2 Stroke Engine Removal; Engine Removal Preparation, Typical (2 Stroke) - Polaris Magnum 2x4 Service Manual

ENGINE
2 Stroke Engine Removal
The following components can be serviced or removed with the engine installed in the frame:
• Flywheel
Alternator/Stator
• Starter Motor/Starter Drive
• Cylinder Head
• Cylinder
• Piston/Rings
Oil pump (250/400L)
Counterbalancer Assembly (400L engines)
Water pump
The following components require engine removal for service:
Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
• Oil pump (300)
Engine Removal Preparation, Typical (2 Stroke)
1 . Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery negative (-) cable.
4. Remove the following parts. Refer to the Body Chapter for removal procedures.
Seat
Left and Right Side Covers
• Fuel Tank Cover
• Fuel Tank (see Fuel System Chapter)
5. Disconnect oil pump cable (2-Strokes).
6. Disconnect spark plug high tension lead.
7. Remove springs from exhaust pipe and remove pipe.
8. Remove air pre-cleaner and duct.
9. Remove airbox.
10. Remove carburetor.
11. I nsert a shop towel into the carburetor flange to prevent
dirt from entering the intake port.
12. Loosen auxiliary brake adjuster locknut, remove
adjusting bolt and brake actuator arm.
13. Remove center chain guard bolt, two screws, and
chain guard on AWD models.
14. Remove center drive and driven sprocket bolts and
remove chain and sprockets as an assembly.
15. Refer to PVT section page 6.9 for procedure to remove
inner PVT cover.
10/96 3.8
Polaris Industries Inc.