3
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
3.13
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 3.3 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 “Engine Oil and Filter Change”
page 2.28 and “Coolant Drain / Fill” page 2.34
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 11.62 procedure.
6. Remove the air box assembly. Refer to “Intake
Removal” page 3.73 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.
8. Remove the outer clutch cover screws
w
and remove
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 6.8 procedure.
IMPORTANT
Be sure to use the correct Drive Clutch Puller (PN
2872085) to prevent damage to crankshaft.
10.Disconnect the T-MAP sensor
e
, fuel injector
harness leads
r
, CPS
t
, ECT sensor
y
, and
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. Refer to “Fuel Line Replacement”
page procedure. Make note of line routing for
installation.
ENGINE / COOLING SYSTEM
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