3.10
ENGINE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Accessible Components
The following components can be serviced or removed
with the engine installed in the frame:
• Flywheel
• Alternator/Stator
• Starter Motor/Starter Drive
• Cylinder Head
• Cylinder
• Piston/RIngs
• Camshaft
• Rocker Arms
• Cam Chain and Sprockets
• Water Pump / Water Pump Mechanical Seal*
The following components require engine removal for
service:
• Oil pump / Oil Pump Drive Gear
• Counterbalance Shaft or Bearing(s)
• Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• 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
IMPORTANT: Some engine repair procedures can be
performed without removing the engine. Refer to
“Accessible Components” for further information.
NOTE: Upon engine removal, use a mechanical lift
or have an assistant help remove the engine from
the vehicle to prevent personal injury or damage to
vehicle components.
1. Start with a clean work area.
2. Thoroughly clean the engine and chassis.
3. Remove the following parts as required.
•Seat
• Left and Right Side Covers (Refer to Chapter 5)
• Fuel Tank Cover / Front Cab (Refer to Chapter 5)
• Fuel Tank (Refer to Chapter 4)
4. Drain the engine oil and engine coolant (see Chapter
2).
NOTE: Drain and dispose of the fluids properly.
5. Remove the spark plug high tension lead.
6. Remove engine to chassis ground cable located at the
starter motor mounting fastener.
7. Remove the red battery cable from the starter motor.
8. Disconnect the engine wiring harness connections
near the flywheel cover (Stator).
9. Disconnect the engine coolant temperature sensor
harness at the cylinder head.
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to
possible injury or death.
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