A Different Pre-filter Approach

I bought my RZR w/60 hrs on it, found a plugged paper filter and
decided to go with a K&N filter w/outer wear and am pretty
confident that with grease and a fit tightening hose clamp on the
throttle body inlet that it's as good as you can get without subjecting
it to abnormal conditions (which we sometimes do). And, again, this
doesn't eliminate dirt, water and mud from getting into the filter
intake.

I believe the main advantage to a snorkel is that it gets the intake
above the bed. Not necessarily that a higher elevation matters but that
the environment under the bed can't leak around the intake tubes,
airbox base and engine access cover that, in turn, allow dirt to enter
the filter can. I've chosen to work with what I have to remedy the
problem.

I've made a simple rubber gasket to seal the intake tubes, airbox and
engine access cover from the under-bed environment. Additionally, I've
made a cheap, serviceable pre-filter for the main and a(new) secondary
airbox inlet.

I'll admit my approach is not as sexy as snorkels, relocated airboxes
and replacement filter cans but I think it will work. Won't be sure
until all the snow goes away.


I used the intake cover base as a template on a sheet of 1/16"
reinforced rubber to lay out the intake tubes(cut inside the lines to
make a tight seal). I left 1-1/2" on the bed side and about 4" on the
seat side to cover the access door interface with the bed. You can see
a velcro strip was used to secure the overlap.

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Next I added 1/8"x1-1/2"x12" flat stock for the intake cover rear seal.

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Front View of the installed intake cover

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Rear View of the installed intake cover

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Here are the parts for my Pre-filter. Clockwise they are a hand formed
wire basket for the discharge, the top 1-1/4" of a Rubbermaid 3-2/3 cup
dish, three 6" pieces of Scotch-Brite pads, wire inlet screen and the
dish cover w/ center removed.

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Using the dish top as a template I located my Pre-filter opening within
the sealed area of the intake cover and made the cutout initially with
a hole saw and finished with a saber saw.

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After riveting the Pre-filter body in place, I added the discharge basket.

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Then I assembled the Scotch-Brite filter media, the wire screen and the cover.

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Here is the bed installed over the intake cover.

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Next I used a 3" section of 9" Scotch-Brite (folded) for the main air inlet Pre-filter.

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I pinned this media to the bed with binder staples.

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Here's the finished prototype. We'll see how it works.

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Finzup,
Good post! I know I can use this info.
Thanks.
Jim

cool

Good job

looks like that will work.

what year is your rzr??

bush wrote:

looks like that will work.

what year is your rzr??

'08. Bought it last July. I appreciate the responses. Let me know if I've missed something other than difficulty in high water crossing.

do you have the new flex boot on the intake?

Finzup, don't worry about any high water crossings in west,va.....their ain't none.

bush wrote:

do you have the new flex boot on the intake?

I guess not. Should I?

bubba53 wrote:

Finzup, don't worry about any high water crossings in west,va.....their ain't none.

How 'bout deep mud hole crossing?

Finzup wrote:

bush wrote:

do you have the new flex boot on the intake?

I guess not. Should I?

yes.

the 08 did not come with the flex boot on the intake. that is where the dirt gets in from most of the time,the new boot flexes with the motor and is less likely to come off. polaris recalled the intake and you should be able to get the new boot.

finzup dag gone it, forgot about them mud holes.

bush wrote:

Finzup wrote:

bush wrote:

do you have the new flex boot on the intake?

I guess not. Should I?

yes.

the 08 did not come with the flex boot on the intake. that is where the dirt gets in from most of the time,the new boot flexes with the motor and is less likely to come off. polaris recalled the intake and you should be able to get the new boot.

I didn't add it, but there is a flexible connection between the filter and throttle body. If this was a solid joint before, it has been replaced. Thanks for asking. I appreciate any help coming up the RZR learning curve.

You have to pay for the flex boot, Polaris did not replace my free of charge even after I had the topend redone. I have a similar intake location, I bought my prefilter from Holtz with outerwear material on it. I got the idea from GETERDUN.

Bubba, you forget about the mud holes because you always go around them!!!!!! This is a well known fact!!!

3012red, I guess you never watched the soggy bottom video.

I'll have to look at it!!!!