Engine Removal

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Drain the engine oil. See the Engine Oil topic for more information.

Drain the coolant. See the Coolant topic for more information.

Remove the front and rear fenders. See the Front Fender and Rear Fender topics for more information.

Remove the exhaust system. See the Exhaust System topic for more information.

Remove the carburetors. See the Carburetor Removal topic for more information.

Remove the front ignition coil from the left side of the frame. See the Ignition System topic for more information.

Remove the footrests. See the Footrests topic for more information.

Loosen the air duct clamp screws with a #2 Phillips screwdriver.

Remove the air duct.

The CVT air intake duct goes up the inside of the right side of the frame.

Loosen the clamps and remove the CVT air intake duct.

Remove the CVT air intake duct joint and clamps.

Open the wire clamp and pull back the rubber cover from the starter motor lead terminal. Remove the nut with a 10 mm wrench and free the lead from the starter motor terminal. Thread the nut back on.

Open the wire clamp on the right side of the engine. Remove the wire clamp and engine ground bolt with an 8 mm socket.

Pull the spark plug caps off of the spark plugs.

On the right side above the ignition coil there is a group of wires secured by two clamps. Open the wire clamps.

Locate the dive belt failure detector 2-pin connector and unplug it.

The alternator wires wrap around the front of the engine and up to the right side of the frame. Unplug the alternator 3-pin connector.

Unplug the 2-pin pickup coil/crank position sensor connector. Free the alternator and pickup coil/crank position sensor wires so they can come out with the engine.

Follow the oil pressure switch wire up from the bottom left of the engine.

Unplug the oil pressure switch bullet connector.

Remove the wire band from the frame to allow the wires that will come out with the engine to be free of the frame.

Unplug the engine braking actuator connector.

The speed sensor is located on the right side of the engine below the torque converter cover. Unplug the speed sensor connector.

The forward / reverse detecting sensor is located to the rear of the engine oil dip stick.

Follow the wire from the sensor and unplug the forward / reverse detecting sensor connector.

The neutral and reverse switches are located to the rear of the engine oil dip stick. Unplug the neutral and reverse switch connectors.

Remove the shift lever tie-rod nut with a 12 mm wrench.

Free the shift lever linkage from the engine.

Loosen the coolant clamps and free the coolant hoses from the cylinder heads and the water pump.

Slide back the O-ring clamps from the rubber covers of the front propeller shaft. Slide back the rubber front propeller shaft covers.

Move the front propeller shaft back towards the engine and free the front end of the shaft from the front differential. Move the shaft forward and free the rear of the shaft from the engine. Remove the front propeller shaft.

Loosen the rear propeller shaft boot clamp. Slide the clamp off the boot.

Move the rear propeller shaft rubber boot forward.

Hold the front engine mounting bolt with a 17 mm socket.

Remove the nut with a 17 mm socket and remove the bolt.

Remove the rear engine mounting bolt with a 17 mm socket.

Remove the two bolts from each of the two rear engine mounting brackets using a 12 mm socket.

Cover the bottom of the left side of the frame in tape to protect it from damage as the engine is brought out from the left side.

Move the engine forward and disconnect the rear propeller shaft.

Turn the engine to the left and remove it from the left side of the frame.