2009 Polaris Sportsman XP 850 Service Manual

• 9921850_Chapter_01.pdf
  • GENERAL INFORMATION
    • VEHICLE IDENTIFICATION
      • Model Identification
      • Engine Designation Number
      • Vehicle Identification Number (VIN)
      • Vehicle and Engine Serial Number Locations
    • VEHICLE INFORMATION
      • Publication Numbers
      • Replacement Keys
      • Special Tools
    • SPECIFICATIONS
      • MODEL: 2009 SPORTSMAN XP 850
      • MODEL: 2009 SPORTSMAN XP 850 EPS
      • 2009 SPORTSMAN XP 850 / XP 850 EPS
    • MISC. SPECIFICATIONS AND CHARTS
      • Conversion Table
      • Standard Torque Specifications
      • SAE Tap / Drill Sizes
      • Metric Tap / Drill Sizes
      • Decimal Equivalents
      • Glossary of Terms
• 9921850_Chapter_02
  • MAINTENANCE
    • PERIODIC MAINTENANCE CHART
      • Periodic Maintenance Overview
      • Break-In Period
      • Maintenance Chart Key
      • Maintenance Intervals
      • Grease Lubrication Points
      • Maintenance Quick Reference
      • Maintenance Quick Reference, Continued.....
    • LUBRICANTS / SERVICE PRODUCTS
      • Polaris Lubricants,Maintenance and Service Products
    • GENERAL VEHICLE INSPECTION AND MAINTENANCE
      • Pre-ride / Daily Inspection
      • Frame, Nuts, Bolts, Fasteners
      • Controls
    • FUEL SYSTEM AND AIR INTAKE
      • Fuel System
      • Fuel Lines
      • Fuel Filters
      • Vent Line
      • Throttle Operation
      • Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment
      • Air Filter / Pre-Filter Service
    • ENGINE
      • Engine Oil Level
      • Engine Oil and Filter Change
      • Engine Breather Hose
      • Engine Breather Assembly
      • Valve Clearance Adjustment
      • Compression and Leakdown Tests
      • Exhaust Silencer Cleaning
      • Engine Mount Fastener Torque
    • TRANSMISSION AND GEARCASES
      • Transmission Lubrication
      • Front Gearcase Lubrication
      • Front Gearcase ADC Fluid
      • Rear Gearcase Lubrication
    • COOLING SYSTEM
      • Cooling System Overview
      • Coolant Level Inspection
      • Cooling System Hoses
      • Coolant Strength / Type
    • PVT / FINAL DRIVE / WHEEL AND TIRE
      • PVT Drying
      • Drive Belt Removal
      • Drive Shaft Boot Inspection
      • Wheel and Hub Torque Table
      • Wheel Removal
      • Wheel Installation
      • Tire Pressure
      • Tire Inspection
    • ELECTRICAL AND IGNITION SYSTEM
      • Battery Maintenance
      • Battery Removal
      • Battery Installation
      • Spark Plug Service
      • Engine / Chassis Ground
    • STEERING
      • Steering Inspection
      • Power Steering Unit (EPS Models)
      • Tie Rod End / Steering Inspection
      • Toe Alignment
      • Toe Alignment Adjustment
    • SUSPENSION
      • Suspension Inspection
      • Suspension Spring Pre-Load Adjustment
    • BRAKE SYSTEM
      • Brake Fluid Inspection
      • Brake Pad Inspection
      • Hose / Fitting Inspection
      • Auxiliary Brake Pedal
    • MAINTENANCE LOG
• 9921850_Chapter_03
  • ELECTRONIC FUEL INJECTION
    • SPECIAL TOOLS
      • Part Numbers / Descriptions
      • Fuel Pressure Gauge Kit - PU-43506-A
      • Fuel Pressure Gauge Adaptor - PS-48762
      • Throttle Position Sensor Tester Kit - 2201519
      • Digital Wrench™ Diagnostic Software PU-47063
      • Digital Wrench™ SmartLink Module Kit - PU-47471
      • Digital Wrench™ - Diagnostic Connector
      • Digital Wrench™ - Download Website
    • FUEL TANK
      • Exploded View
    • FUEL LINE
      • Quick Connect Removal / Installation
    • EFI SERVICE NOTES
    • EFI SYSTEM LAYOUT
      • Exploded View
    • EFI COMPONENTS
      • Identification / Location
    • ELECTRONIC FUEL INJECTION
      • General Information
      • EFI Operation Overview
      • Initial Priming / Starting Procedure
    • ELECTRONIC CONTROL UNIT (ECU)
      • Operation Overview
      • ECU Service
      • ECU Removal / Replacement
    • FUEL PUMP
      • Operation
      • Fuel Sender Test
      • Fuel Pump Test
      • Fuel Pump / Fuel Tank Removal
      • Fuel Pump / Fuel Tank Installation
    • FUEL PRESSURE REGULATOR
      • Operation Overview
    • FUEL INJECTORS
      • Operation Overview
      • Fuel Injector Service
      • Fuel Injector Test
      • Fuel Injector Replacement
    • CRANKSHAFT POSITION SENSOR (CPS)
      • Operation Overview
      • CPS Test
      • CPS Replacement
    • TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
      • Operation Overview
      • T-MAP Test
      • T-MAP Replacement
    • IDLE AIR CONTROL VALVE (IAC)
      • Operation Overview
      • IAC Test
      • IAC Replacement
    • THROTTLE POSITION SENSOR (TPS)
      • Operation Overview
      • TPS Resistance Tests
      • TPS Tester Kit
      • Checking TPS Reading
      • TPS Adjustment
      • TPS Replacement
    • ENGINE COOLANT TEMPERATURE SENSOR (ECT)
      • Operation Overview
      • ECT Sensor Test
      • ECT Sensor Replacement
    • IGNITION COIL
      • Operation Overview
      • Ignition Coil Tests
      • Ignition Coil and HT Lead Replacement
    • EFI DIAGNOSTICS
      • Instrument Cluster Trouble Code Display
    • FUEL SYSTEM TROUBLESHOOTING
      • Fuel Starvation / Lean Mixture
      • Rich Mixture
      • Poor Idle
    • EFI SYSTEM BREAK-OUT DIAGRAMS
      • Fuel Injector Circuit (PTO)
      • Fuel Injector Circuit (MAG)
      • Idle Air Control (IAC) Circuit
      • Crankshaft Position Sensor (CPS) Circuit
      • Fuel Pump / Fuel Level Sensor Circuit
      • Fuel Pump Circuit
      • Fuel Gauge Circuit
      • Engine Coolant Temperature Sensor (ECT) Circuit
      • Throttle Position Sensor (TPS) Circuit
      • Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
      • Diagnostic Connector Circuit
      • Diagnostic Connector Circuit (EPS Models)
• 9921850_Chapter_04
  • COOLING SYSTEM
    • SPECIAL TOOLS
    • TORQUE SPECIFICATIONS
    • COOLING SYSTEM
      • Cooling System Layout and Testing
      • Cooling System Specifications
      • Cooling System Bleeding Procedure
    • RADIATOR
      • Radiator Cleaning
      • Coolant Drain / Radiator Removal
    • WATER PUMP SERVICE
      • Water Pump Impeller Removal
      • Water Pump Mechanical Seal Replacement
      • Water Pump Shaft & Bearing Replacement
      • Stator Cover Installation
      • Water Pump Assembly / Torque Specifications
      • Stator Cover Assembly Torque Specifications
    • THERMOSTAT
      • Removal (Engine Installed)
      • Installation
    • TROUBLESHOOTING
      • Cooling System
• 9921850_Chapter_05
  • ENGINE
    • GENERAL INFORMATION - ENGINE
      • Special Tools
      • Engine Lubrication Specifications
      • Oil Pressure Test
      • Oil Flow Diagram
      • Engine Specifications - EH085OLE-011
    • ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
      • Torque & Torque Sequence - Main Engine Components
      • Valve Cover / Breather Valve
      • Camshaft Carrier / Camshaft / Rocker Arm
      • Cylinder Head / Valve / IAFM
      • Valve & Spring Height Detail
      • Piston / Connecting Rod
      • Crankshaft
      • Crankcase
      • Crankcase - Upper
      • Balance Shaft / Balance Shaft Timing
      • Crankcase (Lower) With Oil Pump
      • Water Pump Coupler
      • Water Pump / Water Pump Coupler / Stator / Flywheel
      • Drive Coupler (Rear) / Starter Gear
    • ENGINE SERVICE
      • Accessible Engine Components
      • Top-End Service (Engine in Chassis)
      • Crankcase Cylinder Service Information
      • Engine Removal
      • Engine Installation Notes
    • ENGINE DISASSEMBLY AND INSPECTION
      • Valve Cover / Breather Valve
      • Rocker Carrier / Camshaft Removal
      • Rocker Arm / Rocker Arm Shaft Inspection
      • Camshaft / Camshaft Bore Inspection
      • Cylinder Head Removal
      • Cylinder Head Cleaning
      • Cylinder Head Warp Inspection
      • Cylinder Head
      • Valve Inspection
      • Combustion Chamber
      • Valve Guide Removal / Installation
      • Valve Seat Reconditioning
      • Cylinder Head Assembly
      • Valve Sealing Test
      • Cylinder Head Installation
      • Camshaft / Carrier Assembly
      • Camshaft / Camshaft Carrier Installation
      • Camshaft Timing
      • Cam Chain Tensioner Installation
      • Camshaft Timing - Quick Reference
      • Crankcase Disassembly
      • Crankcase (Lower) / Oil Pump Disassembly
      • Crankcase Disassembly (Upper)
      • Piston / Connecting Rod Removal
      • Counterbalance Shaft Removal / Inspection
      • Counterbalance Split Gear Replacement
      • Crankshaft / Cam Chain Removal
      • Cam Chain / Sprocket Inspection
      • Crankcase Inspection (Lower)
      • Crankshaft Inspection
      • Connecting Rod Inspection
      • Connecting Rod Big End Bearing Selection
      • Piston / Piston Ring Inspection
      • Piston Ring Removal
      • Piston Ring Installed Gap
      • Piston Pin Bore Inspection
      • Cylinder Inspection
      • Piston-to-Cylinder Clearance
      • Honing - Important Information
    • ENGINE ASSEMBLY
      • Crankcase Preparation - Upper
      • Piston Ring Installation
      • Piston / Connecting Rod Assembly
      • Piston / Connecting Rod Installation
      • Crankshaft Installation
      • Oil Passage Tube
      • Crankcase Assembly - Upper
      • Balance Shaft Installation
      • Balance Shaft Timing
      • Crankcase Preparation (Lower)
      • Crankcase Sealant and Torque Values
      • Crankcase Assembly
    • WATER PUMP
      • Water Pump Impeller Removal
      • Water Pump Mechanical Seal Replacement / Coupler Shaft & Bearing Replacement
    • TROUBLESHOOTING
      • Engine
• 9921850_Chapter_06
  • TRANSMISSION
    • TRANSMISSION SPECIFICATIONS
      • Torque Specifications
      • Lubrication Specifications
    • SHIFT LINKAGE / GEAR SELECTOR
      • Shift Linkage Inspection
      • Gear Selector Removal
    • TRANSMISSION SERVICE
      • Transmission Removal
      • Transmission Disassembly
      • Transmission Shaft Service
      • Transmission Assembly
      • Transmission Installation
      • Transmission Exploded View
    • TROUBLESHOOTING
      • Troubleshooting Checklist
• 9921850_Chapter_07
  • CLUTCHING (PVT)
    • SPECIAL TOOLS AND SUPPLIES
    • TORQUE SPECIFICATIONS
      • PVT System Fastener Torques
    • PVT SYSTEM OVERVIEW
      • General Operation
      • Drive Clutch Operation
      • Shift Weights
      • Driven Clutch Operation
      • PVT Break-In (Drive Belt / Clutches)
      • Maintenance / Inspection
      • Overheating / Diagnosis
    • PVT SYSTEM SERVICE
      • PVT Sealing and Ducting Components
      • Disassembly
      • Assembly
    • DRIVE BELT
      • Belt Removal
      • Belt Inspection
      • Belt Installation
      • PVT Break-In (Drive Belt / Clutches)
    • DRIVE CLUTCH SERVICE
      • Spring Specifications
      • Exploded View
      • Clutch Disassembly
      • Spider Removal
      • Roller, Pin, and Thrust Washer Inspection
      • Button To Tower Clearance Inspection
      • Shift Weight Inspection
      • Bearing Inspection
      • Clutch Inspection
      • Moveable Sheave Bushing Inspection
      • Bushing Service
      • Clutch Assembly
    • DRIVEN CLUTCH SERVICE
      • Clutch Disassembly
      • Bushing Service
      • Clutch Assembly
      • Exploded View
    • TROUBLESHOOTING
• 9921850_Chapter_08
  • FINAL DRIVE
    • GENERAL SPECIFICATIONS
      • Torque Specifications
      • Special Tools
    • WHEELS
      • Removal
      • Installation
    • WHEEL HUBS
      • Front Hub Exploded View
      • Rear Hub Exploded View
    • FRONT BEARING CARRIER
      • Inspection / Removal
      • Bearing Replacement
      • Installation
    • FRONT DRIVE SHAFT
      • Removal
      • Installation
    • FRONT PROPSHAFT
      • Removal
      • Installation
    • PROPSHAFT U-JOINT SERVICE
      • Disassembly
      • Assembly
    • FRONT GEARCASE - CENTRALIZED HILLIARD
      • Exploded View
      • AWD Operation
      • ADC Operation
      • AWD Diagnosis
      • Gearcase Removal
      • Gearcase Disassembly / Inspection
      • Gearcase Assembly
      • Setting Ring Gear Backlash
      • Gearcase Installation
      • ADC System Fluid Bleeding
    • REAR BEARING CARRIER
      • Inspection / Removal
      • Bearing Replacement
      • Bushing Replacement
      • Installation
    • REAR DRIVE SHAFT
      • Removal
      • Installation
    • DRIVE SHAFT SERVICE
      • Drive Shaft / CV Joint Handling Tips
      • Outer CV Joint / Boot Replacement
      • Inner Plunging Joint / Boot Replacement
      • Drive Shaft Exploded View
    • REAR PROPSHAFT
      • Removal
      • Installation
    • REAR GEARCASE
      • Gearcase Removal
      • Gearcase Disassembly and Inspection
      • Gearcase Bearing and Seal Replacement
      • Gearcase Assembly
      • Gearcase Installation
      • Gearcase Exploded View
• 9921850_Chapter_09
  • BODY / FRAME
    • TORQUE SPECIFICATIONS
    • DECAL REPLACEMENT
    • SPECIAL TOOLS
      • Plastic Push Rivet Removal
      • Multi-Function Pliers
    • SEAT AND SIDE PANELS
      • Removal / Installation
    • FRONT RACK
      • Removal / Installation
    • FRONT BUMPER
      • Removal / Installation
    • MUD GUARDS
      • Removal / Installation
    • FOOTWELLS
      • Removal / Installation
    • FRONT CAB
      • Removal
      • Installation
    • REAR RACK
      • Removal / Installation
    • REAR BUMPER COVERS
      • Removal / Installation
    • REAR CAB
      • Removal / Installation
    • HEADLIGHT POD
      • Disassembly / Removal
      • Assembly / Installation
    • MAIN FRAME
      • Frame Support Exploded View
    • CHASSIS
      • Body Plastic Removed View
• 9921850_Chapter_10
  • STEERING / SUSPENSION
    • GENERAL SPECIFICATIONS
      • Torque Specifications
    • HANDLEBAR
      • Removal / Replacement
      • Installation
    • STEERING
      • Steering Post Removal
      • Steering Post Installation
      • Steering Exploded View
    • STEERING (EPS MODELS)
      • Upper Steering Post Removal
      • Upper Steering Post Installation
      • Power Steering Unit Removal
      • Power Steering Unit Installation
      • Steering Exploded View (EPS Models)
    • STEERING TIE ROD
      • Tie Rod / Tie Rod End Replacement
    • FRONT A-ARMS
      • Exploded View
      • Removal / Replacement
    • BALL JOINT SERVICE
      • Removal
      • Installation
    • REAR A-ARMS
      • Exploded View
      • Removal
      • Installation
    • REAR STABILIZER BAR
      • Exploded View
      • Linkage Removal / Installation
      • Stabilizer Bar Removal / Installation
    • SHOCKS / SPRINGS
      • Exploded View
      • Shock Removal / Installation
      • Shock / Spring Replacement
• 9921850_Chapter_11
  • BRAKES
    • SPECIFICATIONS
      • General Brake Specifications
      • General Torque Specifications
      • Special Tools / Brake Fluid
    • BRAKE SYSTEM SERVICE NOTES
    • BRAKE NOISE TROUBLESHOOTING
    • HYDRAULIC BRAKE SYSTEM OPERATION
    • BRAKE SYSTEM EXPLODED VIEW
      • Brake Caliper Exploded View
      • Hand Master Cylinder Exploded View
    • BRAKE BLEEDING
      • Fluid Replacement
      • Bleeding Procedure
    • HAND BRAKE MASTER CYLINDER
      • Removal
      • Disassembly
      • Installation
      • Brake Switch Replacement
    • FOOT BRAKE MASTER CYLINDER
      • Operation Overview
      • Foot Master Cylinder Removal / Installation
      • Brake Pedal Removal / Installation
    • BRAKE PADS
      • Pad Removal
      • Pad Inspection
      • Pad Installation
      • Brake Burnishing Procedure
    • CALIPER SERVICE
      • Caliper Removal
      • Caliper Disassembly
      • Caliper Inspection
      • Caliper Reassembly
      • Caliper Installation
    • BRAKE DISC SERVICE
      • Disc Inspection
      • Disc Removal / Replacement
    • TROUBLESHOOTING
      • Brake Squeal
• 9921850_Chapter_12
  • ELECTRICAL
    • General Information
      • Special Tools
      • Electrical Service Notes
      • Component Locations
    • Instrument Cluster
      • Overview
      • Rider Information Display
      • Speed Information
      • Information Display Area
      • Diagnostic Mode
      • Instrument Cluster Pinouts
    • Ignition Switch
      • Function Test
    • ADC / 4x4 / 2x4 Switch
      • Function Test
    • Off / Run LH Switch
      • Function Test
    • Reverse Override / Mode Button
      • Function Test
    • Head Lamp Switch
      • Function Test
    • Electronic Throttle Control (ETC) Switch
      • Electronic Throttle Control (ETC) Switch
    • Gear Selector Switch
      • Selector Switch Function Test
      • Resistor Module Function Test
    • Speed Sensor
      • Vehicle Speed Sensor
    • Brake Switch
      • Function Test
    • AWD / ADC Coils
      • Operation Overview
      • Diagnosing System Failures
    • Relays
      • Relay Overview
      • Chassis Relay
      • Fan Relay
      • EFI Relay
      • Bumper Lights Relay
      • Start Solenoid Relay
      • Power Steering Relay
    • Fuses
      • Protected Circuits
    • Fuse Box Layout
    • Lights
      • Headlight Adjustment
      • Bumper Lamp Adjustment
      • Headlight Replacement
      • Bumper Lamp Replacement
      • Tail / Brake Bulb Replacement
    • Charging System
      • Charging System Diagram
      • Charging System Testing
      • Current Draw - Key Off
      • Battery Charge Test
      • Stator / Alternator Tests
      • Stator / Alternator Removal
      • Stator / Alternator Installation
    • Battery Service
      • Battery Specifications
      • General Battery Information
      • Battery Removal / Installation
      • Battery Off Season Storage
      • Battery Testing
      • OCV - Open Circuit Voltage Test
      • Load Test
      • Charging Procedure
    • Starter Motor
      • Starter / Starter Lockout System Diagram
      • Troubleshooting
      • Voltage Drop Testing
      • Starter Motor Removal / Replacement
    • Instrument Cluster Troubleshooting
      • Instrument Cluster - Key OFF / No Power
      • Instrument Cluster - Key ON / No Power
      • Instrument Cluster - No High Beam Indicator
      • Instrument Cluster - No / Incorrect Fuel Level
      • Instrument Cluster Circuit
    • Electronic Power Steering (EPS)
      • Electronic Power Steering (EPS) Circuits
      • EPS Operation
      • EPS 8-Way Wire Harness Connector
      • EPS Troubleshooting
    • Electrical BreakOut Diagrams
      • Battery Charging Circuits
      • Constant Power Circuits
      • Key-On Power Circuits
      • Chassis Power Circuits
      • Head Lamp Circuits
      • Brake Lamp Circuits
      • Engine Start Command Circuits
      • ECM Wake-Up Command Circuits
      • AWD / ADC Circuits
      • AWD / ADC Function Tests
      • Radiator Fan Circuit
      • Gear Selector Switch Circuit
      • Ground Speed Sensor Circuit
      • Reverse Override Circuit
    • Controller Area Network (CAN)
      • Overview
      • CAN Troubleshooting
• 9921850_Wire_Diagrams_Intl
  • SPORTSMAN XP 850 INTL (PAGE 1 OF 2)
  • SPORTSMAN XP 850 INTL (PAGE 2 OF 2)
  • AWD / ADC
  • BATTERY CHARGING
  • BATTERY PLUS
  • BRAKE LAMPS-START
  • CHASSIS POWER
  • COOLING FAN
  • ECM WAKE-UP
  • EFI
  • ENGINE CRANK
  • EPS
  • FUEL PUMP & LEVER
  • GEAR SENSOR
  • GROUND SPEED SENSOR
  • KEY ON POWER
  • LIGHTS
  • HAZARD LIGHTS
• 9921850_Wire_Diagrams_r01
  • SPORTSMAN XP 850 (PAGE 1 OF 2)
  • SPORTSMAN XP 850 (PAGE 2 OF 2)
  • AWD / ADC
  • BATTERY CHARGING
  • BATTERY PLUS
  • BRAKE LAMPS-START
  • CHASSIS POWER
  • COOLING FAN
  • ECM WAKE-UP
  • EFI
  • ENGINE CRANK
  • EPS
  • FUEL PUMP & LEVEL
  • GEAR SENSOR
  • GROUND SPEED SENSOR
  • KEY ON POWER
  • HEADLAMPS