68
6. In a crisscross pattern, tighten the 6 mm cap screws
to 10 ft-lb.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.
Installing Engine/
Transmission
1. From the left side, place the engine into the frame
(rear of engine first) tilting the rear up to allow cylin-
der head to clear frame.
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 38 ft-lb.
3. Install the four cap screws securing the rear driveline
to the output drive 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 spark plug cap on the spark plug; then
install the throttle body into the intake boot and
tighten the intake clamp to 30 in.-lb.
FI695A
6. 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
7. Connect the engine ground cable to the starter
mounting flange and secure with a cap screw tight-
ened to 8 ft-lb.
8. From the top side, install the ECT sensor connector
(C), fuel injector connector (D), TMAP sensor con-
nector (E), ISC connector (F), and the TPS connector
(G).
FI522A
9. Place the air filter assembly into position and con-
nect the crankcase breather securing with the clamp,
then connect the air inlet boot to the throttle body
and secure with a hose clamp.
10. 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.
AT THIS POINT
After completing center crankcase components, pro-
ceed to Installing Right-Side Components, to Installing
Left-Side Components, and to Installing Top-Side Com-
ponents.
Summary of Contents for XC 450 2016
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