Max II Engine Replacement

Max II Engine Replacement

This article will act as a basic guide for removing and replacing the engine in a Max II AATV. Before you begin be sure that you disconnect the battery under the seat. Note: Click thumbnails to view larger photos

Start by disconnecting the ground strap and the throttle and choke cables at the motor. Then disconnect the wire at the starter solenoid, the electrical connector at the front of the engine, and the fuel line (1,2,and 3 respectively in the picture).



Note: Make sure that you plug the fuel line and raise it above the tank so that no fuel drains out.

Remove the four bolts that hold on the exhaust. Two are circled in the picture below. Then gently pull it away from the motor and be sure to remove the two exhaust gaskets that will later be replaced.



Remove the four bolts that hold the motor to the mounts.



Remove the belt by sliding the motor forward and rotating it clockwise. This should give you enough room to just slide the belt off. Just be careful that you don’t damage the clutch or exhaust.



Now you are ready to lift the motor straight up out of the Max. I was able to do this by myself by physically lifting the motor but it would be much easier if you have some help or a hoist.