Install Instructions for 76-2018

Before You Start

• Please read the entire installation manual before proceeding.
• Ensure all components listed on the following section 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

  • T40 Torx
  • Panel Popper
  • 4 mm hex key
  • 5 mm hex key
  • Phillips Screwdriver
  • 5/16 Nut Driver
  • 10 mm socket
  • 13 mm socket

STEP 1

Remove the 4 screws securing the bed to the vehicle. Lift it up and out, twisting to get it around the vehicle’s side covers.


STEP 2

STEP 2


STEP 2 (IMAGE 2)

STEP 3

Release the back of the seats (rear if 4 seater) by pressing the release button near the headrest and pull the seats up and out.


STEP 4

Remove the remaining screws securing the rear driver side body panel to the vehicle from the inside of the vehicle.

Note: Some fasteners and snap-ins vary based on model year.

STEP 4 (IMAGE 2)

STEP 4 (IMAGE 3)

STEP 5

Pull the side panel assembly off of the vehicle.


STEP 6

Remove the rear panel panel behind the removed seats by turning the quarter turn fasteners.


STEP 7

Remove the two screws that secure the stock side cover to the frame.


STEP 7 (IMAGE 2)

STEP 8

Loosen the hose clamp securing the side cover tube to the intake box.


STEP 9

Remove the side cover and tube from the vehicle by pulling it out and twisting.


STEP 10

Install the bent bracket to the underside of the particle separator using the provided M6 bolts and washers, orienting the bracket with bend going up as pictured. Fully tighten the screws.


STEP 11

Install the L bracket with the holes that are closer together to the top of the particle separator using the provided M6 bolts and washers. Only hand tighten the screws.


STEP 12

Install the other L bracket to the side of the particle separator using the provided M6 screws and washers, hand tightening the screws.


STEP 13

Press the two straps onto the frame of the vehicle with plastic on the frame to prevent scratching. One strap goes just below the tab sticking out of the frame, and the other right above the weld on the lower end of the same tube.


STEP 14

Install the pivot bodies into the clamp straps with the M8 bolt, washers, and nut. Loosely orient them as pictured.


STEP 15

Fit the particle separator assembly into the area around the suspension going under the tail light, sliding the bent bracket between the frame and panel. Use the removed stock hex screw from step 7 to fasten the bent bracket to the same hole in the frame. Tighten it down slightly so the separator is free to move but not going to fall from the vehicle when you aren’t holding it up.


STEP 15 (IMAGE 2)

STEP 15 (IMAGE 3)

STEP 16

Loosely fasten the two L brackets to the pivot bodies with the shorter M8 screws after applying the supplied threadlocker. Hold up the separator on the outside with your leg or the help of a friend while fastening to the pivot bodies. This makes the particle separator level and helps position the clamps and pivot bodies.


STEP 16 (IMAGE 2)

STEP 17

Fully tighten the hex screw at the stock location.


STEP 18

While pushing up on the particle separator on the outside to correctly align it, fully tighten down the pivot bodies and L brackets. They should be at the pictured locations and the separator should be firmly in place after this step with none of the brackets able to move.

HAVING A LEVEL PARTICLE SEPARATOR IS IMPORTANT FOR ITS EFFICIENCY.

STEP 18 (IMAGE 2)

STEP 18 (IMAGE 3)

STEP 19

Put the two couplers on the tube along with the hose clamps. The side connecting to the particle separator has an indicator line. Push this coupler completely over the tube to make installation easier while installing the other coupler up to the bead.


STEP 20

Connect the end of the tube going to the air box first.


STEP 21

Slide the coupler fully pushed onto the tube to connect it to the outlet of the particle separator. Twist the tube to align the indicators.


STEP 22

Fully tighten the 4 hose clamps on the tube.


STEP 23

Begin the wire harness installation by opening the center console in the dash and removing the tray by pulling up and out.


STEP 24

Route the connector end of the main power harness through the hole in the dash down to the passenger side foot area, pulling enough to route it to the rear of the vehicle.


STEP 24 (IMAGE 2)

STEP 25

Remove all of the screws at the bottom of the center console on the passenger side. Moving the passenger seat can help get the screws in between the center console and the seat.


STEP 25 (IMAGE 2)

STEP 26

Remove all of the screws and rivets at the bottom of the center console on the passenger side of the rear for 4 seater applications.


STEP 27

Flip the bottoms of the seats over to remove all of the screws securing the panel under the seats and remove the panel.


STEP 28

You can tuck the wire in at the front passenger foot area while leaving the connector end free near this hole.


STEP 29

Use the shown area to pass the connector through the frame, while lifting the center console. Route and zip tie the wire underneath the frame as shown, and tuck the wire under the rear center console if applicable.


STEP 29 (IMAGE 2)

STEP 29 (IMAGE 3)

STEP 30

Next, locate the ignition sensor harness and remove the gold screw.


STEP 31

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 on each side of the connector to ensure it does not slide up or down the wire during use.


STEP 31 (IMAGE 2)

STEP 32

Route the connector end of the ignition sensor harness underneath the airbox and zip tie it to the bar on the other side as shown.


STEP 33

Locate the Y connector harness and familiarize yourself with it using the picture for this step. One side will have a single connector that connects to the scavenge fan from the PS. The other end has two connectors: one square 4 pin connector that connects to the ignition sensor, and one flat 3 pin connector that connects to the main power harness.


STEP 34

Connect the single 3 pin connector on the single connector end of the Y harness into the connector from the scavenge fan coming from the main Particle Separator unit. It should go over the tube.


STEP 35

Plug the square 4 pin connector on the Y harness into the connector on the ignition sensor that you pulled through the frame earlier.


STEP 36

Connect the main power harness to the remaining connector on the y splitter harness.


STEP 37

Plug the main power harness into the pulse bar in the dash.


STEP 38

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

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 3000 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.

STEP 39

Ensure the wires are taught and not hanging loosely anywhere, bundling and zip tying the wires to the frame as pictured.


STEP 40

Reinstall the panels underneath the seats.


STEP 41

Reinstall the back panel.


STEP 42

Fasten the bottom of the center console in the front and rear if applicable.


STEP 42 (IMAGE 2)

STEP 42 (IMAGE 3)

STEP 43

Reinstall the rear driver side pane by putting in the area near the door first and then fastening the screws/rivets.


STEP 43 (IMAGE 2)

STEP 44

Reinstall the bed by putting the back prongs into place and then fastening the screws.


STEP 45

Reinstall the seat backs by clipping them in with the bottom prongs in their respective holes.


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.