Service Manual

5.25
ENGINE
5
33. Pull the engine toward the front of the vehicle to disengage
the engine/transmission coupler.
34. Remove the engine through the right side of the chassis and
place on a work bench to begin engine disassembly.
Engine Installation Notes
After the engine is installed in the frame, review this checklist
and perform all steps that apply:
General Items
1. Repeat steps in reverse order in the “Engine Removal”
section above to reinstall the engine.
2. Install previously removed components using new gaskets,
seals, and fasteners where applicable.
3. Perform regular checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the Daily Pre-
ride Inspection Checklist and in the Periodic Maintenance
Table (refer to Chapter 2 “Maintenance”).
Exhaust
1. Replace exhaust seals before installation.
2. Install the exhaust pipe assembly into the cylinder head and
exhaust silencer.
3. Install the nuts and finger tighten only!
4. Install the springs retaining the pipe to the silencer.
5. Torque the exhaust retaining nuts to specification.
Bleed Cooling System
1. Remove radiator cap and slowly add coolant to top of filler
neck.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap and squeeze coolant lines to force air out
of system.
4. Again remove radiator cap and slowly add coolant to top
of fill neck.
5. Alternately elevate the front and back of the vehicle to
allow additional air to vent from the system.
6. Start engine and observe coolant level in the radiator.
Allow air to purge and top off as necessary. Reinstall
radiator cap securely and bring engine to operating temp.
Check coolant level in reservoir tank after engine has
cooled and add if necessary.
Engine Break In Period
The engine break-in period is defined as the first 20 hours of
engine operation or 2 full tanks of fuel.
1. Use only Polaris PS-4 Plus 2W-50 Synthetic engine oil.
Never substitute or mix oil brands. Serious engine damage
can result.
2. Use fuel with a minimum octane of 87 (R+M)/2 method.
3. Change break-in oil and filter at 25 hours.
REMOVE