Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Polaris General 1000 Cab Heater Installation Read all instructions before beginning installation.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Cab Heater Installation Preparation 1. Disconnect the negative battery cable from the battery and secure it away from the terminal. 2. Remove the driver and passenger side doors 3. Remove the front hood 4. Remove the windshield if present 5. Remove the bottom skid plate 6. Remove the center tunnel cover panel from the Passenger side footwell. 7. Remove Dash cover panel as shown in Figure 2.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 8. Use a flat head screw driver to pry up on the Dash Cover Panel until the clips release. Figure 3 Templates 9. Cut out the templates found in the back of this instruction manual. Use a tape measure to verify that the templates are printed at a 1:1 scale. Position the templates as shown in Figure 4, 5, 6 and tape them into place. Figure 4 866.527.7637 3 MotoInfo@motoalliance.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Figure 5 Figure 6 10. Mark the center of each hole and drill using the corresponding bit or hole saws. Remove any plastic burrs from the holes. 866.527.7637 4 MotoInfo@motoalliance.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 11. On each side of the Center Tunnel are dimples in the plastic. Refer to Figure 7 to locate the dimples. Use the 2’’ Hole Saw to drill a hole centered at each dimple. Remove any plastic burrs from the holes. Figure 7 12. Place the two 1’’ Rubber Grommets into the 1 ¼’’ holes drilled through Template #1. 866.527.7637 5 MotoInfo@motoalliance.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 13. Use the two 6mm Flat Head Caps Screws to attach the heater unit to the included mounting bracket as shown in Figure 8. Note the orientation of the copper hoses. Figure 8 14. Remove the two black rubber shipping plugs from the copper ports on the heater unit 15. Test fit the heater and bracket assembly into the four 5/16’’ holes drilled into the passenger footwell.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 17. Route hose from center tunnel to passenger wheel well as shown in Figure 10. Note: The hose should pass over the top of the frame rail and through the firewall via the inner 1 ¼’’ hole. Figure 10 18. Pull excess hose through to the passenger foot well. There should be approximately three feet of hose remaining in the rear wheel well as shown in Figure 9. 19.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Vents 21. Install two of the 2’’ Vents into the plastic dash removed earlier, See Figure 12. They will click into place when installed fully. Note: Do not press on the center portion of the vent as it will crack the louvers. Figure 12 22. Attach the 12’’ piece of compressed 2’’ Duct Hose to the driver side 2’’ Vent on the dash panel.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Switch and Wiring 26. Locate the 54’’ Three Conductor wiring harness and insert the Yellow, Red, and Orange wires into the Black Five Pin Connector as shown in Figure 14. NOTE: The Three Conductor Harness is installed into the top three terminal holes. If installed properly the terminal will snap into place. If the terminal does not snap into place flip it 180 degrees and try again. 27.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 31. Place the switch cover over the switch shaft. 32. Route the 48’’ Single Conductor Red wire to the auxiliary power mounting point behind the radiator. Follow the OEM wiring harnesses that leads through the weather sealed grommet as shown in Figure 16. Figure 16 33. Connect the Red 48’’ Wire to the auxillary power terminal shown in Figure 16. 34.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 36. Insert the Single Black Conductor wire in the orientation shown below in Figure 17 ensuring it snaps into position. Figure 17 Heater Mounting & Vent Attachment 37. Replace the top dash panel being sure to guide the 2’’ Duct Hoses toward the passenger footwell. 38.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 43. Identify and mark the coolant hose as shown in Figure 18. The section being removed is midway between the two bents portions of hose. Remove ¾’’-1’’ of material from the midsection of the formed hose. CAUTION: Ensure that the vehicle is cold before cutting into the coolant line. Wear eye protection and make the first cut toward the bottom of the hose to direct coolant downward. Figure 18 44.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 45. Secure the two ends of the 1’’ Aluminum Y using #16 hose clamps. 46. Position the 5/8’’ Coolant Hose so that it creates a smooth loop toward the 5/8’’ port on the 1’’ Aluminum Y. Refer to Figure 20. Cut the hose to length but do not attach it to the 5/8’’ Port on the 1’’ Aluminum Y. Figure 20 47. Secure the hose to the metal bracket as shown in Figure 20. 48.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 50. Install the hoses to the heater as shown in Figure 21. Secure using #10 hose clamps. Figure 21 51. Mark the middle of the flat portion of 1’’ OEM Coolant line at the bottom of the radiator as shown in Figure 22. Cut along the line and position the remaining 1’’ Aluminum Y so that the Y portion is facing the radiator as shown in Figure 22. Secure using #16 hose clamps.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 52. Cut the 5/8’’ Coolant Hose to length if needed. Do not attach it to the 1’’ Aluminum Y at this point. Figure 23 Coolant Attachment Note: The Cab Heater System has air trapped inside and will need to be removed to produce heat for the vehicle. The following steps are important to perform prior to the bleeding process. 53. Attach the Garden Hose Adapter to a garden hose. 54.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Figure 24 58. Fully turn on the garden hose and run water through the cab heater system for at least 1 minute. Empty the bucket as necessary. 59. Turn off the Garden Hose, remove the Garden Hose Adapter and allow any residual water to drain from the hoses. 60. Attach the 5/8’’ hoses to the 5/8’’ ports on the 1’’ Aluminum Y’s and secure using #10 hose clamps. 866.527.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Bleeding the Coolant System – Read entire section before proceeding IMPORTANT NOTE: Some amount of air will have made its way into the coolant system. The following bleeding procedure must be performed to eliminate the air and obtain heat. Note: The following procedure is most easily accomplished with the help of a partner. 1. Move the vehicle to an area where it can be run safely.
Firestorm Compact Underhood Polaris General 1000 HT_CU-405 23001 Industrial Blvd Rogers, MN 55374 866.527.7637 Troubleshooting Bleeding Procedure 9. If after performing the Coolant Bleeding procedure above the heater does not produce hot air (At fast idle & engine is hot), perform the procedure below. 10. Ensure that all coolant levels are filled to the manufacturers recommended levels before starting. 11. Start your SxS and run the engine at fast idle (3000-4000 RPM) until the engine is hot. 12.
Heater Mounting Template #1 0 1 2 3 4 Use a 5/16" Drill Bit Use the 1 1/4" Hole Saw Position against the Passenger side wheel well
Defrost Template #2 Use the 2" Hole Saw Driver's Side 0 1 2 Position on the Dash Cover Panel 3 4 Passenger's Side
Switch Mounting Template #3 Use a 7/16" Drill Bit Position the Switch Mounting Template to the left of the steering wheel.
