5.19
ENGINE
5
500/600 HO ENGINE
Engine Removal
NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, o-rings, and gaskets
with Genuine Pure Polaris parts during assembly.
1. Remove the side panels (if applicable).
2. Disconnect battery ground (-) if applicable.
3. Turn the fuel valve to the “OFF” position (1).
4. Remove the exhaust system.
5. Disconnect the CDI box and harness from the air box.
6. Pull up the air box and disconnect the vent lines and coil
connections.
7. Remove the spark plug caps from the spark plugs.
8. Remove the air box.
9. Remove the recoil handle and secure the recoil rope (2).
10. Remove the drive belt, driven clutch and drive clutch.
11. Squeeze the vent line clamps and remove the exhaust valve
vent lines from the top of the exhaust valve base.
12. Disconnect the DET sensor connection (4).
13. Remove the panduit strap and, disconnect the throttle
position sensor (TPS) from the carburetor.
14. Disconnect the Regulator Rectifier (5) and the Stator
connections (6). These are located behind the brake disc
area.
15. Loosen up the boot clamps that hold the carburetor onto the
intake.
16. Separate the carburetors from the engine.
17. Disconnect the oil supply lines from the carburetor and
secure the carburetor assembly out of the way.
NOTE: Plug the carburetor areas to keep any debris
from entering the carburetors.
18. Drain the engine coolant.
NOTE: Disconnect the thermostat hose and place
the end into a container and use low air pressure
and coolant should come out of the hose.
19. Move the thermostat hose clamp down on the hose far
enough to clear the fitting on the head, and remove the hose.
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