Polaris GENERAL 2016 Service Manual page 117

11. Install the two longer bolts into left side mounting
holes. Torque left side mounting bolts to specification
using the numbered sequence shown.
12. Torque right side mounting bolts to specification using
the numbered sequence shown.
TORQUE
Engine / Transmission Mounting Bolts:
Step 1-2: 64 lb-ft (87 Nm)
Step 3: 5 lb-ft (7 Nm)
Step 4-7: 44 lb-ft (60 Nm)
13. Remove the clutch center distance tool.
14. Torque the four front engine mount fasteners to
specification.
TORQUE
Front Engine Mount Fasteners:
40 lb-ft (54 Nm)
15. Remove the lifting straps and overhead or portable
engine hoist.
16. Install the two coolant hoses onto the engine.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM
17. Install the exhaust heat shield and push rivets.
18. Replace exhaust gaskets (seals). Install exhaust
head pipe. Install the six fasteners that attach the
exhaust head pipe to the engine and torque to
specification.
TORQUE
Exhaust Head Pipe Bolts:
18 lb-ft (24 Nm)
19. Install the two exhaust spring fasteners that attach
the head pipe to the muffler.
20. Install the breather hose to the crankcase.
21. Install the spark plug wires to the appropriate cylinder
by referencing the MAG and PTO spark plug wire
decals.
NOTICE
Ensure plug wires caps are pushed down all the way so
they engage onto the spark plugs.
22. Install the throttle body assembly and connect fuel
lines. Install throttle cable retaining clip.
23. Secure wire harness in the routing clip on the rear
cross member.
24. Install (+) positive cable to the starter motor.
25. Install (-) negative cable to the starter motor mounting
bolt.
26. Properly route and connect the harness leads for the
stator, CPS, T-MAP sensor, ECT sensor, fuel injectors
and ignition coil.
27. Install the air box assembly. Refer to "Intake
Installation"page 3.86 procedure.
28. Install the inner clutch cover, drive clutch, driven
clutch, drive belt, outer clutch cover and clutch outlet
duct. Refer to "PVT Assembly"page 5.13 procedure.
29. Install the rear cargo box as an assembly. Refer to
"Cargo Box Installation"page 10.43 procedure.
NOTICE
Be sure to connect the engine intake hose and clutch
air intake hose to the rear cargo box asm upon
installation.
30. Connect the (-) negative battery cable.
31. Remove the pressure cap and fill the cooling system
through the filler neck with properly mixed anti-freeze
/ coolant.
3
3.31