Engine Removal 06 900

[Gowest88]

So I have decided to replace the motor mounts on my 900 and have never pulled the motor before, I have a couple questions that would really help:

1. Do you have to take the primary clutch off?

2. How do you remove wiring from the back side of the motor?

3. Once all cennections are removed can I just unbolt the mounts and pull the motor out by hand without ruining anything?

I have looked for a thread under the how to with no luck

Consider me a complete newbie to engine removal! Thanks

 

[06 RMK 900]

In the how to section they have the service manual listed. It tells you step by step in there.

 

[Gowest88]

I have printed out the manual and what I could find was really generic or I am looking in the wrong area. It says to remove alot of things I really dont think need to be removed-like the primary clutch? It looks like I can take out some brackets on either side and the motor would come out.

 

[Gowest88]

When you say service manual are you refering to the 05 Deep snow manual?

 

[06 RMK 900]

I don't think you HAVE to take the primary off but it's a lot easier to get to the cross mount bolts. The primary clutch is actually pretty easy to get off if you have a puller.

 

[06 RMK 900]

When you say service manual are you refering to the 05 Deep snow manual?

Yes

 

[Gowest88]

So once everything is detached from the motor I can just remove the hardware for the mounts and yank it out? Anything I should know or be careful about? Thanks alot for your help

 

[06 RMK 900]

The first time I did it to be honest I didn't follow any instructions. Just started taking stuff off. Just be carefull not to rip any wires. It's pretty easy just take your time.

 

[rmk2112]

2. How do you remove wiring from the back side of the motor?

You have to pull the gas tank to get to the harness and injector connections.

Here's a quick list. On your first time, I'd bag and label everything you take off for easy reassembly

1. Drain coolant
2. Remove can
3. Remove Pipe
4. Remove Y Pipe
5. Remove coolant & oil bottles and disconnect hoses
6. Remove Air box
7. Remove boost box
8. Disconnect Throttle and Oiler cable
9. Disconnect TPS & Remove throttle bodies
10. Pull Primary
11. Remove pull cord handle and knot cord
12. Remove R & L chassis supports
13. Remove seat
14. Remove console
15. Disconnect fuel lines
16. Remove tank
17. Disconnect harness and injector connections
18. Disconnect remaining electrical connections
19. Remove engine mount bolts

The motor will lift right out.

Be extremely careful to make sure all the injector wire ends are pushed thru the opening between the motor and the tank.
If you just pull the motor and the wires straight out, it will pull the connectors off the ends of the injector wires.

That's a quick list in the order that I did it in. Everyone has there own method and order of removal.

Read the stickies and the "How to's" at the top of the forum. There's great tricks and tips for doing just about anything to these sleds.

 

[roni87]

removal

I havent ever removed gas tank to pull motor. My injector wires are long enough to lift motor out and set on bulkhead and then unplug all connections. Also I keep the y pipe and throttle bodies on engine while removing. Much easier that way. Just take it slow and take mental images of where all the bolts, screws and hoses go. Have fun

 

[Super Dave3]

I havent ever removed gas tank to pull motor. My injector wires are long enough to lift motor out and set on bulkhead and then unplug all connections. Also I keep the y pipe and throttle bodies on engine while removing. Much easier that way. Just take it slow and take mental images of where all the bolts, screws and hoses go. Have fun

Then how do you unplug the stator and Det sensor. I agree with leaving the throttle bodies and y-pipe installed.

 

[roni87]

wires

Then how do you unplug the stator and Det sensor. I agree with leaving the throttle bodies and y-pipe installed.

Both of mine are connected behind the motor by all the injector plugs and the wires are plenty long that I leave them connected while lifting engine and set the engine on top of the bulkhead. I also take the coils off and all wires exposed on top before lifting engine

 

[Gowest88]

Thanks for all the input......I have 3/4 of it taken apart and really started to feel overwhelmed, but this info really clears up some of my confusion. Thanks again!

 

[Gowest88]

New Questions

So...I have the motor back in and got it to start with 2 pulls. I let the motor idle for about 30 seconds and killed to check the motor and make sure everything was in place. It wasn't I had probably 1-2 gallons of fuel on my garage floor, found that the fuel line without the Filter had disconnected from the fuel pump and was pumping fuel into all my electrical harnesses. I got really lucky nothing caught on fire cause it would have been bad. With that said this generated a couple of questions:

1. Is the fuel line without the filter a return line or does it feed the motor?

2. I got everything back together and never primed the oil line, however it was never completely empty and i can see a couple of small air bubbles in the line. Will these work themselves out or if not how would I prime this line?

Thanks ahead of time.....Just when I thought I had this thing all figured out. haha

 

[Danbot]

So...I have the motor back in and got it to start with 2 pulls. I let the motor idle for about 30 seconds and killed to check the motor and make sure everything was in place. It wasn't I had probably 1-2 gallons of fuel on my garage floor, found that the fuel line without the Filter had disconnected from the fuel pump and was pumping fuel into all my electrical harnesses. I got really lucky nothing caught on fire cause it would have been bad. With that said this generated a couple of questions:

1. Is the fuel line without the filter a return line or does it feed the motor?

2. I got everything back together and never primed the oil line, however it was never completely empty and i can see a couple of small air bubbles in the line. Will these work themselves out or if not how would I prime this line?

Thanks ahead of time.....Just when I thought I had this thing all figured out. haha

Yes, the fuel line without a filter is the return line from the rail to the tank. There are metal clips inside the fitting that should secure the line when you snap it together... possibly yours is missing or damaged?

The easiest way to prime the oil pump/lines with the engine installed is to get a coat hanger or something in behind the primary clutch to pull on the oiler arm so it is wide open (pulled towards the clutch) and let the sled idle for a while. Also mix your first tank with some oil just in case your pump does end up having to burp a bubble or 2 that you couldn't see

 

[Danbot]

Oh and also... your first step to bleeding / priming the oil injection is to loosen the bleed screw on the oil pump for a few minutes until a solid stream of oil is coming out. Usually just takes a minute or 2. Then bleed the system as I stated above.

 

[Gowest88]

Should I be able to access the Bleed screw on the oil pump with everything installed? I checked the clip on the fuel line and everything looked OK so I just put line back together and I tried pulling it back off and it was on there solid so I must have not gotten it on the right the first time.

 

[Gowest88]

Oh yeah what should I mix the oil to gas ratio?

 

[rmk2112]

Should I be able to access the Bleed screw on the oil pump with everything installed? I checked the clip on the fuel line and everything looked OK so I just put line back together and I tried pulling it back off and it was on there solid so I must have not gotten it on the right the first time.

Be sure you hear the "click" when they go together. If you don't, remove and push them together again. It's tight, but you'll feel and hear it.

 

[Danbot]

Should I be able to access the Bleed screw on the oil pump with everything installed? I checked the clip on the fuel line and everything looked OK so I just put line back together and I tried pulling it back off and it was on there solid so I must have not gotten it on the right the first time.

The easiest way to get at the bleed screw is to remove the exhaust pipe, and the intake plenum, then you will be able to get a screwdriver at it.

As far as the oil goes.... its a judgement call on your part.
Just imagine...... if your oil pump gets air-locked on your first ride... the only oil she's going to get is from what you mix the tank at. I mix my first tank after an engine installation at about 50/1 but I only fill it half full. Bring spare spark plugs!