Let’s be honest. That biting wind on a crisp autumn trail or the deep chill of a winter ride can cut an adventure short. You bought your Polaris General to explore, not to sit in the garage for half the year. Your fingers go numb, your windshield fogs up, and suddenly, heading back to the truck sounds a lot better than pushing on to that scenic overlook.
A heater isn’t just a creature comfort; it’s a game-changer. It transforms your UTV from a three-season machine into a year-round workhorse. It adds a layer of safety by keeping your windshield clear and a level of enjoyment that makes every cold-weather trip a blast. The best part? You can absolutely do this yourself.
This comprehensive guide is your roadmap to a successful polaris general heater install. We’ll cover everything from picking the right kit to the final system check, giving you the confidence to tackle this project and reclaim your winter riding season.
Why You Need a Heater: The Top Benefits of a Polaris General Heater Install
If you’re on the fence, consider this: installing a heater is one of the single best upgrades you can make to your General. It’s not just about warmth; it’s about maximizing your investment and your time on the trail.
Extend Your Riding Season into the Colder Months
This is the big one. A heated cab means you’re no longer at the mercy of the thermometer. Hunting season, winter trail maintenance, or just a fun ride in the snow suddenly become comfortable and enjoyable experiences. You get to use your machine when most others are parked.
Enhance Safety with Windshield Defrosting
A foggy or iced-over windshield is a serious safety hazard. Every quality heater kit comes with defrost vents that direct hot air right where you need it, ensuring you always have a clear line of sight. This is non-negotiable for anyone who rides in cold, damp conditions.
Boost Comfort for You and Your Passengers
Happy passengers make for longer, better rides. Whether it’s your spouse, kids, or a buddy, keeping them warm and comfortable means you can stay out longer and explore further. It turns a chilly endurance test into a cozy adventure.
Gearing Up: Tools and Parts You’ll Need for the Job
Before you turn the first wrench, a little preparation goes a long way. A successful install starts with having the right tools and parts laid out and ready to go. This isn’t a complex job, but it requires patience and the right equipment.
Choosing the Right Heater Kit
You generally have two options: OEM (Original Equipment Manufacturer) or aftermarket. OEM kits are designed by Polaris for a perfect fit but often come at a premium price. High-quality aftermarket kits from brands like Ice Crusher, SuperATV, or Firestorm can offer excellent performance, often with more features for less money. Do your research and read reviews to find the best fit for your budget and needs.
Essential Hand Tools
Most of the tools required are likely already in your garage. Here’s a basic checklist:
- Socket and ratchet set (metric)
- Wrench set (metric)
- Pliers (standard, needle-nose, and especially spring-style hose clamp pliers)
- Drill and a set of bits
- Hole saw (the kit instructions will specify the size, usually around 2-3 inches)
- Utility knife or hose cutter
- Trim panel removal tools (to avoid scratching your plastic)
- Screwdriver set (Phillips and flathead)
Safety and Shop Supplies
Don’t skip the basics. Safety first, always.
- Safety Glasses: Protect your eyes from coolant splashes and debris.
- Mechanic’s Gloves: Keep your hands clean and protected.
- Coolant Drain Pan: A clean pan to catch the old coolant is a must.
- Funnel: For a mess-free coolant refill.
- Shop Rags: You’ll need plenty of these.
- Fresh Coolant: Get the correct type specified for your Polaris General.
The Complete Polaris General Heater Install Guide: A Step-by-Step Walkthrough
Alright, it’s time to get to work. This is the core of our how to polaris general heater install guide. Read each step completely before you begin, take your time, and double-check your connections. A patient install is a successful install.
Step 1: Preparation and Draining the Coolant
Park your General on a level surface and let the engine cool down completely. Never open a hot cooling system. Place your drain pan under the radiator, locate the drain plug or lower radiator hose, and carefully drain the coolant. This is a good time to inspect the old coolant for any signs of contamination.
Step 2: Accessing the Dash and Firewall
To mount the heater unit, you’ll need to get behind the dashboard. This typically involves removing the hood, the center dash console, and possibly the glove box. Use your trim removal tools to gently pry plastic panels off. Keep all your screws and clips organized in a magnetic tray to make reassembly a breeze.
Step 3: Mounting the Heater Core Unit
Your kit will come with a mounting bracket and hardware. Find the designated mounting location under the dash (your instructions will have a diagram). Securely mount the heater core unit. Make sure it’s snug and doesn’t rattle. This is the heart of your new heating system.
Step 4: Drilling and Routing the Coolant Hoses
This step requires precision. Your kit will specify where to drill two holes in the firewall for the coolant hoses to pass through. Measure twice, drill once. Use the supplied grommets to protect the hoses from the sharp metal edge of the firewall. Carefully route the hoses from the heater core through the firewall into the engine bay, avoiding any sharp edges or hot exhaust components.
Step 5: Splicing into the Coolant Lines
This is the most critical part of the install. You need to tap into the engine’s existing coolant lines. Locate the supply and return lines as indicated in your kit’s instructions. Use a sharp utility knife to make clean cuts. Install the provided “Y” fittings and secure them with the hose clamps. Pro Tip: A little bit of coolant on the fitting will help the hose slide on easier. Ensure your clamps are tight but don’t overtighten and damage the fitting.
Step 6: Installing the Vents and Ducting
Now for the fun part. Use your hole saw to carefully cut the openings for your defrost and cab vents in the dashboard. De-burr the edges for a clean look. Connect the flexible ducting from the heater core outlets to the back of the newly installed vents. Secure everything with zip ties or small clamps to prevent rattles.
Step 7: Wiring the Blower Fan and Switch
Most heater kits come with a simple wiring harness. Connect the harness to the fan on the heater unit. Mount the fan speed switch in a convenient location on your dash. Route the power and ground wires as instructed. Connect the positive wire to an accessory power source (so it only works when the key is on) and the negative wire to a solid chassis ground.
Step 8: Refilling and Bleeding the Cooling System
With everything connected, it’s time to refill the cooling system. Slowly pour a 50/50 mix of the correct coolant and distilled water into the radiator. Leave the radiator cap off, start the engine, and turn the heater fan on high with the temperature set to hot. This allows coolant to circulate through the new heater core.
Let the engine run and watch for bubbles in the radiator. This is the air escaping the system. Squeeze the upper and lower radiator hoses to help “burp” any trapped air. Keep adding coolant as the level drops. Once the bubbles stop and the engine reaches operating temperature, top it off and replace the cap. This is one of the most important polaris general heater install best practices to prevent overheating.
Step 9: Final Checks and Testing
Let the machine cool down slightly and re-check the coolant level, topping off as needed. Carefully inspect all your new hose connections for any signs of leaks. Once you’re confident everything is sealed, take it for a short test drive to ensure it’s blowing hot air and the engine temperature remains stable.
Pro Tips and Best Practices for a Flawless Install
Having installed dozens of these kits, we’ve learned a few things. These simple polaris general heater install tips can save you a lot of headaches.
Pre-Fitting is Your Best Friend
Before you drill or cut anything, hold the heater unit, vents, and brackets in place. Make sure everything fits as expected and that you have clearance for hoses and wires. A few minutes of test-fitting can prevent a major mistake.
Mastering the Coolant Splice
Use proper hose cutters for a clean, square cut. Ensure your hose clamps are positioned behind the barb on the “Y” fitting for a secure seal. Don’t use cheap worm-gear clamps if your kit came with high-quality spring clamps—they provide more consistent pressure.
Tidy Wiring for Long-Term Reliability
Don’t just stuff the wires behind the dash. Use zip ties to secure the wiring harness away from any moving parts or hot surfaces. A clean wiring job is a reliable wiring job and prevents future electrical gremlins.
Troubleshooting Common Problems with a Polaris General Heater Install
Even with a careful installation, you might run into a snag. Here are a few common problems with polaris general heater install projects and how to solve them.
Problem: Heater Doesn’t Get Hot
This is almost always caused by air trapped in the system. The heater core is often the highest point, making it a prime spot for an air pocket. Repeat the bleeding procedure. Sometimes, parking the General on a steep incline (nose up) while bleeding can help force the air out.
Problem: The Fan Doesn’t Turn On
This is an electrical issue. Start by checking your fuse. Next, use a multimeter to confirm you have 12-volt power at the switch and at the fan motor itself. The most common culprit is a poor ground connection. Make sure your ground wire is attached to a clean, bare metal spot on the frame.
Problem: I Have a Coolant Leak!
Don’t panic. Shut off the engine immediately. Pinpoint the source of the leak. It’s usually one of the new hose clamp connections. Allow the system to cool, then tighten the clamp slightly. If it’s leaking from a fitting, you may need to drain the system again and re-seat the hose with a new clamp.
Long-Term Care and Sustainable Operation
Your new heater is a robust system, but a little care goes a long way. Following a simple polaris general heater install care guide ensures it works perfectly for years to come.
Regular System Checks
Every few rides, especially after the initial install, pop the hood and visually inspect the heater hoses and clamps for any signs of leaks or wear. Check your coolant level in the overflow bottle regularly.
Eco-Friendly Coolant Handling
A sustainable polaris general heater install includes responsible maintenance. Coolant (antifreeze) is toxic to animals and the environment. Never dump it on the ground. Store your used coolant in a sealed container and take it to your local auto parts store or municipal recycling center for proper disposal.
Frequently Asked Questions About Polaris General Heater Installs
How long does a Polaris General heater install take?
For a first-timer with average mechanical skills, plan for 4-6 hours. Take your time, read the instructions carefully, and don’t rush. An experienced tech can often do it in 2-3 hours.
Can I install a heater without draining all the coolant?
While you can use hose-pinching pliers to minimize coolant loss, it’s highly recommended to do a full drain and fill. This ensures you get all the air out during the bleeding process and gives you a chance to put fresh, clean coolant in your machine.
Will installing an aftermarket heater void my warranty?
Generally, no. In the U.S., the Magnuson-Moss Warranty Act protects you. A manufacturer cannot void your entire vehicle warranty because you installed an aftermarket part. They would have to prove that your heater installation directly caused the specific failure you’re trying to claim under warranty.
Is an OEM heater kit better than an aftermarket one?
Not necessarily. OEM kits guarantee a perfect fit, but premium aftermarket kits often provide higher heat output, more vents, and better features for a lower price. It comes down to your budget and desired performance.
Tackling a polaris general heater install is a hugely rewarding DIY project. You’ll save a ton of money on labor, learn more about your machine, and gain the incredible benefit of a warm, comfortable cab for all your cold-weather adventures.
So gather your tools, turn on some tunes in the garage, and get ready to upgrade your ride. Stay safe, stay warm, and enjoy your General all year long!
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