Accessible Components; Engine Removal - Polaris Ranger 500 2x4 2007 Service Manual

Accessible Components

The following components can be serviced or removed with the
engine installed in the frame:
• Flywheel
• Alternator/Stator
• Starter Motor/Starter Drive
• Cylinder Head
• Cylinder
• Piston/Rings
• Camshaft
• Rocker Arms
• Cam Chain and Sprockets
• Water Pump / Water Pump Mechanical Seal*
The following components require engine removal for service:
• Oil pump / Oil Pump Drive Gear
• Counterbalance Shaft or Bearing(s)
• Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
*It may be necessary to loosen engine mounts and move engine
slightly to access water pump. Use the Water Pump Mechanical
Seal Puller (PN 2872105) to replace mechanical seal with
engine in frame.

Engine Removal

1. Clean work area
2. Thoroughly clean the engine and chassis
3. Disconnect negative (-) battery cable
4. Remove the seat
5. Perform the following:
• Remove spark plug high tension lead
• Remove engine to chassis ground cable
• Disconnect engine wiring harness near the magneto
cover
• Disconnect coolant temperature sensor connector
• Drain coolant and engine oil
• Refer to PVT System (Chapter 6) to remove outer
clutch cover, drive belt, drive clutch, driven clutch, and
inner cover
Carburetor Removal
• Disconnect throttle cable from carburetor
• Disconnect vent line
• Loosen clamps on the carburetor boots
ENGINE
3
Spark Plug Lead
3.7