5.33
Engine and Cooling Systems
5
Engine Removal (Typical)
NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, o-rings, and gaskets
with Genuine Pure Polaris parts during assembly.
NOTE: The following removal and installation
process involves a CFI engine. Carbureted engines
do not use throttle bodies or the electrical
components housed in the drive clutch cover
electrical center.
1. Open the hood, and remove the side panels.
2. Disconnect the battery ground (-) cable from the battery if
equipped.
3. If equipped, unplug exhaust temperature sensor and
remove the exhaust system.
4. Remove the spark plug leads from the spark plugs.
5. If equipped, remove the belt cover/electrical center cover.
6. On CFI models, disconnect the intake air sensor located on
the MAG side of the airbox.
7. On CFI models, remove the return fuel line “P” holder
located on the MAG side of the airbox.
8. On CFI models, separate the fuel filter from the filter clip
that is on the MAG side of the airbox.
9. Remove the airbox by removing the gear clamps, then
pulling the airbox assembly out of the engine compartment.
10. On CFI models, disconnect the main harness at the ECU.
This is the smaller of the two plugs located on the ECU.
Remove it by pressing up on the underside of the plug and
pulling straight off.
11. Disconnect the regulator/rectifier connections.
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