This installation requires the use of a powered electrical busbar found underneath the hood of the vehicle. The provided Wire Harness (J) 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.

Based on the room you have available, and accommodating for other accessories, determine where you want to mount the Particle Separator Assembly (A) to your roll cage. 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 installation. In these instructions, the Particle Separator Assembly (A) will be installed on the lower horizontal bar, highlighted in red.

Once the mounting location has been determined, install both Straps (O, HP1392-01) onto the roll cage. Loosely wrapping some plastic around the roll cage will help with sliding the straps onto the roll cage and prevent scratches.

Install the Pivot Body (N, HP1392-01) onto the Strap (O) with the supplied M8 Screw (S, HP1390-01), M8 Locknut (T, HP1390-01), and M8 Washers (Q, HP1390-01). Do this for both Straps (O). DO NOT tighten the M8 Screws (S) and M8 Locknuts (T), leave this connection hand-tight for now.

Using a 4mm hex key, Install the Adapter (L, HP1392-01) onto the mounting bosses of the Particle Separator (A) with the supplied M6 Screws (P, HP1390-01) and M6 Washers (U, HP1390-01). Fully tighten these screws. Repeat this step on the other side of the Particle Separator Assembly (A).

Determine the proper angle to mount the L-Bracket (M) based on the desired location for the Particle Separator (A). Once decided, using a 5mm hex key, secure the L-Bracket (M, HP1392-01) to the Adapter (F) with the supplied M8 Screw (R, HP1390-01) and M8 Washer (Q, HP1390-01).

Before tightening the M8 Screw (R), make sure the L Bracket is properly seated in the adapter. If the ribs in the L-Bracket (M) are not properly seated inside the grooves of the Adapter (F) damage to these parts may occur. Do not attempt to rotate these parts once assembled, they are designed to lock into place once the M8 Screw (R) is tightened down.

Repeat this step on the other side of the Particle Separator Assembly (A). Double-check that both L-Brackets (M) are pointed in the same direction and are aligned with each other.

Using a 5mm hex key, install the Particle Separator Assembly (A) onto the roll cage by securing the L-Bracket (M) to the Pivot Body (N) using an M8 Screw (R, HP1390-01) and M8 Washer (Q, HP1390-01). Repeat this step for the other side of the Particle Separator Assembly (A). Having an extra pair of hands to hold the Particle Separator Assembly (A) to help line up the holes will make this step much easier.

Once you are satisfied with the position of the Particle Separator Assembly (A), using a 4mm hex key and a 1/2" wrench/socket, fully tighten the M8 Screw (S), M8 Locknut (T), and M8 Washers (D) to lock the Strap (O) into place on the roll cage. Repeat this step for the other clamp assembly.

Double-check that all screws and locknuts are fully tightened down and that the Particle Separator Assembly (A) is firmly attached to the roll cage.

To remove the passenger side Frogzskin cover, use a T40 Torx screwdriver to remove the two screws securing the cover to the vehicle. Once the two screws are removed the cover can be taken off by pulling up and out.

Place a #56 Hose Clamp (G, HP1359-00) over the stock airbox inlet, insert the smaller end of the Duct Adapter (F, HP1359-00) into the stock airbox inlet, then tighten the hose clamp with a 5/16” nut driver to secure the Duct Adapter (F) to the stock airbox inlet.

Insert one end of the Flexible Duct (E) onto the Duct Adapter (F). Bring the other end towards the outlet of the Particle Separator Assembly (A). If you have any excess length of the Flexible Duct (E), make a mark of where you need to cut. Provide enough length of Flexible Duct (E) so that it can easily reach from the outlet of the Particle Separator Assembly (A) to the stock airbox inlet without it becoming taught.

Using a razor blade, pierce the Flexible Duct (E). We suggest making the pierce equidistant between the wire reinforcement. While keeping the razor blade centered between the wire reinforcement, begin making your cut and continue until you complete one loop around the Flexible Duct (E).

Once your razor blade cut has looped around the Flexible Duct (E) one complete rotation, use scissors or a razor blade to cut inward towards the wire reinforcement. Do not try to cut through the wire with scissors or a razor blade, use a mini-bolt cutter or a heavy-duty wire cutter to finish cutting through the wire reinforcement.

Install End Cuffs (V, HP1359-00) and #56 Hose Clamps (G, HP1359-00) onto both ends of the Flexible Duct (E).

Install the End Cuff (V) and Flexible Duct (E) onto the Duct Adapter (F), then tighten the #56 Hose Clamp (G) with a 5/16” nut driver.

Insert the other end of the Flexible Duct (E) onto the outlet of the Particle Separator Assembly (A), then tighten the #56 Hose Clamp (G) with a 5/16” nut driver.

Install the Side Cover (B) onto the vehicle by inserting the mounting tab into the body panel (towards the rear of the vehicle), followed by maneuvering/rotating the Side Cover (B) into the correct position. Using a 4mm hex key, secure the front side of the Side Cover (B) to the vehicle with a supplied M6 Screw (C, HP1363-00) and M6 Washer (D, HP1363-00). Then, using a T40 Torx screwdriver, secure the rear side of the Side Cover with one of the stock screws removed in Step 9.

Use the provided Velcro Strap (H, HP1359-00) to secure the Flexible Duct (E) to the roll cage.

Familiarize yourself with the Wire Harness (J, HP1394-01) and each of the components. The Wire Harness (J) contains an electrical relay, a fan connector, and a set of three-ring terminals. In the coming steps the set of ring terminals will be attached to the vehicle’s electrical busbar and the fan connector will connect to the scavenge fan in the Particle Separator Assembly (A).

Remove the vehicle’s hood by rotating the locking tabs then pulling the hood towards the front of the vehicle.

Using a 3/8” long socket, remove the three lock nuts from the vehicle’s electrical busbar, then attach the set of three-ring terminals, from the Wire Harness (J) to the matching busbar posts. Once the ring terminals have been placed on the correct busbar posts, reinstall the three locknuts to the busbar posts.

Run the fan connector through the rubber grommet to the inside of the vehicle. This wire will be coming through the wall behind the dash. Pull the entire length of the fan connector wiring through the grommet, this length of wire will be needed to reach the scavenge fan in the Particle Separator Assembly (A).

You are free to route the fan connector to the Particle Separator Assembly (A) however it is most convenient for you, however, we prefer to first run the wiring down the driver side wall, then to the back of the vehicle inside the driver side body panels (path shown in the image). This keeps the wiring out of sight and prevents it from becoming tangled with anything. By removing a few screws and/or plastic rivets around the door frame (shown in Image 2 and Image 3), the body panels can be opened up enough to run your wiring inside them.

Whichever direction you choose, complete the routing of the fan connector wiring all of the way to the Particle Separator Assembly (A) before proceeding to Step 24.

The plastic rivets can be removed with a flat-head screwdriver, or panel popper, by unseating the locking tab then prying the entire rivet from the body panel.

The screws can be removed with a T40 Torx Screwdriver.

Once you have finalized the path of the fan connector wiring to the Particle Separator Assembly (A), connect the fan connector to the scavenge fan.

Secure any excess wiring from the fan connector to the roll cage with Cable Ties (I, HP1394-01) or excess Velcro Strap (H), then go back to the hood compartment and secure the relay and excess wiring to the frame of the vehicle with supplied Cable Ties (I).

Reinstall the hood onto the vehicle. Slide the hood towards the back of the vehicle, then rotate the tabs to lock the hood into place.

Double-check that all connectors are plugged in and secure. Turn the ignition on and make sure air begins blowing out of the exhaust of the Particle Separator Assembly (A). 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!