84
2. With engine moved rearward, engage the splines of
the front driveline into the front output drive yoke;
then move into position and install the two
through-bolts. Secure with lock nuts and tighten to
35 ft-lb.
3. Install the four cap screws (coated with red Loctite
#271) securing the output shaft to the rear gear case
flange and tighten to 20 ft-lb.
4. Connect coolant hoses (A) and (B) to the water pump
and connect the upper coolant hose to the thermostat
housing. Tighten all clamps securely.
FI530B
FI537
5. Install the exhaust pipe using a new seal at the cylin-
der head and loosely install the retaining cap screws;
then install the muffler with a new grafoil seal and
secure with two springs. Tighten the exhaust pipe
retainer cap screws to 20 ft-lb.
6. Connect the throttle cable and adjust free-play to
specifications (see Fuel/Lubrication/Cooling); then
tighten the jam-nut securely and install the cover.
Tighten the screws securely.
7. Connect the stator connector (H) and crankshaft
position sensor connector (I) to the main harness;
then connect the positive cable to the starter motor
and tighten securely.
FI534A
8. Connect the engine ground wire to the starter mount-
ing flange and secure with a cap screw tightened to 8
ft-lb.
9. From the top side, install the ECT sensor connector
(C), fuel injector connector (D), MAP/IAT sensor
connector (E), ISC connector (F), and the TPS con-
nector (G).
FI522A
10. Place the air filter assembly into position and con-
nect the crankcase breather securing with the clamp;
then connect the front air inlet duct and secure with a
hose clamp.
11. Install the harness connector onto the coil and install
the spark plug cap.
12. Connect the air ducts to the CVT housing and tighten
the clamps securely; then connect the air duct to the
air filter housing and the throttle body and secure
with the clamps.
13. Install the storage compartment and connect the neg-
ative battery cable; then install the tool tray.
14. Pour the specified amount of coolant into the radiator
and the specified amount and grade of oil into the
engine.
15. Install the left footwell support assembly, footwell,
and footrest. Tighten all fasteners securely.
16. Install the seat making sure it locks securely in place;
then start the engine and allow to warm up while
checking for leaks.
17. Shut engine off and inspect coolant and oil levels.
Add fluids as required.
