Nope,gotta go from the top down.. Get a manual before you start.Polaris ATV Service Manuals PDF Download

 

Thanks for the link OPT.

 

Ok - I’m tearing down the engine. Problem is that the cylinder won’t budge. Removed the 2 screws for the oil line, head bolts, and 2 screws on the flywheel side. What am I missing? Don’t want to break anything.

 

If you have the head removed along with the two 6mm bolts on the cylinder,it may take a little tapping with a dead blow hammer all around it to help jar it loose while you're pulling up on the cylinder. After being on 18 years the cylinder may take a little persuading.

 

What about applying a bit of heat?

 

Silly question, can it be tapped from the side of the head?

 

When separating head or cylinders, the gaskets tend to adhere to the adjoining parts and often require a certain amount of force. I always try to hit with firm, deadblows to reinforced areas and try not to hammer on the sidewalls to prevent any damage. Try hitting right beside where a bolt would be and should feel it start to loosen.
​​​​​​It would take a fair amount of heat on aluminum to do much and should not be required if all bolts are out. Its a bit of knowing and sensing how much force to apply to prevent damage and get the job done.

 

I bought a deadbolt hammer, and could not get it off. After so much pounding I ended up cracking the cylinder. Which is fine because I’m looking at a rebuild kit that includes a new cylinder. Still can’t get it off though.

 

That's too bad about your cylinder. I would suggest next time to check and recheck if things on motors are not moving after a couple firm taps before applying much more force. It's a learning process to get a sense of what force to apply to different materials.

Also, did you remove the cam hold down/caps, cam, chain and chain tensioner?

Isaiah

 

Entire head was removed with no problem. But cylinder won’t come off. I’m worried I now have to pull the entire engine out. Don’t have a flywheel puller - way too much $$$ for a one time job. Was trying to remove cylinder with engine in place. So hard to access all the places where I can hammer.