Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

ENGINE REMOVAL AND INSTALLATIONSERVICE TOOLSDescription Part Number Page

ENGINE LIFTING TOOL ................................................................ 529 036 022 ........................................... 73

4.9 0.4 Nm(43 4 lbfin)

62.5 7.5 Nm(46 6 lbfft) NEW

NEW

8 1 Nm(70 9 lbfin)

NEW

= Component must be replaced when removed.NEW

NEW

NEW4 1 Nm

(35 9 lbfin)

NEW

5 1 Nm(44 9 lbfin)

13 2 Nm(115 18 lbfin)

7 1 Nm (62 9 lbf in )

NEW

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

PROCEDURES

ENGINE REMOVAL1. Place vehicle on a workstation equipped with

an engine-lifting hoist.2. Set transmission to park "P" and engage parking

brake.3. Carry out the following operations. Refer to ta-

ble.

OPERATIONS REFERENCES(SUBSECTION)

Release fuel pressure FUEL TANK ANDFUEL PUMP

Remove battery fromvehicle CHARGING SYSTEM

Drain engine coolantPERIODIC

MAINTENANCEPROCEDURES

Remove front body module

Remove RH footrest panelBODY

Remove air filter housing AIR INTAKE SYSTEM

Remove muffler

Remove exhaust pipesEXHAUST SYSTEM

Remove CVT air inletadapter

Remove CVT air outletadapter

CONTINUOUSLYVARIABLE

TRANSMISSION (CVT)

Disconnect starter cable STARTING SYSTEM

Disconnect TPS andIACV connectors from

throttle body

Disconnect MAPTSconnector from intake

manifold

ELECTRONIC FUELINJECTION (EFI)

Remove intake manifold INTAKE MANIFOLD

Remove spark plug cables IGNITION SYSTEM

4. Remove RH footrest support.

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1. RH footrest support

5. Move throttle body aside to make room.

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TYPICAL - THROTTLE BODY SECURED TO FRAME

6. Move the master cylinder backwards.

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Step 1: Remove these fastenersStep 2: Move master cylinder assembly back

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

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TYPICAL - MASTER CYLINDER SECURED TO REAR FENDER

7. Move crankcase vent hose as illustrated.

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TYPICAL - LH SIDE OF ENGINE1. Crankcase vent hose

8. Disconnect both engine harness connectors(HIC).

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TYPICAL - LH SIDE OF VEHICLE1. Engine harness connectors (HIC)

9. Disconnect ignition coil connector.

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TYPICAL - FROM LH SIDE1. Ignition coil connector2. Locking ties to cut

10. Remove the following locking ties.

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TYPICAL - UPPER ENGINE MOUNTING BRACKET.1. Locking ties to cut

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1. ECM2. Locking tie to cut

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

11. On RH side of engine, remove oil pressureswitch cover.

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TYPICAL - RH SIDE OF ENGINE1. Oil pressure switch cover

12. Cut locking ties and remove electrical har-nesses from harness support.

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TYPICAL - RH SIDE OF ENGINE1. Harnesses support

13. Disconnect magneto connector from voltageregulator rectifier.

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TYPICAL1. Magneto connector

14. Remove magneto harness from its locationalong vehicle and gather it in a bundle nearengine.

15. Disconnect vent hose from gearbox.

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TYPICAL1. Vent hose

16. Disconnect coolant hoses as illustrated.

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

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SOME PARTS REMOVED FOR CLARITY1. Disconnect the following coolant hoses

17. Remove main ground wire from engine.

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TYPICAL - RH SIDE AFT CYLINDER1. Main ground wire

18. Remove the shift rod. Refer to SHIFTER sub-section.

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1. Shift rod

Engine Lifting1. Install the ENGINE LIFTING TOOL (P/N 529 036

022) on engine.

529036022

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TYPICAL

2. Attach hoist to engine lifting tool and pick upsome of the engine weight with the hoist.

3. Remove retaining screws from upper enginemount.

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TYPICAL - LH SIDE1. Upper retaining screws

4. Remove retaining bolt from rear engine mount.

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

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TYPICAL - LH SIDE1. Rear engine mount retaining bolt

5. Remove retaining bolt from front enginemount.

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TYPICAL - LH SIDE1. Front engine mount retaining bolt

6. At forward RH end of engine, remove enginesupport plate from frame.

NOTICE Heat screws in order to releasethreadlocker prior to attempting to unscrewthem. If not done, the welded nuts may breakaway from the frame bracket.

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RH SIDE1. Engine support plate screws

7. Remove the following Oetiker clamps fromfront propeller shaft.

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RH SIDE1. Oetiker clamps

8. Move front propeller shaft bellows forward.

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RH SIDE1. Front propeller shaft bellows

9. Remove rear propeller shaft screw from gear-box output shaft.

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

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TYPICAL - RH SIDE1. Rear propeller shaft screw

10. Slightly lift engine and move it forward to dis-connect rear propeller shaft from engine.

11. Move rear propeller shaft yoke downwards tomake room.

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TYPICAL

12. Move engine rearward to disconnect front pro-peller shaft from engine.

13. Remove engine from RH side of vehicle.

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TYPICAL

ENGINE INSTALLATIONReverse the removal procedure. However, pay at-tention to the following.When installing a part, refer to its applicablesubsection for tightening torques and productsrequired.Inspect condition of engine mounts.Install engine on vehicle.Install all engine retaining bolts loosely.Install front and rear propeller shafts. Tighten re-taining screws to specification.Tighten engine mounting bolts to specification.

TIGHTENING TORQUE

Engine retaining bolts 62.5Nm 7.5Nm(46 lbfft 6 lbfft)

Reconnect all hoses, adapters and electrical con-nections.If applicable, fill engine as per specification withengine oil. Refer to PERIODIC MAINTENANCEPROCEDURE subsection.Fill and bleed cooling system. Refer to PERIODICMAINTENANCE PROCEDURE subsection.Check for any leaks.Install all remaining removed parts.Test drive vehicle to confirm proper operation.

ENGINE MOUNTSREPLACEMENTNOTE: Use the same procedure for the front andrear engine mounts.

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Section02 ENGINE, CVT AND GEARBOXSubsection 01 (ENGINE REMOVAL AND INSTALLATION)

Engine Mount RemovalInsert a punch into one engine mount bushing andpush the opposite bushing out.

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TYPICAL

Engine Mount InstallationPush in each mount bushing until it bottoms out.

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