Engine Removal - Polaris Trail Blazer Service Manual

ENGINE

Engine Removal

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, depending on
model.
Seat
S
Left and Right Side Covers (Gen ll and Gen lV)
S
(Refer to Chapter 5)
Fuel Tank Cover / Front Cab (Refer to Chapter 5)
S
Fuel Tank (Refer to Chapter 4)
S
5. Disconnect oil pump cable.
6. Disconnect spark plug high tension lead.
7. Remove springs from exhaust pipe and remove pipe.
8. Drain coolant and engine oil (where applicable).
9. Remove air pre-cleaner and duct.
10. Remove airbox.
11. Remove carburetor.
carburetor flange to prevent dirt from entering the
intake port.
12. Loosen auxiliary brake master cylinder mount, if
necessary for clearance.
13. Remove center chain guard on chain drive AWD
models.
14. Remove center drive and driven sprocket bolts and
remove chain and sprockets as an assembly.
15. Refer to PVT System to remove outer clutch cover,
drive belt, drive clutch, driven clutch, and inner cover.
16. Starter motor. Note ground cable location. Mark
positive (+) cable mounting angle and remove cable.
17. Remove transmission linkage rod(s) from gear
selector and secure out of the way.
18. Disconnect coolant temperature sensor wire (where
applicable).
19. Remove engine to chassis ground cable (where
applicable).
20. Remove all engine mount nuts and / or engine mount
plates.
21. Remove engine through right side of frame.
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Insert a shop towel into the
3.12 Polaris Sales Inc.