Polaris General Inferno Heater Install Instructions

That biting wind whipping through the cab of your Polaris General can turn an epic trail ride into a teeth-chattering test of endurance. When the temperature drops, most machines get parked for the season. But what if they didn’t have to be?

We’ve all been there, layered up so much you can barely move, wishing for just a little warmth. You bought your General for year-round utility and fun, and a cab heater is the key to unlocking its full potential. We promise this guide will give you the confidence to tackle this project yourself.

This is your complete, no-nonsense walkthrough. We’ll provide the detailed polaris general inferno heater install instructions you need, from unboxing the kit to feeling that first blast of warm air. We’ll cover the tools, the step-by-step process, and the pro tips to get it done right the first time.

Why You Need This Upgrade: Benefits of an Inferno Cab Heater

Before we turn wrenches, let’s talk about why this is one of the best upgrades you can make. Installing a quality heater is about more than just comfort; it’s about capability, safety, and getting more value from your machine.

Extend Your Riding Season Indefinitely

This is the biggest win. A heated cab means you’re no longer at the mercy of the thermometer. Whether you’re hunting in the late fall, plowing snow in the dead of winter, or just hitting the trails on a chilly spring morning, you’ll be comfortable.

Improve Safety with a Clear Windshield

Fogged-up or frosted windshields are a major safety hazard. The Inferno heater kit comes with defrost vents that cut through condensation and ice, ensuring you always have a clear line of sight. This is non-negotiable for safe operation in cold or wet conditions.

Boost Comfort and Resale Value

Let’s be honest, being comfortable makes every ride better. A warm cab reduces fatigue and makes long hours in the seat far more enjoyable. Plus, a professionally installed, high-quality accessory like this adds real, tangible value if you ever decide to sell your General.

Pre-Flight Check: Tools and Prep Before You Start

A good mechanic knows that preparation is half the battle. Rushing in without the right tools or a clear plan is a recipe for frustration. Let’s get organized first with this essential polaris general inferno heater install instructions guide for prep work.

Essential Tools and Supplies List

Gather everything you need before you start. There’s nothing worse than having to stop mid-job for a run to the auto parts store. You’ll likely need:

Standard socket and wrench set (metric)
Torx bit set
Pliers (needle-nose and standard)
Sharp hose cutter or utility knife
Drill with various bits and a hole saw (typically 1 ¾” and 3” for vents and hoses)
Panel popper tool or flathead screwdriver (wrap the tip in tape to prevent scratches)
Zip ties and electrical tape
A clean bucket or drain pan for coolant
Extra coolant (match your Polaris factory type)
Safety glasses and gloves

Kit Inspection and Layout

Open your Inferno heater kit and lay out all the components. Cross-reference them with the parts list in the manual. Make sure everything is there before you start pulling your machine apart. This simple check can save you a massive headache later.

The Main Event: Your Complete Polaris General Inferno Heater Install Instructions

Alright, it’s time to get to work. We’ve broken down the process into logical, easy-to-follow steps. Take your time, read each step carefully, and don’t be afraid to double-check your work as you go. This is how to get your polaris general inferno heater install instructions done right.

Step 1: Gaining Access – Removing Panels

First, you need to get to the guts of your General. The goal is to access the firewall, the dash, and the coolant lines running under the center console.

Park on a level surface and ensure the engine is completely cool. Disconnect the negative battery terminal as a safety precaution.
Remove the seats to give yourself more room to work inside the cab.
Carefully remove the center console and the front hood/access panel. This usually involves removing a series of push-pins and Torx screws. A panel popper tool is your best friend here.

Step 2: Mounting the Heater Core

The heater core is the heart of the system. It needs to be mounted securely under the dash, typically on the passenger side.

Using the supplied bracket as a template, mark the mounting holes on the firewall. Double-check behind the firewall to ensure you aren’t drilling into any wires or critical components.
Drill the mounting holes and securely bolt the heater unit into place.
Drill the pass-through holes for the two coolant hoses. The instructions will specify the exact location and size. Install the rubber grommets to protect the hoses from the sharp metal edge.

Step 3: Tapping Into the Coolant System

This is the most critical part of the installation. Be patient and precise. Your goal is to divert hot coolant from the engine, run it through the heater core, and return it to the engine.

Locate the main coolant lines running from the radiator to the engine. They are typically found under the center console.
Place your drain pan under the area you plan to cut. Expect some coolant spillage.
Using a sharp hose cutter for a clean cut, splice the provided “Y” fittings into the supply and return coolant lines as shown in your kit’s manual. Pay close attention to the flow direction.
Secure all connections with the provided hose clamps. A tight seal is crucial to prevent leaks.

Step 4: Installing Vents and Ducting

Now it’s time to route the heat where you want it. This step requires drilling into your dash plastics, so measure twice and cut once!

Decide on the best locations for your defrost and cab vents. Use the hole saw to carefully cut the openings in the dash.
Install the louver vents into the newly cut holes.
Run the flexible ducting from the outlets on the heater core to the back of each vent. Secure both ends with zip ties for an airtight fit.

Step 5: Wiring the Fan and Switch

The final step is giving your heater power. The Inferno kit’s wiring is straightforward.

Find a suitable location on your dash for the fan switch and drill the appropriate-sized hole.
Mount the switch.
Connect the red (positive) wire to an accessory power source that only turns on with the key. This prevents you from accidentally draining your battery. The Polaris General has a pre-wired accessory terminal block under the hood that makes this easy.
Connect the black (negative) wire to a solid chassis ground. A clean, paint-free bolt on the frame is perfect.
Plug the wiring harness into the fan on the heater core unit.

The Final Check: Bleeding the System and First Run

You’re almost done! But don’t skip this step. Air trapped in the coolant system can prevent the heater from working properly and even cause engine overheating. Following these polaris general inferno heater install instructions best practices is essential.

First, reconnect your battery. Top off the radiator with a 50/50 mix of the correct Polaris-approved coolant and distilled water. Leave the radiator cap off for now.

Start the engine and let it idle. Turn the heater fan on high. As the engine warms up and the thermostat opens, you’ll see the coolant level in the radiator drop as air bubbles work their way out. Continue to add coolant to keep it full.

Gently squeeze the main radiator hoses to help move any stubborn air pockets along. Once the engine reaches operating temperature and you feel hot air blowing from the vents, the system is bled. Shut off the engine, let it cool slightly, and carefully reinstall the radiator cap.

Troubleshooting Common Problems After Installation

Hit a snag? It happens. Here are a few common problems with polaris general inferno heater install instructions and how to fix them quickly.

Heater Isn’t Blowing Hot Air

This is almost always due to air trapped in the system. Repeat the bleeding procedure. Also, double-check that your “Y” fittings are installed correctly and that none of the new coolant hoses are kinked or pinched.

Fan Doesn’t Turn On

This is an electrical issue. Check your connections. Is the ground wire on a clean metal surface? Is the positive wire getting power when the key is on? Check the in-line fuse to make sure it hasn’t blown.

I See a Coolant Leak!

Shut down the engine immediately. Pinpoint the source of the leak. Most often, it’s a hose clamp that isn’t tight enough. Go back and check every single clamp you installed to ensure they are snug.

Long-Term Care and Eco-Friendly Operation

Your new heater is built to last, but a little preventative maintenance goes a long way. This polaris general inferno heater install instructions care guide ensures years of reliable warmth.

Once a season, give your installation a quick once-over. Check the coolant hoses for any signs of cracking or wear and ensure all hose clamps are still tight. When you perform regular coolant flushes on your General, remember that the heater core is now part of that system.

For more sustainable polaris general inferno heater install instructions, always capture and dispose of used antifreeze responsibly. Never pour it on the ground. Most auto parts stores or local recycling centers accept it for free. This simple, eco-friendly practice protects wildlife and groundwater.

Frequently Asked Questions About Your Inferno Heater Install

How long does the Polaris General Inferno heater installation take?

For a first-timer with moderate mechanical skill, plan for about 4-6 hours. An experienced mechanic can often get it done in 3-4 hours. Don’t rush it; take your time and do it right.

Do I have to drain all the coolant from my machine?

No, you don’t have to drain the entire system. By working quickly when you cut the coolant lines and having a drain pan ready, you will only lose a small amount of coolant, which you will then replace when you top off and bleed the system.

Will installing an aftermarket heater void my Polaris warranty?

Generally, installing an aftermarket part does not automatically void your entire vehicle warranty. However, if the part you installed or your installation work directly causes a failure of a warrantied component, the repair for that specific failure may not be covered. If you’re concerned, check with your local dealer.

You did it! By following these steps, you’ve successfully installed a game-changing upgrade on your Polaris General. You’ve added comfort, safety, and extended your ability to use your machine to all four seasons.

Now, go put that hard work to the test. Get out there and conquer the cold. Stay warm, ride safe, and we’ll see you on the trails!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.