3-7
3
Table of Contents
(400)
Removing Engine/Transmission.............................. 3-7
Top-Side Components............................................. 3-9
Removing Top-Side Components ........................... 3-9
Servicing Top-Side Components........................... 3-13
Installing Top-Side Components ........................... 3-20
Left-Side Components .......................................... 3-25
Removing Left-Side Components ......................... 3-25
Installing Left-Side Components ........................... 3-27
Right-Side Components ........................................ 3-28
Removing Right-Side Components....................... 3-28
Servicing Right-Side Components ........................ 3-32
Installing Right-Side Components......................... 3-33
Center Crankcase Components............................ 3-36
Separating Crankcase Halves............................... 3-37
Disassembling Crankcase Half ............................. 3-37
Servicing Center Crankcase Components............ 3-39
Assembling Crankcase Half .................................. 3-41
Joining Crankcase Halves..................................... 3-43
Installing Engine/Transmission.............................. 3-44
Removing Engine/
Transmission
Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.
Secure the ATV on a support stand to elevate the
wheels.
1. Remove the front rack, left and right footwells,
and front body panel (see Section 8); then discon-
nect the negative battery cable from the battery.
2. Remove the heat shield; then remove the gas tank
(see Section 4).
3. Remove the oil fittings from the engine and
account for two O-rings; then disconnect the oil
temperature connector and cooling fan connector.
KC251
KC250
KC249
4. Disconnect the speedometer sensor; then remove
the E-clip securing the shift rod to the shift arm
and disconnect the shift rod. Account for a bush-
ing and flat washer.
AT THIS POINT
If the technician’s objective is to service Top-Side
Components, Left-Side Components, or Right-Side
Components, the engine/transmission does not have
to be removed from the frame.
AT THIS POINT
If the technician’s objective is to service/replace
left-side cover oil seals or the oil strainer (from
beneath the engine/transmission), the engine/trans-
mission does not have to be removed from the frame.
! WARNING
Make sure the ATV is solidly supported on the support
stand to avoid injury.
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