Engine Removal - Polaris TRAIL BOSS 325 2001 Manual

ACCESSIBLE COMPONENTS
The following components can be serviced or
removed with the engine installed in the frame:
SFlywheel
SAlternator/Stator
SStarter Motor/Starter Drive
SCylinder Head
SCylinder
SPiston/RIngs
SOil pump
SCamshaft
SRocker Arms
SCam Chain and Sprockets

ENGINE REMOVAL

1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery negative (-) cable.
4. Remove the following parts as required.
SSeat
SLeft and Right Side Covers (Refer to Chapter 5)
SFuel Tank Cover / Front Cab (Refer to Chapter 5)
SFuel Tank (Refer to Chapter 4)
5. Disconnect spark plug high tension lead.
6. Remove springs from exhaust pipe and remove pipe.
7. Drain engine oil.
8. Remove airbox.
9. Remove carburetor. Insert a shop towel into the carburetor flange to prevent dirt from entering the
intake port.
10. Loosen auxiliary brake master cylinder mount, if necessary for clearance.
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 rod(s) from gear selector and secure out of the way.
14. Remove engine to chassis ground cable.
15. Remove all engine mount nuts and / or engine mount plates.
16. Remove engine through right side of frame.
The following components require engine
removal for service:
SConnecting Rod
SCrankshaft
SCrankshaft Main Bearings
SCrankcase
ENGINE
3.5