ENGINE
Engine Installation
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 15-9
15
ENGINE INSTALLATION
See General Warning on page 1-1.
1. Place engine onto engine mounting plate and tighten the mounting hardware (1, 2 and 5) to 13 ft-lb (17.7
N·m). Tighten nuts (6) to 17 ft-lb (23.1 N·m)
(Figure 15-4, Page 15-4)
.
2. Install drive clutch.
See Drive Clutch Installation, Section 20, Page 20-12.
3. Install drive belt.
See Drive Belt Installation, Section 20, Page 20-3.
4. Install muffler.
See Muffler Installation, Section 17, Page 17-1.
5. Install starter/generator and belt.
See Starter/Generator Installation, Section 13, Page 13-9.
6. Install the powertrain.
See Unitized Transaxle Installation, Section 18, Page 18-13.
7. Install oil drain plug in the crankcase and tighten to 20 ft-lb (27.1 N·m). Apply a light film of oil on the seal
of a new oil filter and install the filter on the crankcase. Fill the crankcase to the proper level with the cor-
rect type of oil. This engine should be regarded as a new engine for next scheduled oil change.
See
Section 10 – Periodic Maintenance.
8. Check all hardware for proper torque/tightness.
9. Check engine oil level
(Figure 15-12, Page 15-9)
.
9.1. With vehicle on level surface, remove dip stick and clean with cloth
(Figure 15-12, Page 15-9)
.
9.2. Reinsert dip stick until fully seated.
9.3. Oil must be in the SAFE LEVEL range.
ý
CAUTION
• Do not overfill with oil.
10. Install a new or cleaned spark plug, gapped to 0.027-0.031 inch (0.686-0.787 mm), and connect plug
wire to plug.
11. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m).
See Figure 1-1, Page 1-3.
Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to
minimize corrosion.
12. Adjust the engine RPM setting.
See Engine RPM Adjustment on page 16-12.
13. Test-drive vehicle to ensure all systems are functional and correctly adjusted.
Figure 15-12 Check Engine Oil Level
1
2
Low
Level
Safe
Level
3
Full
Level
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