63
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 sec-
tion); 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 cable to the starter
mounting flange and secure with a cap screw tight-
ened to 8 ft-lb.
9. From the top side, install the ECT sensor connector
(C), fuel injector connector (D), MAP sensor connec-
tor (E), ISC connector (F), and the TPS connector (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 inlet tube to
the throttle body and secure with the clamps.
13. Install the gas tank (see Fuel/Lubrication/Cooling
section) and connect the negative 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.
Manual
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