Engine Removal - Polaris 1999 Sportsman 400 Service Manual

138
top end only as far as necessary to remove the de-
sired subassembly.
It may be easier in some cases to remove as many
engine components as possible before removing the
lower end from the frame. Following this method
reduces the weight of the engine and allows the
frame to be used as a holding fixture. Disassem-
bling the engine on the workbench without some
type of holding fixture can be diffi c ult, lime con-
suming and may require an assistant to hold the en-
gine when loosening large fasteners.
The engine must be removed from the frame to
serv ice the following compone nts.
1. Counter balance sys tem.
2.
Crankcase.
3. Cra nkshaft and connecting rod.
4. Main bearings.
5. Oi l pump.
Removal
I.
Place the ATV on a level sur face and set the
parkin g brake. Block the whee ls to keep it from roil-
ing in either direction.
2. Remove the
fuel
tank as described in Chapter Six.
3. Remove the scat, front fender and side covers as
described in Chapter Fi fteen,
4. Disconnect the negative battery cable as de-
scribed in Chapter Three. Sec ure the cab le so it will
not acc identa lly mak e contact with the battery ter-
mina l.
5. Drain the engine coolant as described in Chapter
Three.
6. Drain the engine and oil tank as described in
Chapter Three.
7. Disconnect the spark plug high tension lead (A.
Figure 2) and move it out of the way.
8.
Disconnect the engine
breather hose from the
engine.
9. Remove the
air filterandair
box as
described in
Chapter Six.
10. Remove
the carburetor as described in Chapter
Six. Insert a clean. lint free shop towel or plug (B.
Figu re 2) in the exposed intake porI to prevent dirt
from
entering.
I I. Remo ve the exhaust system as described in
Chapter Four.
12. On 1997 models. remove the
center
dri ve
and
driven
sprockets, and chain asdescribed in Chapter Ten.
CHAI' TER FIVE
CAUTION
Do not lose the spacers or the spacer
retaining O-rings from the threaded
ends
(~f
the sc rew,\' that attach the
PVT inner
CU \'el:
13. Remove the PVT (Polaris variable transmis-
sion). dri ve belt. drive pulley. dri ven pulley and in-
ner cover as described in Chapter
Eight.
14. Remove the
recoil starter as described in this
chapter.