3-48
FI530B
FI537
5. Install the exhaust pipe using a new seal at the cyl-
inder 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 Section 4); 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 connec-
tor (C), fuel injector connector (D), MAP sensor
connector (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
duct to the air filter housing and the throttle body
and secure with the clamps.
13. Install the storage compartment and connect the
negative battery cable; then install the tool tray.
14. Pour the specified amount of coolant into the radi-
ator 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.
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