3.18
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Engine Removal (Typical)
WARNING
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.
1. Clean work area.
2. Thoroughly clean ATV engine and chassis.
3. Disconnect battery (-) negative cable.
4. Remove the following parts as required:
• Seat
• Left and right side covers (refer to Chapter 5)
• Fuel tank covers
• Fuel tank (refer to Chapter 4)
• Springs from exhaust pipe and remove pipe.
5. Drain coolant and engine oil.
6. Remove air pre-cleaner and duct.
7. Remove airbox.
8. Disconnect the throttle body sensor (C) and T-BAP
sensor (D). Remove throttle body (A). Insert a shop
towel into the engine intake to prevent dirt from
entering the ports.
9. Relieve the fuel pressure in the fuel rail (refer to
Chapter 4, “FUEL INJECTION”) for proper
procedure. Carefully remove the fuel rail (B) and
injectors.
10. Disconnect spark plug high tension leads.
11. Remove the crank position sensor (E) located on the
mag cover.
12. Remove the air breather line.
13. Disconnect the coolant hoses. Properly dispose of
any antifreeze from the engine or hoses.
14. Refer to PVT System Chapter 6 to remove outer
clutch cover, drive belt, drive clutch, driven clutch,
and inner cover (F).
15. When removing starter cables, note and mark
ground cable and positive (+) cable mounting angle
and locations. Remove cables.
16. Remove transmission linkage rod from gear selector
and secure out of the way.
17. Disconnect coolant temperature sensor wire located
on the cylinder.
18. Remove engine to chassis ground cable.
ENGINE
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