Engine Removal - Polaris Sportsman 400 Service Manual

ENGINE REMOVAL (TYPICAL)
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery negative (-) cable.
4. Remove the following parts as required.
S
Seat
S Left and Right Side Covers (Refer to Chapter 5)
S Fuel Tank Cover / Front Cab (Refer to Chapter 5)
S Fuel Tank (Refer to Chapter 4)
5. Disconnect spark plug high tension lead.
6. Remove springs from exhaust pipe and remove pipe.
7. Drain coolant and engine oil.
8. Remove air pre-cleaner and duct.
9. Remove airbox.
10. Remove carburetor.
carburetor flange to prevent dirt from entering the
intake port.
11. Refer to PVT System to remove outer clutch cover,
drive belt, drive clutch, driven clutch, and inner cover.
12. Starter motor. Note ground cable location. Mark
positive (+) cable mounting angle and remove cable.
13. Remove transmission linkage rods from gear selector
and secure out of the way.
14. Disconnect coolant temperature sensor wire.
15. Remove engine to chassis ground cable.
16. Remove all engine mount nuts and / or engine mount
plates.
17. Remove engine through right side of frame.
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Insert a shop towel into the
ENGINE
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