Polaris 2009 Sportsman XP 850 Manuals

Polaris 2009 Sportsman XP 850 Manuals

Manuals and User Guides for Polaris 2009 Sportsman XP 850. We have 1 Polaris 2009 Sportsman XP 850 manual available for free PDF download: Service Manual

Polaris 2009 Sportsman XP 850 Service Manual

Polaris 2009 Sportsman XP 850 Service Manual (381 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 29.99 MB

Table of Contents

General Information Chapter

1
Maintenance Chapter 2 Maintenance 2

11
- Break-In Period / Maintenance Chart Key
  12
- Chapter 2
  12
- Periodic Maintenance Chart
  12
- Maintenance Intervals
  13
- Grease Lubrication Points
  15
- Maintenance Quick Reference
  16
- Maintenance Quick Reference, Continued
  17
- Lubricants / Service Products
  18
- Fuel System and Air Intake
  19
- General Vehicle Inspection and Maintenance
  19
- Engine
  22
- Transmission and Gearcases
  27
  - Transmission Lubrication
    27
  - Front Gearcase Lubrication
    28
  - Front Gearcase Adc Fluid
    29
  - Rear Gearcase Lubrication
    30
- Cooling System
  31
  - Coolant Level Inspection
    31
  - Cooling System Hoses / Coolant Strength / Coolant Type
    32
- Pvt / Final Drive / Wheel and Tire
  33
- Electrical and Ignition System
  35
  - Battery Maintenance
    35
  - Battery Removal / Installation
    36
  - Spark Plug Service
    36
  - Engine / Chassis Ground
    37
- Steering
  38
  - Steering Inspection
    38
  - Power Steering Unit (Eps Models)
    38
  - Toe Alignment
    39
  - Toe Alignment Adjustment
    40
- Suspension
  40
  - Suspension Inspection / Suspension Spring Pre-Load Adjustment
    40
- Brake System
  41
  - Brake Fluid / Brake Pad / Hose / Fitting Inspection
    41
  - Auxiliary Brake Pedal
    42
- Maintenance Log
  43
Electronic Fuel Injection Chapter 3 Electronic Fuel Injection

45
- Chapter 3
  46
- Special Tools
  46
  - Electronic Fuel Injection
    46
- Fuel Tank
  48
- Efi Service Notes
  49
- Fuel Line
  49
- Efi System Layout
  50
- Efi Components
  51
- Electronic Fuel Injection
  51
- Electronic Control Unit (Ecu)
  54
  - Ecu Service
    54
  - Ecu Removal / Replacement
    55
- Fuel Pump
  55
  - Fuel Sender Test
    56
  - Fuel Pump Test
    56
  - Fuel Pump / Fuel Tank Removal
    57
  - Fuel Pump / Fuel Tank Installation
    58
- Fuel Injectors
  58
- Fuel Pressure Regulator
  58
- Crankshaft Position Sensor (Cps)
  60
  - Cps Test / Replacement
    60
  - Cps Replacement
    60
- Idle Air Control Valve (Iac)
  61
  - Iac Test
    61
  - Iac Replacement
    62
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  61
  - T-Map Test / Replacement
    61
- Throttle Position Sensor (Tps)
  63
  - Tps Resistance Tests / Tps Tester Kit
    63
  - Checking Tps Reading
    64
  - Tps Adjustment
    65
  - Tps Replacement
    66
- Engine Coolant Temperature Sensor (Ect)
  66
  - Ect Sensor Test
    66
  - Ect Sensor Replacement
    67
- Ignition Coil
  67
  - Ignition Coil Tests
    67
  - Ignition Coil and Ht Lead Replacement
    68
- Efi Diagnostics
  69
  - Instrument Cluster Trouble Code Display
    69
- Fuel System Troubleshooting
  72
- Efi System Break-Out Diagrams
  73
Cooling System Chapter 4 Cooling System

81
- Chapter 4
  82
- Cooling System
  82
- Cooling System Layout and Testing
  82
- Special Tools
  82
- Torque Specifications
  82
- Cooling System Specifications
  83
- Cooling System Bleeding Procedure
  84
- Radiator
  84
  - Radiator Cleaning
    84
  - Coolant Drain / Radiator Removal
    84
- Water Pump Service
  86
- Thermostat
  92
- Troubleshooting
  92
Chapter 5 Engine

93
- Engine Lubrication Specifications
  95
- General Information - Engine
  95
- Oil Pressure Test
  95
- Special Tools
  95
- Oil Flow Diagram
  96
- Engine Specifications - Eh085Ole-011
  97
- Engine Assembly Views and Torque Values
  99
  - Torque & Torque Sequence - Main Engine Components
    99
  - Valve Cover / Breather Valve
    100
  - Camshaft Carrier / Camshaft / Rocker Arm
    101
  - Cylinder Head / Valve / Iafm
    102
  - Valve & Spring Height Detail
    103
  - Piston / Connecting Rod
    104
  - Crankshaft
    105
  - Crankcase
    106
  - Crankcase - Upper
    107
  - Balance Shaft / Balance Shaft Timing
    108
  - Crankcase (Lower) with Oil Pump
    109
  - Water Pump Coupler
    110
  - Water Pump / Water Pump Coupler / Stator / Flywheel
    111
  - Drive Coupler (Rear) / Starter Gear
    112
- Engine Service
  113
  - Accessible Engine Components
    113
  - Top-End Service (Engine in Chassis)
    113
  - Crankcase Cylinder Service Information
    113
  - Engine Removal
    113
  - Engine Installation Notes
    117
- Engine Disassembly and Inspection
  118
  - Valve Cover / Breather Valve
    118
  - Rocker Carrier / Camshaft Removal
    118
  - Rocker Arm / Rocker Arm Shaft Inspection
    119
  - Camshaft / Camshaft Bore Inspection
    120
  - Cylinder Head Removal
    120
  - Cylinder Head Cleaning
    120
  - Cylinder Head Warp Inspection
    121
  - Cylinder Head Disassembly
    121
  - Valve Inspection
    122
  - Combustion Chamber
    123
  - Valve Guide Removal / Installation
    123
  - Valve Seat Reconditioning
    124
  - Valve Seat Inspection
    124
  - Cylinder Head Assembly
    126
  - Valve Sealing Test
    126
  - Cylinder Head Installation
    127
  - Camshaft / Carrier Assembly
    128
  - Camshaft / Camshaft Carrier Installation
    128
  - Camshaft Timing
    129
  - Cam Chain Tensioner Installation
    130
  - Camshaft Timing - Quick Reference
    131
  - Crankcase Disassembly
    132
  - Crankcase (Lower) / Oil Pump Disassembly
    133
  - Crankcase Disassembly (Upper)
    135
  - Piston / Connecting Rod Removal
    135
  - Counterbalance Shaft Removal / Inspection
    136
  - Counterbalance Split Gear Replacement
    136
  - Crankshaft / Cam Chain Removal
    138
  - Cam Chain / Sprocket Inspection
    138
  - Crankcase Inspection (Lower)
    138
  - Crankshaft Inspection
    138
  - Connecting Rod Inspection
    139
  - Connecting Rod Big End Bearing Selection
    140
  - Piston / Piston Ring Inspection
    140
  - Piston Ring Removal
    140
  - Piston Ring Installed Gap
    141
  - Piston Pin Bore Inspection
    141
  - Cylinder Inspection
    141
  - Piston-To-Cylinder Clearance
    142
  - Honing - Important Information
    142
- Engine Assembly
  143
  - Crankcase Preparation - Upper
    143
  - Piston Ring Installation
    143
  - Piston / Connecting Rod Assembly
    144
  - Piston / Connecting Rod Installation
    144
  - Crankshaft Installation
    145
  - Oil Passage Tube
    145
  - Crankcase Assembly - Upper
    146
  - Balance Shaft Installation
    147
  - Balance Shaft Timing
    148
  - Crankcase Preparation (Lower)
    149
  - Crankcase Sealant and Torque Values
    150
  - Crankcase Assembly
    151
- Water Pump
  151
  - Water Pump Impeller Removal
    151
- Troubleshooting
  152
  - Engine
    152
Transmission Chapter 6 Transmission

155
- Chapter 6
  156
- Lubrication Specifications
  156
- Shift Linkage / Gear Selector
  156
  - Shift Linkage Inspection
    156
  - Gear Selector Removal
    156
- Torque Specifications
  156
- Transmission Specifications
  156
- Transmission Service
  157
  - Transmission Removal
    157
  - Transmission Disassembly
    158
  - Transmission Shaft Service
    162
  - Transmission Assembly
    164
  - Transmission Installation
    168
  - Transmission Exploded View
    170
- Troubleshooting
  172
Clutching (Pvt) Chapter 7 Clutching (Pvt)

173
- Chapter 7
  174
- Drive Clutch Operation
  174
- General Operation
  174
- Pvt System Overview
  174
- Special Tools and Supplies
  174
- Torque Specifications
  174
- Driven Clutch Operation
  175
- Maintenance / Inspection
  175
- Pvt Break-In (Drive Belt / Clutches)
  175
- Shift Weights
  175
- Overheating / Diagnosis
  176
- Pvt System Service
  177
  - Pvt Sealing and Ducting Components
    177
  - Disassembly
    178
  - Assembly
    179
- Drive Belt
  181
  - Belt Removal
    181
  - Belt Inspection
    182
  - Belt Installation
    182
  - Pvt Break-In (Drive Belt / Clutches)
    182
- Drive Clutch Service
  183
  - Spring Specifications
    183
  - Exploded View
    184
  - Clutch Disassembly
    184
  - Spider Removal
    185
  - Roller, Pin, and Thrust Washer Inspection
    186
  - Button to Tower Clearance Inspection
    186
  - Shift Weight Inspection
    186
  - Bearing Inspection
    187
  - Clutch Inspection
    187
  - Moveable Sheave Bushing Inspection
    188
  - Bushing Service
    189
  - Clutch Assembly
    191
- Driven Clutch Service
  192
  - Clutch Disassembly
    192
  - Bushing Service
    194
  - Clutch Assembly
    196
  - Exploded View
    199
- Troubleshooting
  200
Final Drive Chapter 8 Final Drive

203
- General Specifications
  204
- Wheels
  204
- Wheel Hubs
  205
- Chapter 8
  206
- Front Bearing Carrier
  206
- Inspection / Removal
  206
- Bearing Replacement
  207
- Installation
  208
- Front Drive Shaft
  209
  - Removal
    209
  - Installation
    210
- Front Propshaft
  211
- Propshaft U-Joint Service
  211
  - Disassembly
    211
  - Assembly
    212
- Front Gearcase - Centralized Hilliard
  213
  - Exploded View
    213
  - Awd Operation
    214
  - Adc Operation
    215
  - Awd Diagnosis
    216
  - Gearcase Removal
    217
  - Gearcase Disassembly / Inspection
    218
  - Gearcase Assembly
    222
  - Setting Ring Gear Backlash
    224
  - Gearcase Installation
    225
  - Adc System Fluid Bleeding
    227
- Rear Bearing Carrier
  228
  - Inspection / Removal
    228
  - Bearing Replacement
    229
  - Bushing Replacement
    230
  - Installation
    230
- Rear Drive Shaft
  232
  - Removal
    232
  - Installation
    233
- Drive Shaft Service
  234
- Rear Propshaft
  239
- Rear Gearcase
  240
  - Gearcase Removal
    240
  - Gearcase Disassembly and Inspection
    242
  - Gearcase Bearing and Seal Replacement
    243
  - Gearcase Assembly
    244
  - Gearcase Installation
    245
  - Gearcase Exploded View
    246
Body / Frame Chapter 9 Body / Frame

247
- Chapter 9
  248
- Decal Replacement
  248
- Multi-Function Pliers
  248
- Plastic Push Rivet Removal
  248
- Special Tools
  248
- Torque Specifications
  248
- Front Rack
  249
- Seat and Side Panels
  249
  - Removal / Installation
    249
- Footwells
  250
- Front Bumper
  250
  - Removal / Installation
    250
- Mud Guards
  250
- Front Cab
  251
  - Removal
    251
  - Installation
    251
- Rear Bumper Covers
  252
- Rear Cab
  252
- Rear Rack
  252
  - Removal / Installation
    252
- Headlight Pod
  253
  - Disassembly / Removal
    253
  - Assembly / Installation
    253
- Frame Support Exploded View
  254
- Main Frame
  254
- Chassis
  255
  - Body Plastic Removed View
    255
Steering / Suspension Chapter 10 Steering / Suspension

257
- Chapter 10 Torque Specifications
  258
- General Specifications
  258
- Handlebar
  258
  - Removal / Replacement
    258
  - Installation
    259
- Steering
  259
  - Steering Post Removal
    259
  - Steering Post Installation
    260
  - Steering Exploded View
    261
- Steering (Eps Models)
  262
- Steering Tie Rod
  267
  - Tie Rod / Tie Rod End Replacement
    267
- Front A-Arms
  268
  - Exploded View
    268
  - Removal / Replacement
    269
- Ball Joint Service
  270
  - Removal
    270
  - Installation
    270
- Rear A-Arms
  272
  - Exploded View
    272
- Rear Stabilizer Bar
  274
  - Exploded View
    274
  - Linkage Removal / Installation
    275
  - Stabilizer Bar Removal / Installation
    275
- Shocks / Springs
  276
  - Exploded View
    276
  - Shock Removal / Installation
    276
  - Shock / Spring Replacement
    276
Brakes Chapter 11 Brakes

277
- Chapter 11
  278
- General Brake Specifications
  278
- General Torque Specifications
  278
- Special Tools / Brake Fluid
  278
- Specifications
  278
- Brake Noise Troubleshooting
  279
- Brake System Service Notes
  279
- Brake System Exploded View
  280
  - Brake Caliper Exploded View
    281
  - Hand Master Cylinder Exploded View
    281
- Hydraulic Brake System Operation
  280
- Brake Bleeding
  282
  - Fluid Replacement
    282
  - Bleeding Procedure
    282
- Hand Brake Master Cylinder
  284
  - Brake Switch Replacement
    284
- Foot Brake Master Cylinder
  285
  - Foot Master Cylinder Removal / Installation
    285
  - Brake Pedal Removal / Installation
    285
- Brake Pads
  286
  - Caliper Removal
    287
  - Brake Burnishing Procedure
    287
  - Caliper Disassembly
    287
- Caliper Service
  287
  - Caliper Inspection
    288
  - Caliper Installation
    289
  - Caliper Reassembly
    289
- Brake Disc Service
  290
- Troubleshooting
  292
  - Poor Brake Performance
    292
  - Brakes Lock
    292
Chapter 12 Electrical

293
- Electrical Service Notes
  295
- General Information
  295
- Instrument Cluster
  296
  - Rider Information Display
    297
  - Diagnostic Mode
    300
- Ignition Switch
  301
  - Instrument Cluster Pinouts
    301
- Adc / 4X4 / 2X4 Switch
  302
- Off / Run Lh Switch
  302
- Head Lamp Switch
  303
- Reverse Override / Mode Button
  303
- Electronic Throttle Control (Etc) Switch
  304
- Gear Selector Switch
  304
- Speed Sensor
  305
- Awd / Adc Coils
  306
- Brake Switch
  306
  - Diagnosing System Failures
    306
- Relays
  307
- Fuse Box Layout
  309
- Lights
  310
  - Headlight Adjustment
    310
  - Tail / Brake Bulb Replacement
    311
- Charging System
  312
  - Current Draw - Key off
    312
  - Battery Charge Test
    312
  - Stator / Alternator Tests
    312
  - Stator / Alternator Removal
    313
  - Stator / Alternator Installation
    314
- Battery Service
  315
  - Battery Removal / Installation
    315
  - Battery off Season Storage
    315
  - Battery Testing
    315
  - Charging Procedure
    316
- Starter Motor
  317
  - Starter / Starter Lockout System Diagram
    317
  - Troubleshooting
    317
  - Voltage Drop Testing
    317
  - Starter Motor Removal / Replacement
    318
- Instrument Cluster Troubleshooting
  319
- Electronic Power Steering (Eps)
  324
  - Electronic Power Steering (Eps) Circuits
    324
  - Eps Operation
    324
  - Eps 8-Way Wire Harness Connector
    325
  - Eps Troubleshooting
    325
- Electrical Breakout Diagrams
  326
  - Battery Charging Circuits
    326
  - Constant Power Circuits
    328
  - Key-On Power Circuits
    330
  - Chassis Power Circuits
    331
  - Head Lamp Circuits
    332
  - Brake Lamp Circuits
    333
  - Engine Start Command Circuits
    334
  - Ecm Wake-Up Command Circuits
    336
  - Awd / Adc Circuits
    337
  - Awd / Adc Function Tests
    339
  - Radiator Fan Circuit
    340
  - Gear Selector Switch Circuit
    342
  - Ground Speed Sensor Circuit
    344
  - Reverse Override Circuit
    345
- Controller Area Network (Can)
  346
  - Overview
    346
  - Can Troubleshooting
    346

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