap (A) with the supplied Screw (B), Washer (E), Locknut (G) on the roll cage. Do this for both sides. Do not fully tighten the screws and locknuts. Leave the strap loose.


STEP 13 ūüíß

Install the Adapter (K) on the mounting bosses of the Particle Separator (F) with the supplied Screw (D) and Washer (E). Tighten these screws using a 4mm Hex Key. Install the spacers provided if installed on the top utmost bar on the cage. Note: Mounting on the top bar will require the use of the supplied Spacers (W), Screws (X), and Washer (E).


STEP 14 ūüíß

When installing the L Bracket (J), make sure the ribs in the L Bracket are properly seated inside the grooves of the Adapter (K). Any misalignment will damage these parts. Do not attempt to rotate these parts once assembled. They are designed to lock into place once seated. Determine the proper angle to mount the L Bracket to the adapter based on the desired location for the Particle Separator (F). Make sure the L Bracket is properly seated on the adapter before tightening it in place with the Screw (I) and Washer (C) using a 5mm Hex Key. Do not tighten the hardware if these parts are not seated properly or damage may result. Repeat for the other side of the Particle Separator and make sure the L Bracket on both sides are pointed in the same direction and are aligned with each other.


STEP 14 (IMAGE 2) ūüíß

STEP 14 (IMAGE 3) ūüíß

STEP 15 ūüíß

Install the L Bracket (J) onto the Pivot Body (H) using Screw (I) and Washer (C). Use a 5mm Hex Key to tightening the screw. You may have to adjust the position of the Strap (A) and pivot body to get the holes to line up. Do this for both sides. Having an extra pair of hands holding the Particle Separator (F) to help line up the holes will make the install easier.


STEP 15 (IMAGE 2) ūüíß

STEP 16

Once you are satisfied with the position, tighten the Screw (B), Washer (E), and Locknut (G) at the Strap (O) with a 4mm Hex Key and 10mm wrench. Do this for both sides.


STEP 17

Go over all the screws and locknuts again to make sure they are secure and that the Particle Separator (F) is firmly attached to the roll cage.


STEP 18

Insert one end of the Duct (P) onto the Air Tube (N). Bring the other end towards the opening on the Particle Separator (F). Note the length on the duct you want to cut. We recommend cutting the duct an extra 3" longer so that the ends, along with any wire and strings, can be folded in for a cleaner look.


STEP 19

Pierce the Duct (P) centered between the two-wire reinforcements using a razor blade to cut the duct to length. Cut all the way around. Try to cut the duct straight around the center as close as possible.


STEP 20

Use scissors to begin the cut. Aim the scissors towards the start of the cut. Do not try to cut through the wire with scissors. Use a mini-bolt or a heavy-duty wire cutter to finish the cutting through the wire and strings.


STEP 21

(Optional) Regular staples can be used to secure the ends of the strings to the duct.


STEP 22

Place the provided Hose Clamp #56 (O) on both ends of the Duct (P).


STEP 23

Use a little oil or silicone lubricant around the inlet of the Air Tube (N). This will help slide the Duct (P) onto the tube easier.


STEP 24

(Optional) For a cleaner appearance, take the end of the wire and tuck it inside the duct. Do this for both ends of the duct if needed.


STEP 25

Install the Duct (P) onto the Air Tube (N). Tighten Hose Clamp #56 (O) with a flat head screwdriver or a 5/16 socket.


STEP 26

Install the Duct (P) onto the plenum on the Particle Separator (F). Tighten Hose Clamp #56 (O) with a flat head screwdriver or a 5/16 socket.


STEP 27

Look underneath the rear passenger side seat and remove the battery cover. Lift up to unseat the four prongs.


STEP 28

Remove the screws holding the factory positive and negative battery terminals with a screwdriver.


STEP 29

Familiarize yourself with the Wire Harness (T) and each of the connectors. Coming from the relay should be a pigtail, fan connector, and ring terminals. Pig Tail Wire is used in conjunction with the Posi-Tap (U) to tap into a power source. Ring Terminals has the fuse holder with the red and black ring terminals for the battery. Fan Connector has the connector to power the Particle Separator (F).


STEP 29 (IMAGE 2)

STEP 30

Grab the Ring Terminals, from the Wire Harness (T).


STEP 31

Feed the Ring Terminals with the fuse holder and relay down behind the rear passenger side seat to the battery compartment. If the relay or fuse holder snags on something try to get it loose through the gap between the seat cushions.


STEP 31 (IMAGE 2)

STEP 31 (IMAGE 3)

STEP 32

Install the ring terminals onto the battery terminal clamps. Red wire with the fuse holder to (+) and Black wire to (-) and reinstall the screws using a screwdriver that was removed in Step 34. Secure the positive terminal first and then secure the negative terminal. Use Cable Tie (R) to tuck any excess wires and the relay around the battery compartment.


STEP 33

Reinstall the battery cover. Press down on the battery cover to fully seat the prongs on the grommet.


STEP 34

Find the Pig Tail and strip about 3/8” off the end of the wire using a wire stripper.


STEP 35

Feed Wire B down the roll cage in between the tubing and fender. You should see the wire come out through the gap on the bottom by the wire loom.


STEP 35 (IMAGE 2)

STEP 36

Split open the wire loom. Look for the orange/green wire.


STEP 37

Use the supplied Posi-Tap (U) and unscrew the large top cap. Place the cap in between the orange/green wire.


STEP 38

Screw the body around the cap until it is firmly tight.


STEP 39

Unscrew the bottom cap on the Posi-Tap (U) and insert the Wire B through it.


STEP 40

Insert the bottom cap and wire back into the Posi-Tap (U) making sure the strands go around the metalcore. While holding the wire in place, screw the bottom cap back on until it is firmly tight. Double-check both caps to make sure they are tight.


STEP 41

Route the Fan Connector, from the Wire Harness (T) up the roll cage. and connect the harness into the fan connector on the Particle Separator (A). Make sure not to cross the connectors. Power to power and ground (black) to ground (black). Note the color of the wires whenever connecting or disconnecting this connector. The connector should snap into each other with very little resistance. Do not try to force the connectors into each other.


STEP 41 (IMAGE 2)

STEP 42

Using the supplied Cable Ties (R) or Velcro (S) to secure the Wire Harness (T) and Duct (P) to the roll cage.


STEP 43

Cable Tie (R) together with any excess wires from the Wire Harness (T) and effectively secure the harness away from any exhaust components or moving parts that could potentially damage the harness.


STEP 43 (IMAGE 2)

STEP 44

Reinstall the rear cargo rack with the six factory screws and lock nuts using a T30 Torx and 10mm wrench.


STEP 45

Make sure the connectors are all plugged in and secure. Turn the ignition on and make sure air is blowing out the exhaust. If air is not blowing out, double check your electrical connections. When you turn the ignition off, the fan will stay on for several seconds and is normal. Your installation is now complete.


Side Note

S&B recommends that you apply a layer of waterproof grease, such as made by Bel-Ray or Super Lube, on the inside flange of the stock air filter to keep dust from bypassing the seal.


Ongoing Maintenance

Your Particle Separator requires very little if any maintenance depending on where you drive; however, you should check to make sure that none of the openings in front of the Particle Separators are blocked by mud or other debris each time you exit the UTV. You should also make sure the scavenge fan is operating properly. To do so, simply check to make sure the fan is still blowing out air (for about 15-20 seconds) when you turn off your UTV as this is a normal condition. If the fan is not blowing out air or the airflow seems lower than when you initially installed your system, please contact S&B tech support. To clean your Particle Separator, review the cleaning instructions below.