Polaris RANGER 500 2018 Service Manual page 95

14. Install the throttle body and air box. Tighten the hose
clamps that secure the throttle body to the intake
duct, intake boot and air box.
15. Install the lower stater motor bolt through the lower
starter motor mounting boss.
16. Instal the starter motor onto the engine.
17. Install the starter motor and battery cables as
outlined in the Electrical Chapter.
TORQUE
Starter Motor Fastener:
3 ft-lbs (4 Nm)
18. Connect the harness leads to the ETC (Item 8) and
T-MAP sensor (Item 9). Verify routing is correct.
19. Connect the fuel injector harness lead to the fuel
injector.
20. Connect the fuel line to the fuel rail.
21. Connect the ignition coil harness connector and
install the spark plug wire.
22. Install the CPS and mounting bolt into the stator
cover and torque to specification.
TORQUE
CPS Fastener:
9 ft-lbs (12 Nm)
23. Connect the stator wire connector and install a new
tie strap to secure the wiring to the front engine
mount bracket.
24. Install the inner clutch cover (See PVT System
chapter).
25. Install the drive clutch, driven clutch, belt and outer
clutch cover as outlined in the PVT System chapter.
Be sure all hose and wire routing is correct. Torque
all fasteners to specification as outlined in the PVT
System chapter.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM
26. Install the intake baffle assembly. Secure the 3
clamps that attach the assembly to the crankcase
vent, air box lid and inner clutch cover.
27. Install the rear bumper and cargo box assembly (See
Body / Frame chapter).
28. Install the left-hand rear wheel and torque wheel nuts
to specification.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)
Aluminum Wheel Nuts:
30 ft-lbs + 90º (41 Nm + 90º)
29. Remove the pressure cap and fill the cooling system
through the filler neck with properly mixed anti-freeze
/ coolant.
30. If the engine oil was completely drained, add
approximately 2 quarts (1.9 L) of Polaris PS-4
Synthetic Engine Oil into the crankcase.
31. Install a new oil filter. Lubricate the seal with engine
oil prior to installation (see Maintenance chapter).
32. Connect the (-) negative battery cable to the battery.
33. Install the engine service panel and seats.
34. Follow the "Cooling System Bleeding Procedure" as
outlined in this chapter.
35. Start engine and check for any oil or coolant leaks.
36. Check the engine oil level (see Maintenance
chapter).
37. Refer customer to "Engine Break-In Period" upon
returning vehicle to customer.
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