Polaris 2005 Sportsman MV7, Service Manual

Page: 73 / 312

ENGINE
3.15
ENGINE REMOVE & INSTALL
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. Remove springs from exhaust pipe and remove
pipe.
6. Drain coolant and engine oil.
7. Remove air pre-cleaner and duct.
8. Remove airbox.
B
A
C
9. Remove carburetor (A). Insert a shop towel into
the carburetor flange to prevent dirt from entering
the intake port.
10. Disconnect spark plug high tension lead (B).
11. Remove the air breather line (C).
D
12. Disconnect the coolant hoses. Properly dispose
of any antifreeze from the engine or hoses.
13. Refer to PVT System Chapter 6 to remove outer
clutch cover, drive belt, drive clutch, driven clutch,
and inner cover (D).
14. When removing starter cables, note and mark
ground cable and po) cable mounting
angle and locations . Remove cables.
15. Remove transmission linkage rod 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. Remove the frame brace (E) from
the front left side of the frame.
E
19. Remove the engine from the left side of the frame.
NOTE: Use caution when lifting the engine out of
frame. Use an engine lift or other means if the engine
is too heavy to be lifted manually.
20. For
engine installation, reverse these
procedures.