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01-30-2012, 02:46 AM
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ATV Enthusiast
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Member #22639
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HELP!!! Engine Removal Instructions - 2007 Sportsman 500 HO EFI
I need to remove the engine from my 2007 Sportsman 500 HO EFI so I can take it to the shop today to rebuild the top and bottom. I have the service manual, but the instructions are very confusing.. I have attached the instructions from the manual. What I am concern about is how to disconnect the engine from the transmission. Can someone please provide a step by step instructions and point out anything I need to watch out for.
Last edited by pglover19; 01-30-2012 at 03:06 AM.
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01-30-2012, 03:53 PM
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Anyone? I need help....
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01-30-2012, 08:24 PM
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We just recently took our tranny of our 2007 700 efi out.....you might start with that. It was fairly simple! what have you done so far...ill try to help you with what i have done!
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01-31-2012, 12:10 AM
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Junior Member
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Member #14428
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The only thing connecting engine to trans is a belt.
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01 Scrambler 500 4x4
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01-31-2012, 01:41 AM
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Quote:
Originally Posted by scramblinman 01
The only thing connecting engine to trans is a belt.
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Can you be more specific... Unfortunately the service manual does not show how the engine connects to the transmission... Should I look at the breakdown of the transmission to see how it connects.. Below is a link to the Polaris parts website( Browse). Maybe you can point it out to me in one of these drawings.. Once again, I have a 2007 Sportsman 500 HO EFI..
I am trying to pull the engine out today..... The only thing we have done so far is to disconnect all the hoses and wiring harnesses to the engine.
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01-31-2012, 02:27 AM
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Quote:
Originally Posted by POLARIS13
We just recently took our tranny of our 2007 700 efi out.....you might start with that. It was fairly simple! what have you done so far...ill try to help you with what i have done!
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Maybe I am wrong, but I don't see where the engine connects to the transmission in the service manual. However; it does look like it connects to the clutch system somehow.. Please help.....
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01-31-2012, 12:08 PM
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Member #14428
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The trans and engine is 2 seperate pieces. The only thing that connects engine to trans is the drive belt. You should not have to remove trans to take engine out. The only thing you need to remove engine is the motor mounts,there should be 3 if it's the same as mine,and of course the wiring and hoses.
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01 Scrambler 500 4x4
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01-31-2012, 12:57 PM
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Quote:
Originally Posted by scramblinman 01
The trans and engine is 2 seperate pieces. The only thing that connects engine to trans is the drive belt. You should not have to remove trans to take engine out. The only thing you need to remove engine is the motor mounts,there should be 3 if it's the same as mine,and of course the wiring and hoses.
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According to the service manual it looks like the engine drive shaft connects to the clutch system. Additionally you need a special tool to remove the drive clutch in order to disconnect it from the engine shaft. Am I not seeing this correctly. Please advise am I am trying to pull the engine out tonight.
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01-31-2012, 01:37 PM
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Member #230
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Quote:
Originally Posted by pglover19
Quote:
Originally Posted by scramblinman 01
The trans and engine is 2 seperate pieces. The only thing that connects engine to trans is the drive belt. You should not have to remove trans to take engine out. The only thing you need to remove engine is the motor mounts,there should be 3 if it's the same as mine,and of course the wiring and hoses.
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According to the service manual it looks like the engine drive shaft connects to the clutch system. Additionally you need a special tool to remove the drive clutch in order to disconnect it from the engine shaft. Am I not seeing this correctly. Please advise am I am trying to pull the engine out tonight. |
You are seeing it correctly. There is no mechanical connection between the engine and the tranny, other then the belt.
You need to remove the big black clutch cover, then the belt, and then the driven pulley. You do need a clutch puller to remove the driven pull, since it is pressed onto the crank. The clutch puller is nothing more then a threaded rod with a "nut" welded on the end of it. Essentially you remove the center bolt on the driven clutch, and thread in the puller. It buts up against the end of the crank shaft, and as you keep threading it in agains the crank, it pull the driven off of the crank.
At that point the only thing holding the motor in is the 3 motor mounts, the hoses, and the electrical, essentially. Don't forget to unplug the starter and such.
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01-31-2012, 02:01 PM
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Member #14428
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I'm sorry,I forgot the drive and driven clutch does need to be removed to remove backing plate for clutch cover.The backing plate connects from engine to trans. The driven clutch comes off with just removing bolt. The drive clutch needs a special tool to remove,but a 3/4 fine thread bolt can also be used. If you can find a 6inch 3/4 fine thread bolt( got mine from a semi-truck parts store) you can use that along with a spacer like a impact socket small enough to fit in hole,the reason for spacer is there is not enough threads on bolt unless you have a grinder and shave off some of the shoulder on bolt(about a 1 1/2 is plenty),or you can use a all thread rod if you can find correct size.
If you go to youtube and punch in (polaris sportsman EPI clutch kit install part 1 of 4) it will give you a good idea of what needs to be done.
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01 Scrambler 500 4x4
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