3.12
ENGINE
Engine Removal
1. Clean work area.
2. Thoroughly clean the engine and chassis.
3. Disconnect battery.
4. Drain engine oil.
5. Disconnect spark plug high tension lead.
6. Disconnect all electrical wires from the engine.
7. Remove the following parts as required:
• Rear Cab Assembly (Refer to Chapter 5)
8. Remove exhaust pipe.
9. Remove the carburetor. Insert a clean shop towel into the
carburetor flange to prevent dirt from entering the intake.
10. At the starter motor, note the chassis ground cable location
and remove it.
11. Mark the positive (+) cable mounting angle and remove
cable.
12. Remove the transmission shift cables from the transmission
and secure out of the way.
13. Raise the rear of the unit until the wheels are off the ground.
Secure with jackstands under the frame.
14. Remove the drive chain.
15. Remove the top rear shock bolts and allow the swing arm
to drop. (OPTIONAL - Refer to Chapter 5 to remove the
axle and swing arm as an assembly)
16. Remove all engine mount bolts and / or engine mount
plates.
17. Using the aid of an assistant, lift and remove engine out the
rear of the vehicle.
Engine Installation Notes
After the engine is installed in the frame, review this checklist
and perform all steps that apply:
General Items
• Install previously removed components using new
gaskets, seals, and fasteners where applicable.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the daily
pre-ride inspection checklist (refer to Chapter 2).
CVT System
• Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing.
• Inspect clutch rollers, shoes and springs before
reassembly.
Transmission
• Inspect transmission operation and adjust linkage if
necessary.
Exhaust
• Replace exhaust gaskets. Seal connections if desired
with high temp sealant.
• After running the engine, verify all bolted exhaust
connections are tight and in good condition.
Engine Mount Torque
• Front Mount
• Rear Mounts
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.
• Use only Polaris Youth (40w) Oil, or API certified
“SH” oil equivalent.
• Use fuel with a minimum octane of 87 (R+M)/2
method.
• Change break-in oil at 10 hours or 100 miles, whichever
comes first.
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