Polaris Outlaw 500, Service Manual

Page: 55 / 202

3.8
ENGINE
Accessible Components
The following components can be serviced or removed with
the engine installed in the frame:
• Flywheel
• Alternator/Stator
• Starter Motor/Starter Drive
• Water Pump / Water Pump Mechanical Seal*
* Mechanical Water Pump Seal Removal Tool ( PN 2872105 ) is
required to replace mechanical seal with engine in frame.
The following components require engine removal for
service:
• Counterbalance Shaft or Bearing(s)
• Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• Cylinder Head
• Cylinder
• Piston/RIngs
• Camshaft
• Cams
• Cam Chain and Sprockets
• Transmission Gears and Bearings
Engine Removal
1. Thoroughly clean the ATV engine and chassis.
2. Clean work area.
3. Support the ATV with jackstands under the footrests at a
height sufficient to raise the rear wheels off the floor at least
5 inches (12.7 cm).
4. Drain coolant and engine oil.
5. Remove the following components:
• Seat
• Side Panels
• Front Cab (Refer to Chapter 5)
• Fuel Tank (Refer to Chapter 4)
• RH footwell (Refer to Chapter 5)
6. Disconnect battery cables, starting with the negative (–)
cable first.
7. Remove air intake duct.
8. Remove carburetor. Caution: Fuel will leak if carb is
turned upside down. In most instances, the carburetor will
not have to be disconnected from the throttle cable, choke
cable and fuel line for engine removal. Insert a shop towel
into the carburetor flange to prevent dirt from entering the
intake of the engine.
9. Disconnect all electrical connections to the engine (coolant
sensor, neutral switch, plug wire, starter cable, ground
cable). Remove the magneto side cover, leaving the
electrical components attached, and secure out of the way.
10. Remove clutch and reverse cable linkage and secure out of
the way.
11. Remove fasteners from exhaust pipe and remove header
pipe.
12. Remove oil tank and hoses as an assembly. Disconnect vent
line and secure out of the way.
13. Loosen chain, disconnect and remove. An acceptable
alternative is to remove the transmission drive sprocket and
roll chain off.
14. Remove all engine mount nuts and engine mount plates,
starting at the rear with the combination engine / swing arm
pivot mount first. Using a suitable tool, push the bolt out
far enough to loosen the engine, but not drop the swing arm
pivot. Use a jack under the bearing carrier to relieve tension
from the pivot bolt for easier removal and installation.
15. With an assistant helping you, remove the engine by tilting
forward and turning to exit through left side of frame.
To reinstall the engine, reverse the procedures. Refer to engine
installation notes on Page 3.9.
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