3-3
3
Table of Contents
Removing Engine/Transmission.............................. 3-3
Top-Side Components............................................. 3-5
Removing Top-Side Components ........................... 3-6
Servicing Top-Side Components............................. 3-7
Installing Top-Side Components ........................... 3-12
Left-Side Components .......................................... 3-13
Removing Left-Side Components ......................... 3-14
Servicing Left-Side Components .......................... 3-15
Installing Left-Side Components ........................... 3-19
Right-Side Components ........................................ 3-20
Removing Right-Side Components....................... 3-20
Servicing Right-Side Components ........................ 3-22
Installing Right-Side Components......................... 3-23
Disassembling Crankcase Half ............................. 3-26
Servicing Center Crankcase Components............ 3-28
Assembling Crankcase Half .................................. 3-30
Installing Engine/Transmission ............................. 3-32
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 seat; then remove the left and right
side covers and footwells.
2. Remove the gas tank (see Section 4).
3. Move the battery cover and disconnect the nega-
tive battery cable.
TR022A
4. Remove the crankcase breather hose from the
crankcase ventilator valve; then loosen the intake
boot clamp and remove the air filter assembly.
TR050A
5. Remove the nuts securing the intake to the cylin-
der head; then remove the intake pipe/carburetor
assembly leaving the throttle cable and choke
cable connected. Set the assembly aside.
TR054A
6. From the right side, remove the spark plug cap and
starter lead; then disconnect the shift rod from the
lower shift arm.
AT THIS POINT
If the technician’s objective is to service/replace
left-side cover oil seals, the engine/transmission 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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