Engine Removal - Polaris GENERAL 2016 Service Manual

ENGINE / COOLING SYSTEM

ENGINE REMOVAL

NOTICE
Some engine repair procedures can be performed
without removing the engine assembly from the vehicle.
Refer to "Service Notes - Engine / Cooling
System"page 3.4 for further information.
The use of an overhead or portable engine hoist is the
only recommended method for removing and installing
the engine.
Have an assistant help guide the engine in and out of
the vehicle while using an engine hoist to prevent
personal injury or damage to vehicle components.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this Service
Manual. Failing to do so may lead to possible injury.
1. If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Drain the engine oil and coolant prior to engine
removal. Refer to
Change"page 3.20 and "Coolant Drain / Fill"page
2.23 procedures.
4. Remove the driver seat and disconnect the (-)
negative battery cable from the battery.
5. Remove the cargo box. Refer to "Cargo Box
Removal"page 10.41 procedure.
6. Remove the air box assembly. Refer to "Intake
Removal"page 3.85 procedure.
7. Elevate the rear of the vehicle off the ground using a
suitable lift.
WARNING
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.
3.26
"Engine Oil and Filter
8. Remove the outer clutch cover screws
the cover from the vehicle.
9. Remove drive belt, drive clutch, driven clutch, inner
clutch cover and clutch outlet duct. Refer to "PVT
Disassembly"page 5.12 procedure.
CAUTION
Be sure to use the correct Drive Clutch Puller (PN
2872085) to prevent damage to crankshaft.
10. Disconnect the T-MAP sensor
r
harness leads , CPS
ignition coil harness lead. Remove wire ties retaining
harness to the fuel rail and rear cross member.
11. Disconnect the stator harness.
12. Remove (+) positive cable from the starter motor.
13. Remove (-) negative cable from the starter mounting
bolt.
14. Disconnect fuel lines and remove throttle body and air
inlet assembly.
Replacement"page
routing for installation.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
w
and remove
e
, fuel injector
t y
, ECT sensor
Refer to "Fuel
procedure. Make note of line
© Copyright Polaris Industries Inc.
, and
Line