Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
3.8
ACCESSIBLE COMPONENTS
The following components can be serviced or
removed with the engine installed in the frame:
S
Flywheel
S
Alternator/Stator
S
Starter Motor/Starter Drive
S
Cylinder Head
S
Cylinder
S
Piston/Rings
S
Camshaft
S
Rocker Arms
S
Cam Chain and Sprockets
S
Water Pump / Water Pump
Mechanical Seal*
The following components require engine
removal for service:
S
Oil pump / Oil Pump Drive Gear
S
Counterbalance Shaft or Bearing(s)
S
Connecting Rod
S
Crankshaft
S
Crankshaft Main Bearings
S
Crankcase
* It may be necessary to loosen engine mounts and
move engine slightly to access water pump. Use the
Water Pump Mechanical Seal Puller ( PN 2872105 ) to
replace mechanical seal with engine in frame.
ENGINE REMOVAL
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery negative (-) cable.
4. Remove the following parts as required.
S
Seat
S
Left and Right Side Covers (Refer to
Chapter 5)
S
Fuel Tank Cover / Front Cab (Refer to
Chapter 5)
S
Fuel Tank (Refer to Chapter 4)
5. Disconnect spark plug high tension lead.
6. Remove springs from exhaust pipe and remove
pipe.
7. Drain coolant and engine oil.
8. Remove air pre-cleaner and duct.
9. Remove airbox.
10. Remove carburetor. Insert a shop towel into the
carburetor flange to prevent dirt from entering the
intake port.
11. Remove center chain guard on chain drive AWD
models.
12. Remove center drive and driven sprocket bolts
and remove chain and sprockets as an assembly.
13. Refer to PVT System to remove outer clutch
cover, drive belt, drive clutch, driven clutch, and
inner cover.
14. Starter motor. Note ground cable location. Mark
positive (+) cable mounting angle and remove
cable.
15. Remove transmission linkage rod(s) from gear
selector and secure out of the way.
16. Disconnect coolant temperature sensor wire.
17. Remove engine to chassis ground cable.
18. Remove all engine mount nuts and / or engine
mount plates.
19. Remove engine through right side of frame.
ENGINE INSTALLATION
NOTES
After the engine is installed in the frame, review this
checklist and perform all steps that apply.
General Items
1. Install previously removed components using
new gaskets, seals, and fasteners where
applicable.
2. Perform regular 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 or the Owner’s Safety and
Maintenance Manual).
PVT System
1. Adjust center distance of drive and driven clutch.
(Chapter 6)
2. Adjust clutch offset, alignment, and belt
deflection. (Chapter 6)
3. Clean clutch sheaves thoroughly and inspect inlet
and outlet ducts for proper routing and sealing.
(Chapter 6)
Transmission
1. Inspect transmission operation and adjust linkage
if necessary. Refer to Chapter 2 and Chapter 8.
Exhaust
1. Replace exhaust gaskets. Seal connections with
high temp silicone sealant.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
1. Remove radiator cap and slowly add coolant to
top of filler neck.
2. Fill coolant reservoir tank to full mark.