Page 1 Service Manual FOREWORD The information printed within this publication includes the latest product information at time of print. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer ® technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Page 2 SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
Page 3 Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX: 2018 SPORTSMAN...
Page 5 2018 Sportsman 850/1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION...
Page 7: Table Of Contents
............1.6 POLARIS MOBILE DIGITAL WRENCH (PMDW) .
Page 8: Vehicle Identification
GENERAL INFORMATION VEHICLE IDENTIFICATION MODEL NUMBER DESIGNATION (2015 +) Example: R15RUE57AC GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION 4th* 5th* 6th* 7th* 8th* 10th** * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only.
Page 9: Vehicle And Engine Serial Number Locations
GENERAL INFORMATION VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1).
Page 10: Reference Information
SPORTSMAN 850 A18SXA85B1 / B7 9928123 SPORTSMAN 850 SP A18SXE85B9 / BM / BS 9928123 SPORTSMAN 1000 XP A18SXE95BR / BL / BP 9928123 2018 SPORTSMAN 850 TOURING A18SYE85BB 9928122 SPORTSMAN 1000 TOURING A18SYE95BU 9928122 SPORTSMAN 850 HIGH LIFTER A18SXN85B8 9928123...
Page 11: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 12: Polaris Mobile Digital Wrench (Pmdw)
To access the user’s guide, launch the app, and then (PMDW) click on the “Help” button in the Settings/Preferences Polaris Mobile Digital Wrench (PMDW) is a diagnostic menu. software application (app) designed specifically for • Only CAN-based vehicles are compatible with PMDW Android™...
Page 13: Master Torque Table
GENERAL INFORMATION MASTER TORQUE TABLE ENGINE / COOLING SYSTEM ITEM TORQUE MAINTENANCE Cam Chain Tensioner ITEM TORQUE 7 ft. lbs (10 Nm) Fasteners Oil Drain Plug 12 ft-lbs (16 Nm) Camshaft Carrier 13 ft. lbs (18 Nm) Fasteners Turn by hand until filter O-ring contacts sealing Oil Filter Spark Plug...
Page 14 GENERAL INFORMATION PVT SYSTEM FINAL DRIVE ITEM TORQUE ITEM TORQUE 47 ft. lbs (64 Nm) Lug Nut (Aluminum Drive Clutch Bolt 75 ft. lbs (102 Nm) Wheel) 225 ft. lbs (305 Nm) (Apply 0.4 mL Loctite® Lug Nut (Steel Wheel) 45 ft.
Page 15 GENERAL INFORMATION STEERING / SUSPENSION ELECTRICAL ITEM TORQUE ITEM TORQUE 14 ft-lbs (19 Nm) Tail Light Fasteners Until Fully Seated Tie Rod Jam Nut 42 ft-lbs (57 Nm) Battery Terminal Tie Rod End Fastener 6 ft. lbs (8 Nm) Fasteners Rear Shock Mounting 30 ft-lbs (54 Nm) Fasteners...
Page 16: Vehicle Specifications
GENERAL INFORMATION VEHICLE SPECIFICATIONS 2018 SPORTSMAN 850 ENGINE Pressurized Wet Sump Lubrication Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe w/ Dual Outlet Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI...
Page 17 Circuit Breaker Fan Motor: 20A Single Control Brakes Hydraulic 3-Wheel Disc Lights: 20 Amp Drive: 20 Amp Brake Fluid Polaris DOT 4 Brake Fluid Fuses Accessory: 20 Amp (Located in Relay/Fuse EFI: 20 Amp Box) CLUTCH SETTINGS Unswitched: 10 Amp...
Page 18 GENERAL INFORMATION 2018 SPORTSMAN 850 SP ENGINE +Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe w/ Dual Outlet Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI Throttle Body / Size...
Page 19 Carlisle AT 489 II / 26 x 10 - Rear Tire Model / Size Front: 7 psi (48 kPa) Tire Air Pressure Rear: 7 psi (48 kPa) Single Control Brakes Hydraulic 3-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid 1.13...
Page 20 GENERAL INFORMATION 2018 SPORTSMAN 850 TOURING ENGINE Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe w/ Dual Outlet Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI Throttle Body / Size...
Page 21 Carlisle AT 489 II / 26 x 10 - Rear Tire Model / Size Front: 7 psi (48 kPa) Tire Air Pressure Rear: 7 psi (48 kPa) Single Control Brakes Hydraulic 3-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid 1.15...
Page 22 GENERAL INFORMATION 2018 SPORTSMAN 1000 XP ENGINE Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe with Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI Throttle Body / Size Mikuni Dual Bore / 42 mm Electronic Fuel Pump (in Fuel Delivery tank)
Page 23 Lights: 20 Amp Single Control Brakes Drive: 20 Amp Hydraulic 4-Wheel Disc Fuses Accessory: 20 Amp Brake Fluid Polaris DOT 4 Brake Fluid (Located in Relay/Fuse EFI: 20 Amp Box) Unswitched: 10 Amp EPS: 30 Amp CLUTCH SETTINGS Fuel Pump: 10 Amp...
Page 24: 2018 Sportsman 1000 Xp Touring
GENERAL INFORMATION 2018 SPORTSMAN 1000 XP TOURING ENGINE Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe with Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI Throttle Body / Size Mikuni Dual Bore / 42 mm Electronic Fuel Pump (in Fuel Delivery tank)
Page 25 Carlisle AT 489 II / 26 x 10 - Rear Tire Model / Size Front: 7 psi (48 kPa) Tire Air Pressure Rear: 7 psi (48 kPa) Single Control Brakes Hydraulic 4-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid 1.19...
Page 26: 2018 Sportsman Xp 850 High Lifter
GENERAL INFORMATION 2018 SPORTSMAN XP 850 HIGH LIFTER ENGINE +Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe w/ Dual Outlet Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI Throttle Body / Size Mikuni Dual Bore / 42 mm Electronic Fuel Pump (in Fuel Delivery...
Page 27 Carlisle AT 489 II / 29.5 x Rear Tire Model / Size 9.5- 14 Front: 7 psi (48 kPa) Tire Air Pressure Rear: 7 psi (48 kPa) Single Control Brakes Hydraulic 3-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid 1.21...
Page 28 GENERAL INFORMATION 2018 SPORTSMAN XP 1000 HIGH LIFTER ENGINE Engine Oil Requirement PS-4 / 2 qt. (1.9 l) Stainless Steel Dual Header Exhaust System Pipe with Silencer FUEL SYSTEM Bosch Multi-Port Fuel System Type Sequential EFI Throttle Body / Size Mikuni Dual Bore / 42 mm Electronic Fuel Pump (in Fuel Delivery...
Page 29 Circuit Breaker Fan Motor: 20A Single Control Brakes Hydraulic 4-Wheel Disc Lights: 20 Amp Drive: 20 Amp Brake Fluid Polaris DOT 4 Brake Fluid Fuses Accessory: 20 Amp (Located in Relay/Fuse EFI: 20 Amp CLUTCH SETTINGS Box) Unswitched: 10 Amp...
Page 30: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS CONVERSION TABLE UNIT OF MEASURE MULTIPLIED BY CONVERTS TO ft-lbs x 12 = in-lbs in-lbs x 0.0833 = ft-lbs x 1.356 = Nm ft-lbs in-lbs x 0.0115 = kg-m x 0.7376 = ft-lbs kg-m x 7.233 = ft-lbs kg-m...
Page 31: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE TAP / DRILL SIZES METRIC TAP / DRILL SIZES DECIMAL THREAD THREAD EQUIVA- NEAREST SIZE DRILL SIZE SIZE DRILL SIZE TAP SIZE DRILL SIZE LENT FRACTION #0–80 3/64 1/2–13 27/64 3 x .50 0.0995 3/32 #1–64 1/2–20 29/64 3 x .60 3/32...
Page 32: Decimal Equivalents
GENERAL INFORMATION DECIMAL EQUIVALENTS FRACTION DECIMAL MM TO INCHES FRACTION DECIMAL MM TO INCHES 1/64 0.0156″ 41/64 0.6406″ 1/32 0.0312″ 1 mm = 0.0394″ 0.6563″ 17 mm = 0.6693″ 21/32 3/64 0.0469″ 43/64 0.6719″ 1/16 0.0625″ 11/16 0.6875″ 5/64 0.0781″ 2 mm = 0.0787″...
Page 33 ........2.11 POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS .
Page 34 MAINTENANCE ..................2.26 TIRE INSPECTION TRANSMISSION / GEARCASE.
Page 35: Maintenance
E = Emission Control System Service (California). NOTE Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.
Page 36: Pre-Ride Checklist
Ensure proper operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/taillight Check operation, apply POLARIS dielectric grease when lamp is replaced Heat Shields...
Page 37: Maintenance Intervals
MAINTENANCE MAINTENANCE INTERVALS MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES (KM) HRS. CALENDAR ▶ Air Filter (main element) Weekly Inspect; replace as needed ■ 100 (160) Inspect periodically Brake Pad Wear 10 H Battery 200 (320) Check terminals; clean; test 20 H Inspect;...
Page 38 ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. *Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant...
Page 39: Grease Lubrication Points
FREQUENCY ITEM RECOMMENDED LUBE METHOD Front Propshaft Yoke Grease before long periods Rear Bearing Grease fittings every 500 of storage, and after Polaris Premium U-Joint Grease Carrier miles (800 km). thoroughly washing or submerging the ATV. Front A-Arms Rear A-Arms...
Page 40: Maintenance Quick Reference
Add fluid until it is visible at Transmission Polaris AGL change fluid yearly the fill hole threads Check level daily, change Polaris 50/50 Extended Maintain coolant level in Engine Coolant coolant every 2 years Life Antifreeze coolant reservoir bottle. * More often under severe use, such as operated in water or under severe loads.
Page 41 MAINTENANCE FREQUENCY* ITEM LUBE REC. METHOD Check level daily; change fluid Front Gearcase Polaris Demand Drive Maintain fluid level in ADC every two years or 2000 miles ADC Reservoir Fluid Reservoir to indicated level Check level every 25 hours; Polaris Demand Drive...
Page 42: Maintenance Quick Reference, High Lifter
MAINTENANCE MAINTENANCE QUICK REFERENCE, HIGH LIFTER Top View NOTE High Lifter models engine coolant system components are located in different locations than other models. Side View REF. DESCRIPTION Pressure Cap Recovery Bottle Hose REF. DESCRIPTION Radiator Recovery Bottle Cap Recovery Bottle MAX Coolant Level MIN Coolant Level 2.10...
Page 43: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS LUBRICANTS, MAINTENANCE, AND SERVICE NOTE PRODUCTS • Each item can be purchased separately at your local Starter Drive Grease (12 count) 2871460 Polaris dealer. Premium U-Joint Lube (3 oz.) (24 count) 2871515 •...
Page 44: 50/50 Extended-Life Engine Antifreeze
MAINTENANCE 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE Beginning in the later part of 2014, Polaris began using 50/50 Extended Life antifreeze in some vehicles. All model- year 2015 and newer vehicles will use 50/50 Extended Life antifreeze. Using the 50/50 Extended-life antifreeze extends the service interval from two to five years.
Page 45: Fuel System / Air Intake
MAINTENANCE FUEL SYSTEM / AIR INTAKE FUEL SYSTEM FUEL FILTERS This machine uses a serviceable high-volume, high- WARNING pressure fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator. If Gasoline is extremely flammable and explosive under the fuel pump filters require service, the fuel pump must certain conditions.
Page 46: Throttle Release Switch (Trs) /Throttle Cable Adjustment
MAINTENANCE 5. Replace the throttle cable if worn, kinked, or 5. Turn the cable adjuster sleeve clockwise (in) 1.5 - 2 damaged. turns; tighten locknut and reinstall boot. After this adjustment there should be .079-.118” (2-3 mm) gap between throttle arm and throttle arm stop. THROTTLE RELEASE SWITCH (TRS) /THROTTLE CABLE ADJUSTMENT NOTE...
Page 47 MAINTENANCE 2. Remove the rubber strap retaining the airbox cover 11. Close airbox cover and secure cover by installing the and open the cover. rubber strap. NOTE NOTE High lifter Models: Use a T27 torx bit to remove the air High Lifter Models: Reinstall and tighten the cover box cover screw and remove the cover.
Page 48: Engine
ENGINE ENGINE OIL LEVEL ENGINE OIL AND FILTER CHANGE Polaris recommends the use of Polaris PS-4 synthetic Always change engine oil and filter at the intervals engine oil. Oil may need to be changed more frequently if outlined in the Periodic Maintenance Chart. Always Polaris engine oil is not used.
Page 49: Engine Breather Hose
MAINTENANCE 10. Locate oil filter through the access hole in the CAUTION frame. Place shop towels beneath the oil filter. Using Make sure line is not kinked or pinched. filter wrench (PU-50105) turn filter counterclockwise to remove it. 11. Use a clean dry towel to clean the filter sealing surface on the crankcase.
Page 50: Valve Clearance Adjustment
MAINTENANCE VALVE CLEARANCE ADJUSTMENT 10. Disconnect the chassis harness from the IAC valve. Remove the two hoses from the valve ports 1. Remove seat and upper side panels. 2. Disconnect the shift linkage from the shift lever. 3. Remove the (4) push rivets from each front mud guard and remove the mud guards from the vehicle.
Page 51 MAINTENANCE 13. Lift up on the air box and rotate it towards the left 19. Turn the drive clutch counter-clockwise until the cam side of the vehicle. Open the wire harness retainer sprocket is in the MAG adjustment position (both and remove the harness.
Page 52: Compression And Leakdown Tests
MAINTENANCE 22. After tightening the jam nut, turn the rocker arm 31. Torque intake runner mounting bolts to specification. bearing with your fingers. If it spins as it did before TORQUE contacting the valve, it is too loose. If it cannot be turned, it is too tight.
Page 53: Engine Mount Fastener Torque
MAINTENANCE ENGINE MOUNT FASTENER TORQUE 1. Remove the spark arrestor nut and bolt Check engine mount fasteners and ensure they are tight. Also inspect the condition of the rubber mounts. If mounts are cracked or show signs of fatigue, replace them.
Page 54: Cooling System
3. If the coolant level is below the “MIN” line on the Polaris recommends the use of Polaris Premium 50/50 bottle, remove the front rack assembly to access the anti-freeze or a 50/50 mixture of high quality aluminum radiator pressure cap and recovery bottle cap.
Page 55: Coolant Level Inspection, High Lifter
MAINTENANCE 9. If coolant was required, start engine and check for 2. View the coolant level in the recovery bottle. The leaks. Make sure radiator fins are clean to prevent coolant level can be viewed from inside the left right overheating.
Page 56: Cooling System Hoses
MAINTENANCE 7. Fill recovery bottle to “MAX” level with Polaris Premium 50/50 antifreeze/coolant or a 50/50 mixture of antifreeze/coolant and distilled water as required for freeze protection in your area. 8. Reinstall the recovery bottle cap. 9. If coolant was required, start engine and check for leaks.
Page 57: Pvt / Final Drive / Wheels / Tires
MAINTENANCE PVT / FINAL DRIVE / WHEELS / TIRES PVT DRYING DRIVE SHAFT BOOT INSPECTION Inspect the front and rear drive shaft boots for damage, NOTE tears, wear, or leaking grease. If the rubber boots exhibit any of these symptoms, replace the boot (s). Refer to If operating the ATV through water, be sure to check the Chapter 8 for drive shaft boot replacement.
Page 58: Wheel Removal
MAINTENANCE WHEEL REMOVAL TIRE PRESSURE 1. Position the vehicle on a level surface. TIRE PRESSURE INSPECTION (PSI - COLD) 2. Stop the engine, place the transmission in PARK and FRONT REAR lock the parking brake. 7 psi (48 kPa) 7 psi (48 kPa) 3.
Page 59: Transmission / Gearcase
Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill. FLUID CAPACITY Recommended Transmission Lubricant: Polaris AGL Capacity: 37 oz (1100 mL) 11. Reinstall fill plug with a new O-ring and torque to specification.
Page 60: Front Gearcase Lubrication
FLUID CAPACITY checking or changing the fluid. Recommended Front Gearcase Fluid: • Check vent hose to be sure it is routed properly and Polaris Demand Drive Fluid unobstructed. Front Gearcase Fluid Level Check Capacity: The fill plug is located on the right side of the front 9.3 oz (275 mL)
Page 61 11. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole. FLUID CAPACITY Recommended Rear Gearcase Lubricant: Polaris Angle Drive Fluid Capacity: 7.1 oz (210 mL) 2.29...
Page 62: Electrical / Ignition System
BATTERY MAINTENANCE EXTREME USE 30 AH BATTERY Keep battery terminals and connections free of Polaris offers an optional 30 AH battery (PN 4011224) for corrosion. If cleaning is necessary, remove the corrosion use in extreme conditions where the factory installed with a stiff wire brush.
Page 63: Spark Plug Service
MAINTENANCE SPARK PLUG SERVICE CAUTION Severe engine damage may occur if the incorrect spark 1. Remove the seat and upper right-hand side panel. plug is used. 2. Disconnect the shift linkage from the shift lever. 3. Remove the spark plug wires from the plugs.
Page 64: Battery Off Season Storage
NOTE Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Page 65: Steering
Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.
Page 66: Toe Alignment
MAINTENANCE • Replace any worn steering components. Steering 3. Tie a length of string between two stands as shown should move freely through entire range of travel in the following illustration. Position the stands so the without binding. string is flush or parallel with the side of the rear tire. •...
Page 67: Toe Alignment Adjustment
MAINTENANCE TOE ALIGNMENT ADJUSTMENT If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment. CAUTION During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod...
Page 68: Suspension
MAINTENANCE SUSPENSION SUSPENSION INSPECTION FOX SHOCK SPRING PRELOAD ADJUSTMENT Compress and release the suspension. Damping should be smooth throughout the range of travel. The front and rear shocks on EPS and International models have a spring preload adjustment. Suspension • Check all suspension components and mounting spring preload may be adjusted to suit different riding fasteners for wear or damage.
Page 69: Shock Compression Adjustment
MAINTENANCE SHOCK COMPRESSION ADJUSTMENT 3. Turn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease The compression damping adjustment is located on top preload. of the shock ‘Piggyback’ reservoir of each shock. Turn the clicker adjuster knob to make damping adjustments.
Page 70: Brake System
. If it is clear, it is an indication that fluid is needed or the brake pads may be worn, which can reduce the fluid level. • Use Polaris DOT 4 Brake Fluid (PN 2872189). CAUTION DO NOT OVERFILL! Excess brake fluid may cause brake drag.
Page 71: Hose / Fitting Inspection
MAINTENANCE HOSE / FITTING INSPECTION 3. Pads should be changed when the friction material is worn below the service limit. Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. AUXILIARY BRAKE PEDAL The hydraulic auxiliary brake system requires no adjustment.
Page 72 MAINTENANCE NOTES 2.40...
Page 73 ENGINE / COOLING SYSTEM CHAPTER 3 ENGINE / COOLING SYSTEM GENERAL INFORMATION - ENGINE ..............3.4 .
Page 74 ENGINE / COOLING SYSTEM ............3.32 VALVE AND SPRING HEIGHT DETAIL - SPM1000 .
Page 75 ENGINE / COOLING SYSTEM ................3.66 PISTON RING INSTALLATION .
Page 76: General Information - Engine
Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com ENGINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Capacity - Approximately 2 U.S. Quarts (1.9 l) Oil Type - Polaris PS-4 Synthetic Engine Oil Oil Filter Wrench - PU-50105 or 2.5” (64 mm) equivalent Oil Pressure Specification - Using Polaris PS-4, Engine at operating temperature, 12-100 PSI @ Idle RPM, 60–85 PSI @ 7000 RPM...
Page 77: Oil Pressure Test
ENGINE / COOLING SYSTEM OIL PRESSURE TEST 5. If oil pressure is high, this indicates additional restriction/resistance to flow. This could be from 1. Engine off, remove center Main Oil Gallery plug (A) using oil with heavier viscosity than recommended. If from right side of upper crankcase.
Page 78: Oil Flow Diagram
ENGINE / COOLING SYSTEM OIL FLOW DIAGRAM...
Page 79: Engine Specifications - 850
ENGINE / COOLING SYSTEM ENGINE SPECIFICATIONS - 850 CYLINDER HEAD (IN. / MM) Cam Lobe Height - Intake (Standard) 1.566" (39.795 mm) Cam Lobe Height - Exhaust (Standard) 1.577" (40.067 mm) Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm) Camshaft Camshaft Journal Bore Inner Diameter - (All) .8665"...
Page 80 ENGINE / COOLING SYSTEM CYLINDER / PISTON (IN. / MM) Piston Pin Piston Pin Outside Diameter 0.7873" ± .0001" (19.9975 ± .0025 mm) Piston Pin - Standard Clearance - Piston Pin 0.0004" ± .0002" (0.0095 ± 0.0065 mm) to Pin Bore Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68°...
Page 81: Engine Specifications - 1000
ENGINE / COOLING SYSTEM ENGINE SPECIFICATIONS - 1000 CYLINDER HEAD (IN. / MM) Cam Lobe Height - Intake (Standard) 1.566" (39.795 mm) Cam Lobe Height - Exhaust (Standard) 1.577" (40.067 mm) Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm) Camshaft Camshaft Journal Bore Inner Diameter - (All) .8665"...
Page 82 ENGINE / COOLING SYSTEM CYLINDER / PISTON (IN. / MM) Cylinder Cylinder - Surface warp limit (mating with 0.004" (0.10 mm) cylinder head) Cylinder Bore - Standard 3.5630" ± .0005 (90.5 mm ± .012 mm) Cylinder Out of Round Limit 0.0003"...
Page 83: Cooling System
Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 50/50 Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.
Page 84: Cooling System Bleeding Procedure
6. Squeeze coolant lines to help purge the system of air. 7. With engine still idling, top off the radiator with Polaris Premium Antifreeze. If no air bubbles are seen at the radiator filler neck, the system should be purged of air.
Page 85: Coolant Drain / Radiator Service (Sportsman)
ENGINE / COOLING SYSTEM COOLANT DRAIN / RADIATOR SERVICE 4. Remove recovery bottle return line from the radiator. (SPORTSMAN) Coolant Drain 1. Remove the front rack to access the pressure cap. CAUTION Never drain the coolant when the engine and radiator are warm or hot.
Page 86 ENGINE / COOLING SYSTEM 3. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant. 4. Refer to the “Cooling System Bleeding Procedure”. Cooling System Bleeding Procedure, page 3.12 3.14...
Page 87: Coolant Drain / Radiator Service (High Lifter)
ENGINE / COOLING SYSTEM COOLANT DRAIN / RADIATOR SERVICE (HIGH LIFTER) COOLING SYSTEM ASSEMBLY VIEW (HIGH LIFTER) COOLING SYSTEM ASSEMBLY VIEW REF. DESCRIPTION NOTES RADIATOR COOLANT HOSE, ENGINE IN SPRINGBAND CLAMP GEAR CLAMP COOLANT HOSE, ENGINE OUT HOSE CLAMP SCREW Torque until fully seated SCREWS Torque until fully seated...
Page 88: Coolant Drain/Fill (High Lifter)
ENGINE / COOLING SYSTEM COOLANT DRAIN/FILL (HIGH LIFTER) 11. Fill the cooling system and overflow, and run the engine up to operating temp. Verify the level is correct 1. Remove the upper radiator shroud to access the before re-assembly. Refer to the cooling system pressure cap.
Page 89: Radiator Installation (High Lifter)
ENGINE / COOLING SYSTEM 4. Remove the (4) fasteners to remove the radiator. 5. Position the fuse block from the underside of the shroud, and install both fasteners. Torque to specification. Ensure the fuse block cap is re-installed as well. TORQUE Fuse Block Fastener Torque until fully seated...
Page 90: Water Pump Mechanical Seal Replacement
ENGINE / COOLING SYSTEM 4. Slide the clamp back and remove the coolant inlet 8. Remove gasket, impeller bolt, washer, and impeller. hose from the water pump housing. 5. Slowly drain the coolant into the drain pan. Dispose of used coolant properly. WATER PUMP MECHANICAL SEAL REPLACEMENT 6.
Page 91 ENGINE / COOLING SYSTEM 4. Remove CPS, stator wire guide, and stator from the 6. Press shaft down until flush with end of mechanical cover. seal or until the seal spring starts to compress. 7. Select a suitable arbor (D) and press the shaft through the seal until the shaft assembly is removed.
Page 92: Stator Cover Installation
ENGINE / COOLING SYSTEM 8. Protect water pump cover gasket surface and turn 10. Press pump shaft / bearing assembly into housing cover over. Drive mechanical seal out from stator until firmly seated. side of cover. 11. Turn cover over and press the new mechanical seal squarely into the housing using seal installer PA- 44995-A.
Page 93: Water Pump Assembly / Torque Specifications
ENGINE / COOLING SYSTEM WATER PUMP ASSEMBLY / TORQUE SPECIFICATIONS 3.21...
Page 94: Stator Cover Assembly Torque Specifications
ENGINE / COOLING SYSTEM STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS 3.22...
Page 95: Thermostat
ENGINE / COOLING SYSTEM THERMOSTAT TORQUE Fuel Rail Mounting Screws: THERMOSTAT REPLACEMENT 44 in. lbs (5 Nm) 1. Drain coolant so the coolant level is below the thermostat housing, see: Coolant Drain / Radiator TORQUE Service (Sportsman), page 3.13. Plenum to Throttle Body Fasteners: 2.
Page 96: Intake / Exhaust System
ENGINE / COOLING SYSTEM INTAKE / EXHAUST SYSTEM AIR INTAKE ASSEMBLY VIEW AIR INTAKE ASSEMBLY VIEW REF. DESCRIPTION NOTES AIR INTAKE BOOT High Lifter only AIR IN DUCT High Lifter only BOLTS Torque until fully seated AIRBOX / INTAKE DUCT SEAL High Lifter only U-NUT High Lifter only...
Page 97: Intake Replacement
ENGINE / COOLING SYSTEM INTAKE REPLACEMENT 1. Remove the following body components. Refer to Chapter 9 “Body / Frame” for component removal. • Seat • Left Hand Upper Side Panel • Right hand Upper Side Panel 2. Remove the breather hose from the side of the airbox.
Page 98: Exhaust
ENGINE / COOLING SYSTEM IMPORTANT DO NOT attempt to remove the intake runners from the intake plenum or remove the plenum from the airbox. 10. Install is reverse of removal. EXHAUST 850/1000 1-UP HEAT SHIELDS Inspect the heat shields. Ensure they are not damaged, and are properly secured.
Page 99: Engine Assembly Views / Torque Values
ENGINE / COOLING SYSTEM ENGINE ASSEMBLY VIEWS / TORQUE VALUES TORQUE SPECIFICATION AND TORQUE SEQUENCE - MAIN ENGINE COMPONENTS Step 1: 8 ft. lbs (11 Nm) 12-14 ft-lbs (16-19 Nm) Step 2: 43 ft. lbs (59 Nm) VALVE COVER Step 3: Additional 180° Step 4: M6 bolts: 7 ft-lb (10 Nm) CYLINDER HEAD 13 ft.
Page 100: Valve Cover
ENGINE / COOLING SYSTEM VALVE COVER 3.28...
Page 101: Camshaft Carrier / Camshaft / Rocker Arm
ENGINE / COOLING SYSTEM CAMSHAFT CARRIER / CAMSHAFT / ROCKER ARM 3.29...
Page 102: Cylinder Head / Valves / Integrated Throttle Body
ENGINE / COOLING SYSTEM CYLINDER HEAD / VALVES / INTEGRATED THROTTLE BODY 3.30...
Page 103: Valve And Spring Height Detail - Spm850
ENGINE / COOLING SYSTEM VALVE AND SPRING HEIGHT DETAIL - SPM850 3.31...
Page 104: Valve And Spring Height Detail - Spm1000
ENGINE / COOLING SYSTEM VALVE AND SPRING HEIGHT DETAIL - SPM1000 3.32...
Page 105: Piston / Connecting Rod
ENGINE / COOLING SYSTEM PISTON / CONNECTING ROD 3.33...
Page 106: Crankshaft
ENGINE / COOLING SYSTEM CRANKSHAFT 3.34...
Page 107: Crankcase
ENGINE / COOLING SYSTEM CRANKCASE 3.35...
Page 108: Crankcase - Upper
ENGINE / COOLING SYSTEM CRANKCASE - UPPER 3.36...
Page 109: Balance Shaft / Balance Shaft Timing
ENGINE / COOLING SYSTEM BALANCE SHAFT / BALANCE SHAFT TIMING 3.37...
Page 110: Crankcase (Lower) With Oil Pump
ENGINE / COOLING SYSTEM CRANKCASE (LOWER) WITH OIL PUMP 3.38...
Page 111: Stator Cover / Flywheel / Water Pump Coupler
ENGINE / COOLING SYSTEM STATOR COVER / FLYWHEEL / WATER PUMP COUPLER 3.39...
Page 112: Water Pump / Water Pump Coupler / Stator
ENGINE / COOLING SYSTEM WATER PUMP / WATER PUMP COUPLER / STATOR 3.40...
Page 113: Drive Coupler (Rear) / Starter Gear
ENGINE / COOLING SYSTEM DRIVE COUPLER (REAR) / STARTER GEAR 3.41...
Page 114: Engine Service
ENGINE / COOLING SYSTEM ENGINE SERVICE ACCESSIBLE ENGINE COMPONENTS ENGINE REMOVAL Components serviceable with engine installed: IMPORTANT • Flywheel Some engine repair procedures can be performed • Alternator (Stator) without removing the engine from the vehicle. Refer to • Starter Motor / Solenoid “Accessible Engine Components”...
Page 115 ENGINE / COOLING SYSTEM 8. Remove the high tension leads from the engine 13. Disconnect wire harness from ignition coil, intake and remove the nuts from each exhaust flange at air temp sensor, and IAC valve. the engine. 14. Remove the two hoses from the IAC valve.
Page 116 ENGINE / COOLING SYSTEM 17. Remove the push rivets retaining the right-hand 26. Remove all bolts rom both sides retaining the portion of the rear cab to gain access to the bolts engine to the transmission. retaining the upper right-hand frame support. 18.
Page 117 ENGINE / COOLING SYSTEM 28. Remove the fasteners etaining the LH engine 31. Remove the screws hat retain the throttle body to isolator mount to the engine and remove the lower the cylinder head. Replace the gaskets upon fom the mount. Pry up between the frame and installation.
Page 118: Engine Installation Notes
Engine Break In Period The engine break-in period is defined as the first 20 hours of engine operation or 2 full tanks of fuel. 15. Use only Polaris PS-4 Synthetic engine oil. Never substitute or mix oil brands. Serious engine damage can result.
Page 119: Engine Disassembly / Inspection
ENGINE / COOLING SYSTEM ENGINE DISASSEMBLY / INSPECTION VALVE COVER REMOVAL / INSPECTION 2. Using an 8mm socket, remove cam chain tensioner bolts evenly and remove tensioner. Note “TOP” 1. Remove the six rocker cover bolts and isolators marked on plate for assembly.
Page 120: Rocker Arm / Rocker Arm Shaft Inspection
ENGINE / COOLING SYSTEM ROCKER ARM / ROCKER ARM SHAFT 4. Measure I.D. of rocker arms and O.D. of rocker arm shafts. Measure shaft bore in cam carrier. Compare INSPECTION to specifications (See “Engine Specifications”, page 1. Mark or tag rocker arms and shafts to keep them in 3.7).
Page 121: Cylinder Head Removal
ENGINE / COOLING SYSTEM CYLINDER HEAD REMOVAL 2. Measure all cam lobe heights from base circle to highest point on lobe. 1. Loosen two outer bolts , then loosen all head bolts evenly, 1/8 turn at a time until all are loose. Remove all bolts, cylinder head, and gasket 3.
Page 122: Cylinder Head Warp Inspection
ENGINE / COOLING SYSTEM CYLINDER HEAD WARP INSPECTION Valve Spring Compressor: PV-1253 (or PV-4019 with adapter PV-43513-A) 1. Lay a straight edge (A) across surface of cylinder head at several different points and measure warp by inserting a feeler gauge between the straight 1.
Page 123: Valve Inspection
ENGINE / COOLING SYSTEM VALVE INSPECTION 5. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure 1. Remove all carbon from valves with a soft wire wheel again (six measurements total). Compare or brush.
Page 124: Combustion Chamber
ENGINE / COOLING SYSTEM COMBUSTION CHAMBER 4. Drive or press new guides from camshaft side of head to proper installed height. Note difference 1. Clean accumulated carbon deposits from between intake and exhaust guide height: combustion chamber and valve seat area. NOTE Carbon Clean Fuel Treatment (2871326) can be used to help remove carbon deposits.
Page 125 ENGINE / COOLING SYSTEM and the seat must be the proper width all the way 5. To check the contact area of the seat on the valve around. If the seat is uneven, compression leakage will face, apply a thin coating of Prussian Blue paste to result.
Page 126 ENGINE / COOLING SYSTEM 7. Remove valve and check where the Prussian Blueä NOTE indicates seat contact on the valve face. The valve When using an interference angle, the seat contact seat should contact the middle of the valve face or point on the valve will be very narrow, and is a normal slightly above, and must be the proper width.
Page 127: Crankcase Disassembly
ENGINE / COOLING SYSTEM 8. Clean all filings from the area with hot soapy water. 2. Remove all water pump cover screws and stator Rinse and dry with compressed air. cover screws , noting location of hose retainer 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.
Page 128: Crankcase (Lower) / Oil Pump Disassembly
ENGINE / COOLING SYSTEM 5. Remove the water pump drive coupler / retaining bolt 8. Loosen the twelve outer crankcase bolts evenly 1/ from the flywheel. 2 turn, then loosen the two longer case bolts , then the six main crankcase bolts .
Page 129: Crankcase Disassembly (Upper)
ENGINE / COOLING SYSTEM 5. Rotate pump gear until rotors are positioned as 9. Remove oil pressure relief from crankcase. Replace shown below. Use a feeler gauge to measure tip if debris has entered, or if oil pressure was outside of clearance.
Page 130: Counterbalance Shaft Removal / Inspection
ENGINE / COOLING SYSTEM 2. Push connecting rod / piston assembly out through 4. Inspect both counterbalance shaft bearings. top of cylinder bore of upper crankcase. NOTE Due to extremely close tolerances, balance shaft bearings must be inspected visually and by feel. Look for signs of discoloration, scoring, galling or contamination from moisture or dirt.
Page 131: Crankshaft / Cam Chain Removal
ENGINE / COOLING SYSTEM CRANKSHAFT / CAM CHAIN REMOVAL 2. Measure each main journal (A) and rod journal (B) in locations, degrees apart. Record 1. Remove crankshaft with cam chain and end seals. measurements for bearing selection on page 5.49, page 3.62.
Page 132 ENGINE / COOLING SYSTEM 2. Remove piston circlip 6. Measure small end I. D. in two directions as shown. Record measurements. The difference between measurements concentricity. Compare specifications. NOTE Notice the location of the piston circlip gap at top. MEASUREMENT 3.
Page 133 ENGINE / COOLING SYSTEM 10. Select appropriate bearing insert (color) from table (Connecting Rod Bearing Selection Chart, page 3.62). MEASUREMENT Connecting Rod (Big End) Diameter: 1.8892 - 1.8902" (47.987 - 48.011 mm) Connecting Rod (Big End) Concentricity: < 0.00047" (0.012 mm) 3.61...
Page 134: Connecting Rod Big End Bearing Selection
ENGINE / COOLING SYSTEM CONNECTING ROD BIG END BEARING 2. If re-installing the original connecting rod, select the appropriate bearing from the table below based on SELECTION connecting rod big end I. D. measurements 1. If using NEW connecting rods, install the bearing (Connecting Rod Big End ID measurement, page color that matches the bore tolerance letter marked 3.59).
Page 135: Piston / Piston Ring Inspection
ENGINE / COOLING SYSTEM PISTON / PISTON RING INSPECTION PISTON RING INSTALLED GAP 1. Measure piston ring to ring land clearance with a 1. Place each piston ring inside the cylinder . Use the thickness gauge (A) inserted between bottom edge piston to push the ring squarely into cylinder.
Page 136: Piston Pin Bore Inspection
ENGINE / COOLING SYSTEM PISTON PIN BORE INSPECTION 5. Inspect taper and out of round with a dial bore gauge. 1. Measure piston pin bore. 6. Measure in two directions (front to back and side to MEASUREMENT side) on three levels and record measurements. If Piston Pin Bore: cylinder is tapered or out of round beyond .001", the 0.7877 ±...
Page 137: Piston-To-Cylinder Clearance
ENGINE / COOLING SYSTEM PISTON-TO-CYLINDER CLEARANCE Measure piston outside diameter at a point 33 mm down from piston crown, at a right angle to piston pin bore. Subtract measurement from maximum measurement obtained in Step 6 of Cylinder Inspection. Piston to Cylinder Clearance: .0013 ±...
Page 138: Engine Assembly
ENGINE / COOLING SYSTEM ENGINE ASSEMBLY CRANKCASE PREPARATION - UPPER 4. Install second ring with undercut facing bottom of piston. Rotate ring to place end gap generally toward 1. Refer to Oil Flow Diagram (page 5.4, page 3.6) and (intake) side of piston as shown below. trace the oil path through the upper crankcase / cylinder.
Page 139: Piston / Connecting Rod Assembly
ENGINE / COOLING SYSTEM PISTON / CONNECTING ROD ASSEMBLY 5. Install the remaining circlip with gap at the top or bottom. Push the piston pin in both directions to 1. Lubricate connecting rod small end, piston pin bore, make sure the clips are properly seated in the and piston pin with engine oil.
Page 140: Crankshaft Installation
ENGINE / COOLING SYSTEM CRANKSHAFT INSTALLATION 10. Torque the bolts using the following procedure: Refer to Crankcase Assembly (Upper) page 5.56, page 3.69. 1. Clean the bearing bore surfaces of upper crankcase (main bearings), connecting rods and connecting rod caps. 2.
Page 141: Crankcase Assembly - Upper
ENGINE / COOLING SYSTEM CRANKCASE ASSEMBLY - UPPER 3.69...
Page 142: Balance Shaft Installation
ENGINE / COOLING SYSTEM BALANCE SHAFT INSTALLATION 5. Align bearing locating ring in groove on crankcase and fully seat the shaft. See “Balance Shaft Timing”, page 3.71. 6. Rotate crankshaft until SINGLE dot on crankshaft 1. Balance shafts are identical but should be installed in gear is visible.
Page 143: Balance Shaft Timing
ENGINE / COOLING SYSTEM BALANCE SHAFT TIMING 3.71...
Page 144: Crankcase Preparation (Lower)
ENGINE / COOLING SYSTEM CRANKCASE PREPARATION (LOWER) Clean lower crankcase gasket sealing surfaces. Refer to Oil Flow Diagram and trace the oil path from the through the lower crankcase. Flush all passages with solvent and then warm soapy water. Rinse with clear warm water and dry with compressed air.
Page 145: Crankcase Sealant And Torque Values
ENGINE / COOLING SYSTEM CRANKCASE SEALANT AND TORQUE VALUES 3.73...
Page 146: Crankcase Assembly
ENGINE / COOLING SYSTEM CRANKCASE ASSEMBLY 3. Install valve in guide. 1. Prepare upper and lower crankcase and install all 4. Valve seals should be installed after the valves are in components as described previously. the head to avoid valve seal damage. Install NEW valve seals on valve guides carefully with a rotating 2.
Page 147: Valve Sealing Test
ENGINE / COOLING SYSTEM VALVE SEALING TEST 4. Lift cam chain and install chain guide. 1. Clean and dry the combustion chamber area 5. Be sure tabs are engaged in slots. Secure cam chain with a wire so it will not fall into crankcase. 2.
Page 148: Camshaft / Carrier Assembly
ENGINE / COOLING SYSTEM 8. Tighten main head bolts finger tight, then install the 2. Place the camshaft in the cylinder head. two 6 mm outer bolts. 3. Lubricate rocker arms, rollers and shafts with engine CYLINDER HEAD TORQUE PROCEDURE oil.
Page 149: Camshaft Timing
ENGINE / COOLING SYSTEM CAMSHAFT TIMING 4. Rotate camshaft until pin is at 10:00 position Refer to Camshaft Timing Quick Reference ( [Either the href or the keyref attribute should be set on xref elements] page). IMPORTANT Valve and/or piston damage can occur if engine is rotated with camshaft incorrectly timed.
Page 150 ENGINE / COOLING SYSTEM 2. Remove CPS from MAG cover. Rotate crank until 7. Screw in the sprocket bolt finger tight. Sprocket the appropriate timing mark is visible in the center of bolt must be fully tightened after cam chain tensioner the CPS hole.
Page 151: Cam Chain Tensioner Installation
ENGINE / COOLING SYSTEM CAM CHAIN TENSIONER INSTALLATION 7. Torque camshaft sprocket bolt to specification. 1. Lubricate tensioner plunger and install in tensioner bore with check valve end of plunger facing OUT (toward cap plate). TORQUE Camshaft Sprocket Bolt: 28 ft-lb (38 Nm) 2.
Page 152: Troubleshooting
ENGINE / COOLING SYSTEM TROUBLESHOOTING ENGINE Piston Failure - Scoring Spark Plug Fouling • Lack of lubrication • Dirt entering engine through cracks in air filter or ducts • Restricted air filter (main or pre-cleaner) or breather • Engine oil dirty or contaminated (water) system •...
Page 153 ENGINE / COOLING SYSTEM • Faulty hot lamp circuit • Thermostat stuck closed or not opening completely Temperature Too Low • Thermostat stuck open Leak at Water Pump Weep Hole • Faulty water pump mechanical seal • Worn pump shaft or pump shaft bearing 3.81...
Page 154 ENGINE / COOLING SYSTEM NOTES 3.82...
Page 155 FUEL SYSTEM CHAPTER 4 FUEL SYSTEM EFI SPECIAL TOOLS ..................4.4 .
Page 156 FUEL SYSTEM THROTTLE CONTROL SWITCH ................4.25 .
Page 157 ............4.48 POLARIS MOBILE DIGITAL WRENCH (PMDW) FUEL SYSTEM TROUBLESHOOTING .
Page 158: Efi Special Tools
Digital Wrench® Vehicle Interface Cable PU-47469 Digital Wrench® SmartLink Module PU-47468 Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com WARNING * Gasoline is extremely flammable and explosive under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly.
Page 159: Digital Wrench® - Diagnostic Connector
ECU and the Digital Wrench® diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This kit is available to Polaris dealers through our tool supplier, SPX (1-800- 328-6657).
Page 160: Fuel Tank
FUEL SYSTEM FUEL TANK FUEL TANK ASSEMBLY VIEW...
Page 161: Fuel Pump Assembly
FUEL SYSTEM FUEL PUMP ASSEMBLY FUEL SENDER TEST If the fuel gauge reading on the instrument cluster is not OPERATION OVERVIEW working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance An electric fuel pump assembly is used to transfer fuel to test on the fuel sender.
Page 162 FUEL SYSTEM 2. Locate the fuel pressure valve attached to the fuel 7. If voltage at the plug was within the specified range, rail. and there was continuity across the pump terminals, reconnect the plug to the pump, making sure you have clean connections.
Page 163: Fuel Tank Removal
FUEL SYSTEM FUEL TANK REMOVAL 11. While holding a shop towel over the fuel line connector, disconnect the quick connect fuel line NOTE from the fuel pump. Syphon as much fuel from the tank as possible before CAUTION attempting to remove it from the ATV. It is possible for pressurized fuel to be present when disconnecting the fuel line.
Page 164 FUEL SYSTEM 2. Be sure top of fuel tank is clean. If it requires 4. Carefully lift the fuel pump out of the fuel tank. As the cleaning, hand wash the top of the tank to ensure no fuel pump assembly is being removed, be aware of debris will enter the fuel system when the fuel pump float arm and pump pre-filter.
Page 165 FUEL SYSTEM 8. Use cleaning wipes provided to clean fuel tank 14. Torque PFA nut to specification using the Fuel surface and threads. Remove all debris, grease and Pump Service Tool (PU-50326) and a calibrated oil. Allow surfaces to dry completely. torque wrench.
Page 166: Fuel Tank Installation
FUEL SYSTEM FUEL TANK INSTALLATION 13. Test the fuel pump by turning on the key and listening for the pump to activate. 1. Reinstall the fuel tank assembly through the right side. Be sure the tabs on the bottom of the fuel tank are sitting in the slots of the support bracket.
Page 167: Fuel Line / Hose
FUEL SYSTEM FUEL LINE / HOSE QUICK DISCONNECT SERVICE FUEL VENT LINE/ CHECK VALVE TESTING When removing the fuel line, follow these steps to avoid In-Tank Check Valve damage to the components: 1. Always thoroughly clean the fitting from both sides. Grit can become lodged between the nipple and the collar of the line, making it difficult to move the tabs of the collar.
Page 168: Fuel Vent Line Routing
FUEL SYSTEM FUEL VENT LINE ROUTING The primary fuel tank vent hose runs from the tank vent nipple up to the vent tee. The vent splits to the upper line that runs into the headlight pod, and the lower line that runs down along the frame rail.
Page 169: Fuel Supply Line Routing
FUEL SYSTEM FUEL SUPPLY LINE ROUTING The line routes under the frame rail. There are no anchor/retention fasteners related to this line. 4.15...
Page 170: Efi System Layout
FUEL SYSTEM EFI SYSTEM LAYOUT EFI SYSTEM ASSEMBLY VIEW 4.16...
Page 171: Efi Components
FUEL SYSTEM EFI COMPONENTS IDENTIFICATION / LOCATION 4. Crankshaft Position Sensor (CPS) - Mounted in the top portion of the magneto cover on 1. Electronic Control Unit (ECU) the front of the engine - Attached to front of airbox, under the front cab. 5.
Page 172 FUEL SYSTEM 7. Fuel Line (Quick Connect) 10. Throttle Position Sensor (TPS) - Located between the injector fuel rail and the fuel - Mounted on the MAG end (front) of the throttle body tank 8. Fuel Pump / Regulator / Fuel Gauge Sender 11.
Page 173: Efi Service Notes
6. If the sensor and wiring passes inspection, and reconnecting the ECU does not resolve the issue, use a known-good ECU (from another Polaris 850) to test for problem resolution. • Never attempt to service any fuel system component while engine is running or ignition switch "on".
Page 174: Electronic Fuel Injection
FUEL SYSTEM ELECTRONIC FUEL INJECTION GENERAL INFORMATION During operation the ECU has the ability to re-adjust temporarily, providing compensation for changes in The Electronic Fuel Injection (EFI) system is a complete overall engine condition and operating environment, so it engine fuel and ignition management design. This will be able to maintain the ideal air/fuel ratio.
Page 175: Electronic Control Unit
FUEL SYSTEM ELECTRONIC CONTROL UNIT OPERATION OVERVIEW This process repeats it self in rapid succession, limiting operation to the preset maximum. The ECU is a solid state component that serves as the controller for the fuel injection system. Maximum RPM Limit: 7600 The ECU receives input from the EFI sensors including, but not limited to: •...
Page 176: Ecu Service
NOTE For the purpose of troubleshooting, a known-good ECU from another Polaris vehicle of the same model and year If replacing the ECU, you must reflash the new ECU may be used, but ensure that you do not put an ECU...
Page 177: Ecu Connector Pinout
FUEL SYSTEM ECU CONNECTOR PINOUT FUNCTION EFI Relay Ground Fan Relay Ground MAG Fuel Injector Ground TPS 5V Reference T-MAP 5V Reference Key Switch Power TPS Signal Override Signal PTO Fuel Injector Ground AWD Hub Coil Ground Fuel Pump Relay Ground Manifold Pressure Signal Gear Position Signal Air Temp Sensor Signal...
Page 178: Electronic Throttle Control
No internal servicing or adjustments may be performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC under warranty without factory authorization.
Page 179: Etc Learn Procedure
FUEL SYSTEM THROTTLE CONTROL SWITCH ETC LEARN PROCEDURE IMPORTANT DRIVE MODE SWITCH DESCRIPTION AND OPERATION This procedure MUST be performed on the vehicle whenever the ECU is replaced or reflashed or the Some vehicle models are equipped with a drive mode throttle body is replaced.
Page 180: Throttle Control Switch Replacement
FUEL SYSTEM THROTTLE CONTROL SWITCH REPLACEMENT The switch is a rocker switch, and will be mounted on either the dash or in the headlight pod of an ATV. Remove the component it is mounted to, remove the connector, and disengage the switch from the panel by depressing the retention tabs.
Page 181: Throttle Control Sensor (Tcs)
FUEL SYSTEM THROTTLE CONTROL SENSOR (TCS) THROTTLE LEVER POSITION SENSOR 3. Disconnect the throttle control assembly connector OVERVIEW form the wiring harness. NOTE DO NOT attempt to service the Throttle Lever Position Sensor. The Throttle Lever Position Sensor is a non- serviceable component and can only be tested using Digital Wrench®.
Page 182: Fuel Injectors
FUEL SYSTEM FUEL INJECTORS OPERATION OVERVIEW If an injector is not operating, it can indicate either a bad injector, or a wiring/electrical connection problem. Check The fuel injectors mount into the throttle body, and the as follows: fuel rail attaches to the top end of them. O-rings on both Injector leakage is very unlikely, but in rare instances it ends of the injector prevent external fuel leaks and also can be internal (past the tip of the valve needle), or...
Page 183: Fuel Injector Test
FUEL SYSTEM ITEM PART COLOR POSITION CAUTION NUMBER Ensure you have a shop rag to clean up the fuel that will TOP OF spill when removing this line. 1500198 Blue INJECTOR BOTTOM OF 5415066 Brown 4. Remove the two fasteners that retain the fuel rail.
Page 184: Crankshaft Position Sensor (Cps)
FUEL SYSTEM CRANKSHAFT POSITION SENSOR (CPS) OPERATION OVERVIEW CPS SERVICE The crankshaft position sensor is essential to engine 1. Remove the intake/plenum. , page 3.25 operation, constantly monitoring the rotational speed 2. To perform a static test on the CPS, disconnect the (RPM) and position of the crankshaft.
Page 185: Temperature / Manifold Absolute Pressure Sensor (T-Map)
FUEL SYSTEM TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) OPERATION OVERVIEW TMAP REPLACEMENT Mounted on the throttle body, the temperature and 1. Remove the intake/plenum. , page 3.25 manifold absolute pressure sensor (T-MAP) performs 2. Thoroughly clean around the TMAP to avoid getting two functions in one unit.
Page 186: Idle Air Controller (Iac)
FUEL SYSTEM IDLE AIR CONTROLLER (IAC) OPERATION OVERVIEW IAC REPLACEMENT The Idle Air Control (IAC) is used to stabilize idle quality 1. Remove the seat and upper RH side panel. of the engine at cold start-up and after warm-up 2. Disconnect the wire harness from the IAC motor operations.
Page 187: Throttle Position Sensor (Tps)
FUEL SYSTEM THROTTLE POSITION SENSOR (TPS) OPERATION OVERVIEW TPS RESISTANCE TESTS Mounted on the throttle body and operated directly off The TPS is a non-serviceable item. If it is faulty, it must the end of the throttle shaft, the TPS works like a be replaced.
Page 188: Tps Replacement And Adjustment
FUEL SYSTEM TPS REPLACEMENT AND ADJUSTMENT 9. Loosen the TPS mounting screw 10. Slowly rotate the TPS until the display reading is 1. Remove the intake/plenum. , page 3.25 within specification. 2. Thoroughly clean the area around the TPS. Take care 11.
Page 189: Engine Coolant Temperature Sensor (Ect)
“Check Engine” indicator should display on the instrument cluster. This indicates all other components are working properly. Refer to Chapter 4 for additional ECT information. Polaris dealers can test the sensor by using the Digital Wrench® Diagnostic Software (dealer only).
Page 190: Igntion Coil
FUEL SYSTEM IGNTION COIL OPERATION OVERVIEW Secondary Test The ignition coil is used to provide high voltage to fire the spark plugs. When the ignition key is on, DC voltage is present in the primary side of the ignition coil windings. During engine rotation, an AC pulse is created within the crankshaft position sensor for each passing tooth on the flywheel.
Page 191 FUEL SYSTEM 5. Using a T20 driver, remove the screw retaining the ignition coil to the airbox. 6. Remove the coil assembly and disconnect the high tension leads by pulling on the coil side end caps. 7. Install the spark plug wires. NOTE Be sure to install the PTO (long) wire on the coil...
Page 192: Efi Diagnostics
FUEL SYSTEM EFI DIAGNOSTICS INSTRUMENT CLUSTER TROUBLE CODE 2. If the trouble code (s) are not displayed, use the MODE button to toggle until “CK ENG” displays on DISPLAY the information display area. NOTE The diagnostic mode is accessible only when the check engine MIL has been activated.
Page 193: Diagnostic Trouble Codes (Dtcs)
FUEL SYSTEM DIAGNOSTIC TROUBLE CODES (DTCS) DIAGNOSTIC TROUBLE CODES DIGITAL COMPONENT CONDITION WRENCH® P- CODE Voltage Too High P0123 Throttle Position Sensor (TPS) Voltage Too Low P0122 Data Erratic, Intermittent or Missing P0503 Vehicle Speed Signal Received Vehicle Speed Has Error C1069 Voltage Too High P0108...
Page 194 FUEL SYSTEM DIAGNOSTIC TROUBLE CODES DIGITAL COMPONENT CONDITION WRENCH® P- CODE Driver Circuit Grounded P1483 Driver Circuit Open / Grounded P1615 Starter Enable Circuit 1321 Driver Circuit Short to B+ P1617 Driver Circuit Grounded P1616 Driver Circuit Open / Grounded P0230 Fuel Pump Driver Circuit 1347...
Page 195: Digital Wrench
Refer to Section 2, 3 and 4 in the Instruction Manual • Perform output state control tests (some models) provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the...
Page 196: Digital Wrench Software Version And Update
4. The Digital Wrench® portal website should appear in a new web browser. 5. Click on “Digital Wrench Version Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. NOTE You must already have the current version installed before adding an update.
Page 197: Digital Wrench® Communication Errors
Open the configuration screen by clicking on the wrench any Digital Wrench® related problem, visit the Digital icon. The serial number is located on the right side of the Wrench® Knowledge Base for the most current screen. troubleshooting information, FAQs, downloads and software updates at: http://polaris.diagsys.com/. 4.43...
Page 198: Digital Wrench® Feature Map
FUEL SYSTEM DIGITAL WRENCH® FEATURE MAP View, or clear trouble codes Enter / Edit / Change in the Engine Controller Vehicle Information Memory. This is the most viewed Enter customer and vehicle screen. View sensor and information and view ECU ECU information in a grid, Identification.
Page 199: Ecu Replacement
• Proceed to http://polaris.diagsys.com for specific reprogram an ECU. information and FAQs on how to troubleshoot The Digital Wrench® Engine Controller Reprogramming communication problems.
Page 200 FUEL SYSTEM If you are not familiar with the reprogramming process, 7. Select the file you want to load into the ECU then review the “Reprogramming (Reflash) Tips” before you click the “Continue” icon to proceed to the Integrity begin. Follow the on-screen instructions as you progress Check and obtain a Request Code.
Page 201 FUEL SYSTEM 10. Enter or paste the Request Code into the box. 13. Enter or paste the Authorization Key in the box located on the Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 11.
Page 202: Polaris Mobile Digital Wrench (Pmdw)
To access the user’s guide, launch the app, and then (PMDW) click on the “Help” button in the Settings/Preferences Polaris Mobile Digital Wrench (PMDW) is a diagnostic menu. software application (app) designed specifically for • Only CAN-based vehicles are compatible with PMDW Android™...
Page 203: Fuel System Troubleshooting
FUEL SYSTEM FUEL SYSTEM TROUBLESHOOTING POOR IDLE The correct position of the throttle body stop screw is established and set at the factory. Symptom: Idle Too High (If greater than 1400 RPM when DO NOT remove the tamper proof cap to adjust the engine is warm) throttle body stop screw or alter its position in any •...
Page 204 FUEL SYSTEM NOTES 4.50...
Page 205 PVT SYSTEM CHAPTER 5 PVT SYSTEM PVT GENERAL INFORMATION ............... . . 5.2 .
Page 206: Pvt General Information
(initial vehicle movement), clutch upshift and backshift. During the development of a SPECIAL TOOLS AND SUPPLIES Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions PART NUMBER TOOL DESCRIPTION vehicle’s...
Page 207: Drive Clutch Operation
PVT SYSTEM DRIVE CLUTCH OPERATION SHIFT WEIGHTS Drive clutches primarily sense engine RPM. The two Shift weights have many factors designed into them for major components which control its shifting function are controlling engagement RPM and shifting patterns. Shift the shift weights and the coil spring. Whenever engine weights should not be changed or altered without first RPM is increased, centrifugal force is created, causing having a thorough understanding of their positioning and...
Page 208: Overheating / Diagnosis
PVT system. 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift transmission to Low during loading of the vehicle to prevent belt Clutch malfunction.
Page 209: Pvt System Service
PVT SYSTEM PVT SYSTEM SERVICE PVT SEALING AND DUCTING COMPONENTS PVT DUCTING ASSEMBLY VIEW REF. DESCRIPTION NOTES AIR INTAKE BOOTS SCREW CLUTCH DUCT BOOT WORM DRIVE CLAMPS 14 in-lbs (1.6 Nm) INNER CLUTCH COVER Apply RTV silicone sealant to the outside edge of the inner PVT cover to ensure a water tight fit between the cover and the transmission.
Page 210 PVT SYSTEM 2. Remove the fasteners securing the side panels. 9. Loosen the clamp retaining the PVT Duct to the PVT Housing. 3. Remove the upper side panels. 10. Loosen the clamp securing the rubber duct to the 4. Remove the fasteners securing the rear cab rack and plastic duct storage assembly to the chassis.
Page 211 PVT SYSTEM 15. With the belt removed, completely remove the 18. Insert the Drive Clutch Puller (PA-48595) into the retaining bolt and driven clutch drive clutch and use it to remove the clutch from the shaft. 16. Install the Drive Clutch Holder (PN 9314177-A) onto the drive clutch.
Page 212: Pvt Assembly
PVT SYSTEM PVT ASSEMBLY 4. Install the cover and torque the inner PVT cover screws to specification. 1. Inspect the inner PVT cover. Replace if cracked or damaged. The mating surface must be clean to ensure adhesion of new silicone sealant. 2.
Page 213 PVT SYSTEM TORQUE Driven Clutch Retaining Bolt: 37 ft. lbs (50 Nm) 12. Install the PVT outlet duct and align it with the inner PVT cover. Install the push rivet and tighten the hose clamps to specification. NOTE PVT Duct Clamp: 24 in-lbs (3 Nm) 13.
Page 214: Drive Belt
PVT SYSTEM DRIVE BELT PVT BREAK-IN (DRIVE BELT / CLUTCHES) 8. Using care, pull the outer PVT cover out the left-hand wheel well. A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and drive belt by operating at slower speeds Flexing the PVT outlet duct aids PVT cover removal.
Page 215: Belt Inspection
PVT SYSTEM DRIVE BELT INSTALLATION 11. Once the sheaves have been spread, walk the drive belt out of the driven clutch and drive clutch, and IMPORTANT remove it from the vehicle. Orient the Belt as it was removed or orient the new belt so you may read the text.
Page 216 PVT SYSTEM TORQUE Outer PVT Cover Screws: 30 in. lbs (3.5 Nm) 5. Reinstall the lower left-hand frame support. Torque to specification. TORQUE Lower Left-Hand Frame Support Bolts: 36 ft. lbs (49 Nm) 6. Install rear wheel and torque wheel nuts. Torque to specification.
Page 217: Drive Clutch Service
PVT SYSTEM DRIVE CLUTCH SERVICE DRIVE CLUTCH EXPLODED VIEW (ALL MODELS) 5.13...
Page 218 PVT SYSTEM REF. DESCRIPTION NOTES Stationary Sheave Washers Needle Bearing (non-EBS models) One Way Clutch (EBS models) Spacer Bushing Moveable Sheave Spider 225 ft-lb (305 Nm) (Apply 0.4 mL Loctite® 7088 Primer and 0.4 mL Loctite® 620™) Shift Weight Shift Weight Bolt 20 in-lb (2 Nm) Washer Button...
Page 219: Drive Clutch Disassembly
PVT SYSTEM DRIVE CLUTCH DISASSEMBLY 4. Inspect cover bushing . The outer cover bushing is manufactured with a Teflon™ coating. Wear is CAUTION determined by the amount of Teflon™ remaining on the bushing. The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly! 1.
Page 220: Drive Clutch Spring Inspection
PVT SYSTEM DRIVE CLUTCH SPRING INSPECTION SHIFT WEIGHT INSPECTION Remove shift weight bolts and weights. Inspect the CAUTION contact surface of the weight . The surface should be smooth and free of dents or gall marks. Inspect the Never shim a drive clutch spring to increase its weight pivot bore and bolts for wear or galling.
Page 221: Spider Removal
PVT SYSTEM SPIDER REMOVAL 2. Inspect the Teflon™ coating on the moveable sheave bushing. 1. Install clutch in holding fixture in a vise. Loosen the spider (clockwise) using Clutch Spider Removal Tool with a breaker bar. Threads are left-handed. ITEM DESCRIPTION 2871358–B Clutch Holding Fixture...
Page 222: Roller, Pin, And Thrust Washer Inspection
PVT SYSTEM ROLLER, PIN, AND THRUST WASHER 2. Inspect sheave surfaces. Replace the entire clutch if worn, damaged or cracked. INSPECTION Inspect all rollers, bushings and roller pins by pulling a BEARING INSPECTION flat metal rod across the roller. Turn roller with your finger.
Page 223: Drive Clutch Inspection
PVT SYSTEM DRIVE CLUTCH INSPECTION 3. Lift bearing and thrust washers off shaft. Replace as an assembly if worn, damaged, or if NOTE problems were noted. Remove cover, spring, and spider following instructions for drive clutch removal, then proceed as follows: 1.
Page 224: Bushing Service
PVT SYSTEM BUSHING SERVICE NOTE Special Tools Required EBS Clutch Bushing Tool Kit - 2201379-A QTY. ITEM PART DESCRIPTION PART # A, B EBS Puller Tool 5132027 EBS Puller Nut 5132501 EBS Main Adapter 5132029 EBS Bushing Removal 5132028 Tool Instructions NOTE Bushing Tool –...
Page 225 PVT SYSTEM 5. Install main adapter (D) onto puller. 20. Remove installation tool. Cover Bushing Removal 21. Install main adapter (8) on puller. 6. With towers pointing toward the vise, slide sheave onto puller rod. 7. Install bushing removal tool into center of sheave with small side toward sheave.
Page 226: Drive Clutch Assembly
PVT SYSTEM DRIVE CLUTCH ASSEMBLY 5. Install the spider assembly onto the shaft threads. Be sure all of the alignment marks are in alignment. CAUTION Do not apply oil or grease to the bushings. Reassemble the drive clutch in the following sequence. Be sure the marks that were made during disassembly are aligned during each phase of assembly.
Page 227 PVT SYSTEM 8. Reinstall clutch spring and limiter spacer 9. Reinstall cover , aligning “X” mark with other marks. IMPORTANT If the aligning marks are not in alignment, the clutch will not be in balance. The drive clutch assembly must be replaced.
Page 228: Driven Clutch Service
PVT SYSTEM DRIVEN CLUTCH SERVICE DRIVEN CLUTCH SLIDER INSPECTION DRIVEN CLUTCH DISASSEMBLY The square sliders can be inspected with the driven 1. Remove driven clutch from the transmission input clutch installed on the vehicle. shaft. Do NOT attempt disassembly of the driven Using a feeler gauge, measure the distance between the clutch from the outside snap ring .
Page 229 PVT SYSTEM 3. Remove the four screws that secure the cam 6. Remove the spider assembly and spring. (helix) assembly using a T25 Torx driver. NOTE 4. Place the driven clutch into the Universal Clutch Spring is compression only and has no torsional wind. Compressor.
Page 230: Driven Clutch Assembly
PVT SYSTEM DRIVEN CLUTCH ASSEMBLY 10. Press the shaft and bearing out of the outer sheave using an arbor press. BEARING INSTALLATION 1. Install a new bearing onto the clutch shaft using an arbor press. Once bearing is fully seated, install a new snap ring 11.
Page 231: Clutch Assembly
PVT SYSTEM CLUTCH ASSEMBLY 4. If removed, install the rollers , washers and E- clips onto the spider. 1. Align the X’s on the moveable and stationary sheaves. 5. Install the spring so the arm rests into the notch in the moveable sheave.
Page 232 PVT SYSTEM CAUTION The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 8. Align the marks previously made on the helix cover and moveable sheave. Install the helix/cover and the four fasteners .
Page 233: Troubleshooting
PVT SYSTEM TROUBLESHOOTING SITUATION PROBABLE CAUSE REMEDY -Wrong or broken drive clutch spring -Replace with recommended spring Engine RPM below specified -Drive clutch shift weight too heavy -Install correct shift weight kit to match engine operating range, application although engine is -Driven clutch spring broken or installed in properly tuned wrong helix location...
Page 234 PVT SYSTEM SITUATION PROBABLE CAUSE REMEDY -Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s Safety and Maintenance Manual -Cover seal or ducts leaking -Find leak and repair as necessary Water ingestion -Operator error -Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and...
Page 235 TRANSMISSION CHAPTER 6 TRANSMISSION TRANSMISSION SPECIFICATIONS ..............6.2 .
Page 236: Transmission Specifications
TRANSMISSION TRANSMISSION SPECIFICATIONS LUBRICATION SPECIFICATIONS TRANSMISSION CAPACITY Gearcase Lubricant 37 oz. (1100 ml) (PN 2878068) (Quart)
Page 237: Shift Linkage / Gear Selector
TRANSMISSION SHIFT LINKAGE / GEAR SELECTOR GEAR SELECTOR REMOVAL (SPORTSMAN) 1. Remove the seat and upper RH side panel. 2. Push linkage rod out of the snap linkage at the gear selector. 3. Remove the retaining screw from the back side and pull the gear selector out from the frame support as an assembly.
Page 238: Transmission Service
TRANSMISSION TRANSMISSION SERVICE TRANSMISSION VENT ROUTING There are two vents for the transmission, they terminate with all other vent lines in the headlight pod. The upper vent pictured tees into the vent for the rear gear case. The lower vent pictured, located near the starter, vents the bell housing.
Page 239: Transmission Removal
TRANSMISSION TRANSMISSION REMOVAL 12. Disconnect the linkage rod from the gear selector. 1. Position the vehicle on a level surface. 2. Remove the seat and side panels. 3. Disconnect negative (-) battery cable. 4. Remove rear cab and both footwells. 5.
Page 240 TRANSMISSION 15. Remove the (7) bolts retaining the transmission to 19. Remove the (3) screws retaining the rear right-hand the engine. footwell support and remove the support from the frame (TOURING Models Only). 16. Remove the (2) vent lines from the top left portion of the transmission.
Page 241 TRANSMISSION 22. Carefully slide the transmission away from the engine and remove the front propshaft from the transmission shaft. 23. Once you have disengaged the transmission input shaft from the engine coupler, carefully lift the transmission assembly out the right side the of vehicle.
Page 242: Transmission Disassembly
TRANSMISSION TRANSMISSION DISASSEMBLY 5. Carefully lift up on the cover. Use a soft-faced hammer to tap on the input shaft and rear output 1. Remove the drive belt, drive clutch and driven clutch. shaft to ease cover removal. 2. Remove the (10) screws that secure the inner PVT cover to the transmission case and remove the cover.
Page 243 TRANSMISSION 8. Remove the four bolts for the coupler shaft retainer 11. Remove the springs, shift shaft rail and park shaft plate. rail. 12. Lift up on each end of the shift fork and rotate the 9. Lift up on the coupler input shaft assembly and fork out of the shift shaft cam.
Page 244: Transmission Shaft Service
TRANSMISSION 14. Remove the input shaft assembly and reverse shaft 18. Remove the retaining ring and washer from the cam assembly together from the transmission. shift shaft. Remove the nut, bellcrank and washer from the bellcrank shift shaft. 15. If servicing either shaft assembly, remove the 19.
Page 245 TRANSMISSION Primary Shaft Reverse Shaft Rear Output Shaft Coupler Input Shaft 6.11...
Page 246 TRANSMISSION Cam Shift Shaft Bellcrank Shift Shaft 6.12...
Page 247: Transmission Assembly
TRANSMISSION TRANSMISSION ASSEMBLY 1. Thoroughly clean the transmission case halves and 3. If the cam shift shaft was disassembled, install the shafts. detent gear with the step facing the O-ring. 2. Inspect all seals and O-rings for damage. If transmission was disassembled, seal and O-ring replacement is recommended (see exploded view above).
Page 248 TRANSMISSION 4. If the bellcrank shift shaft was disassembled, install 7. Place the two shafts into the transmission as an the gear sector with the step facing the O-ring. assembly. 5. Install new O-rings on both shift shafts and lubricate NOTE prior to installation.
Page 249 TRANSMISSION 11. Install the transmission switch, washer and snap 15. Lift up on the lower shift fork and rotate the end into ring. the cam. 16. Install the upper shift fork and rotate the end into the 12. Install the detent plug and torque to specification. cam.
Page 250 TRANSMISSION 17. Install both rails and springs. 24. Apply grease to the primary shaft and coupler input shaft shim (s) (if found during removal), and place them into the transmission cover for assembly. 25. Apply Crankcase Sealant (PN 2871557) to mating surfaces.
Page 251 TRANSMISSION 31. Apply RTV silicone sealant to the outside edge of the inner PVT cover to ensure a water tight fit between the cover and the transmission. 32. Install the cover and torque the inner PVT cover screws to specification. TORQUE Inner PVT Cover Screws: 5 ft.
Page 252: Transmission Installation
TRANSMISSION TRANSMISSION INSTALLATION 8. Install the (2) through-bolt fasteners on the lower LH side and torque to specification. 1. Install a new gasket onto the engine mounting surface. TORQUE Transmission Through-Bolt Fasteners: 19 ft. lbs (26 Nm) 2. Carefully place the transmission assembly into the chassis.
Page 253 TRANSMISSION 12. Install the rear propshaft and torque the retaining bolts to specification. TORQUE Rear Propshaft Bolts: 18 ft. lbs (25 Nm) 13. Reverse the transmission removal procedure to complete the installation. 14. Clean the drain plug magnetic surface. 15. Reinstall drain plug with a new O-ring and torque to specification.
Page 254: Transmission Exploded View
TRANSMISSION TRANSMISSION EXPLODED VIEW 6.20...
Page 255 TRANSMISSION REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION Fill Plug, M18 Park Pawl Drain Plug w/Magnet, M18 Gear, Sector (See Parts Book) Torx Screw, M6 Detent Bullet Screw, M8 Sprocket (See Parts Book) Reverse Shaft (See Parts Book) Screw, M10 Nut, Nylon Lock, 5/16-24 Ball Bearing Washer, Thrust Gear, Helical (See Parts Book)
Page 256: Transmission Troubleshooting
TRANSMISSION TRANSMISSION TROUBLESHOOTING TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered. • Engine idle speed is above specification • Transmission fluid type/quality • Loose or worn snap linkage bushings • Worn linkage rod pivot end at the transmission bellcrank •...
Page 257 FINAL DRIVE CHAPTER 7 FINAL DRIVE GENERAL INFORMATION................7.3 .
Page 258 FINAL DRIVE ............7.38 FRONT GEARCASE ASSEMBLY VIEW - 4WDC .
Page 259: General Information
FINAL DRIVE GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool Axle Boot Clamp Tool PU-48951 CV Boot Clamp Pliers (Ear) 8700226 Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com...
Page 260: Wheels
FINAL DRIVE WHEELS WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Stop the engine, place the transmission in PARK and lock the parking brake. Loosen the wheel nuts slightly. 3. Elevate the appropriate side of the vehicle by placing a suitable stand under the footrest frame.
Page 261: Wheel Studs
FINAL DRIVE WHEEL STUDS WHEEL STUD SERVICE 5. Obtain new wheel stud (s) . Thoroughly clean stud to remove all oil. To ensure proper wheel stud replacement, follow the pro- cedure outlined below. 6. Clean brake disc / hub IMPORTANT 7.
Page 262 FINAL DRIVE 9. Install the lug nut for the corresponding new stud(s). 10. Using a calibrated torque wrench, torque lug nut to specification to set the stud in the brake disc. TORQUE 1st Torque Application: 5 ft-lbs (6.7 Nm) NOTE Failure to properly set the stud in the hub may damage the knurling seat in the hub.
Page 263: Wheel Hubs
FINAL DRIVE WHEEL HUBS FRONT HUB ASSEMBLY VIEW REF. DESCRIPTION NOTES Bearing Carrier Bearing Install with sharp edge out. Snap (Retaining) Ring Wheel Stud Brake Disc Cone Washers Castle Nut 80 ft-lbs (108 Nm) Cotter Pin Air Valve Hub Cover Dust Cover Wheel Nuts 75 ft-lbs (102 Nm)
Page 264: Rear Hub Assembly View
FINAL DRIVE REAR HUB ASSEMBLY VIEW REF. DESCRIPTION NOTES Bearing Carrier Bearing Snap (Retaining) Ring Install with sharp edge out. Wheel Stud Brake Disc Cone Washers Castle Nut 80 ft-lbs (108 Nm) Cotter Pin Air Valve Hub Cover Dust Cover Wheel Nuts 75 ft-lbs (102 Nm)
Page 265: Front Bearing Carrier
FINAL DRIVE FRONT BEARING CARRIER INSPECTION / REMOVAL 6. Remove the front wheel hub assembly. 1. Elevate front of vehicle and safely support machine 7. Remove cotter pin from the bottom of the tie rod end. under the frame area. 8.
Page 266: Bearing Replacement
FINAL DRIVE BEARING REPLACEMENT 12. Remove the bearing carrier from the front drive shaft. Bearing Removal 1. Remove the outer retaining ring from the bearing carrier. 13. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion.
Page 267: Installation
Torque new pinch bolts to specification. press the new bearing into the bearing carrier NOTE housing. Refer to the Polaris Electronic Parts Catalog for replacement pinch bolts and fastener hardware. NOTE Use care to not allow any of the Loctite compound to get in the bearing.
Page 268 FINAL DRIVE 6. Install the brake caliper and torque the new mounting 8. Torque the wheel hub castle nut to specification and bolts to specification. install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TORQUE Front Caliper Mounting Bolts: 37 ft.
Page 269: Front Driveshaft
FINAL DRIVE FRONT DRIVESHAFT REMOVAL 5. Remove the front wheel hub assembly. 1. Elevate front of vehicle and safely support machine 6. Remove the upper ball joint pinch bolt. under the frame area. 7. Using a soft faced hammer, lightly tap on the upper A-arm to remove it from the bearing carrier.
Page 270: Installation
FINAL DRIVE INSTALLATION 1. Install a new spring ring on the end of the drive shaft and apply an anti-seize compound to the splines. 2. Align the splines of the drive shaft with the front gearcase and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary.
Page 271: Front Propshaft
FINAL DRIVE FRONT PROPSHAFT REMOVAL INSTALLATION 1. Locate front propshaft roll pin through the right front 1. Apply anti-seize compound to all splines. Slide wheel well. Position the vehicle for roll pin removal. propshaft back onto the transmission output shaft, then slide it up onto the front gearcase input shaft, 2.
Page 272: Propshaft U-Joint Service
FINAL DRIVE PROPSHAFT U-JOINT SERVICE PROPSHAFT U-JOINT DISASSEMBLY 3. Place a remover adapter on other end of U-joint with a smaller OD than the U-joint cap. NOTE Before servicing the prop shaft U-joint, be sure the joint is clean to ensure no debris damages the yoke. 1.
Page 273: Propshaft U-Joint Assembly
FINAL DRIVE 6. Discard and replace all U-joint parts that were 5. Place clamp and installer adapters with smaller removed from the yoke. OD than caps over each cap. PROPSHAFT U-JOINT ASSEMBLY 1. With NEW U-joint, remove two opposing caps from end of joint to go into yoke and secure other two so they do not fall off during installation.
Page 274 FINAL DRIVE 9. Install retaining ring with sharp, square edge facing away from U-joint into exposed groove. 10. Place larger adapter with ID larger than yoke bore on side with retaining ring. 11. Tighten clamp until other cap is below retaining ring groove.
Page 275: Front Gearcase Removal / Installation
FINAL DRIVE FRONT GEARCASE REMOVAL / INSTALLATION NON-EPS 7. Remove the (2) bolts retaining the lower steering post bracket to the front gearcase. FRONT GEARCASE REMOVAL (NON-EPS MODELS) 1. Stop engine and place gear selector in Park. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 276: Front Gearcase Installation (Non-Eps Models)
FINAL DRIVE 11. Remove the vent line and the (4) bolts securing the 2. Install the vent line and the (4) bolts that secure the front gearcase to frame. front gearcase to frame. Torque bolts to specification. 12. Lay the gearcase on its side and rotate it in the frame so the input shaft is facing you.
Page 277 FINAL DRIVE 5. Secure the steering post to the frame by installing 8. When all of the fasteners for the lower steering post the upper steering post bracket and bushings. are installed, torque all to specification. Torque fasteners to specification. TORQUE Front Gearcase to Post Fasteners: 18 ft.
Page 278: Eps
FLUID CAPACITY Recommended Front Gearcase Fluid: Polaris Demand Drive Fluid (PN 2877922) (Quart) Capacity: 9.3 oz. (275 ml) 15. Reinstall fill plug with a new O-ring and torque to specification.
Page 279: Front Gearcase Installation - Eps Models
FINAL DRIVE 8. Remove the bolts and flange nuts retaining the lower 12. Remove the gearcase from the front LH wheel well steering post assembly to the frame on each side. area and carefully slide it between the upper and lower A-arms.
Page 280 FINAL DRIVE 2. Install the vent line and the (4) bolts that secure the 4. Place the lower steering post assembly into the front front gearcase to frame. Torque bolts to specification. gearcase. 5. Loosely install the two screws and flange nuts that attach the lower steering post assembly to the frame.
Page 281 FLUID CAPACITY Tie Rods to Steering Frog: Recommended Front Gearcase Fluid: 42 ft. lbs (58 Nm) Polaris Demand Drive Fluid (PN 2877922) (Quart) 9. Install the front cover and front rack. Capacity: 9.3 oz. (275 ml) 10. Install the front propshaft onto the front gearcase 14.
Page 282: Highlifter
FINAL DRIVE HIGHLIFTER FRONT GEARCASE INSTALLATION (HIGHLIFTER) FRONT GEARCASE REMOVAL (HIGHLIFTER) 1. Install the gearcase on the right side of the unit as shown. 1. Remove the fan/snorkel cover (lock and ride fasteners) 2. Remove six screws holding on the front cover. 3.
Page 283 FINAL DRIVE 4. Loosely install the two screws and flange nuts that TORQUE attach the lower steering post assembly to the frame. Tie Rods to Steering Frog: 42 ft. lbs (58 Nm) 5. Loosely install the bolts retaining the lower steering post assembly to the front gearcase.
Page 284 FLUID CAPACITY 10. Reinstall the power steering unit, attach the upper Recommended Front Gearcase Fluid: steering post.. Polaris Demand Drive Fluid 11. Connect the EPS wiring harnesses. (PN 2877922) (Quart) Capacity: 9.3 oz. (275 ml) 12. Install the EPS Unit. See EPS Unit Installation 13.
Page 285: Front Gearcase - Non-Adc
FINAL DRIVE FRONT GEARCASE - NON-ADC FRONT GEARCASE ASSEMBLY VIEW - NON-ADC REF# DESCRIPTION REF# DESCRIPTION Square o-ring H-clip O-ring Coil insert Dowel pin Thrust button Bearing Thrust plate Open bearing Spring retainer Needle roller bearing Nylon spacer Bushing Pinion gear Bushing Armature plate Oil seal...
Page 286: Operation
FINAL DRIVE OPERATION The AWD switch may be turned on or off while the vehicle is moving, however, AWD will not enable until the engine RPM drops below 3100. Once the AWD is enabled, it remains enabled until the switch is turned off. Engage the AWD switch before getting into conditions where the front wheel drive may be needed.
Page 287: Awd Diagnosis
FINAL DRIVE AWD DIAGNOSIS 4. Inspect the armature plate for a consistent wear pattern. There should be two distinct wear bands Symptom: AWD Will Not Engage (one band inside the other). If only one band of wear 1. Check the gearcase AWD coil resistance. Measure is present or if there is wear between the two bands, between the Grey (C) and Brown/White (B) wires.
Page 288: Gearcase Disassembly / Inspection
FINAL DRIVE 6. Inspect the rollers for nicks and scratches. The 3. Remove the cover plate assembly from the rollers must slide freely within the roll cage and H- gearcase. springs. 4. Remove the female (LH) output hub assembly. Inspect the thrust bearing (A) for wear. Inspect the output hub ball bearings, contact surfaces and splines for signs of wear or damage.
Page 289 FINAL DRIVE 6. Remove the torsion spring retainer and torsion 8. Remove the male (RH) output hub assembly. Inspect spring from the top of the ring gear. the bearings, contact surfaces and splines for signs of wear or damage. Visually inspect the clutch plate area.
Page 290 FINAL DRIVE 12. Remove and inspect the H-springs (E). If the spring 14. Inspect the magnetic coil (F) in the cover plate legs appear to be flattened or damaged, replace the assembly (refer to “AWD Diagnosis” for inspection). roll cage and H-springs as an assembly. 15.
Page 291: Gearcase Assembly
FINAL DRIVE GEARCASE ASSEMBLY 17. Remove the input shaft assembly from the main gearcase. NOTE Refer to the photos used in the “Gearcase Disassembly / Inspection” procedure when needed, while assembling the front gearcase. 1. Thoroughly clean all gearcase components before beginning reassembly.
Page 292 FINAL DRIVE 8. Install the torsion spring by wrapping each leg of the 11. Install the male (RH) output hub assembly into the spring around the dowel pin on the ring gear. main gearcase. NOTE Take care not to damage the seal lip or seal spring while installing the output hub.
Page 293 FINAL DRIVE 13. Install the armature plate on top of the roll cage / ring TORQUE gear assembly. Be sure that the armature plate tabs Cover Plate Screws: are fully engaged into the roll cage assembly and are 8 ft. lbs (11 Nm) resting on the cut-out grooves of the ring gear.
Page 294: Front Gearcase (Adc)
FINAL DRIVE FRONT GEARCASE (ADC) FRONT GEARCASE ASSEMBLY VIEW - 4WDC REF. PART DESCRIPTION NOTES ASM., GEARCASE, RH, ADC, 4WDC [INCL. ALL] ASM., COVER, OUTPUT ASM., OUTPUT HUB KIT, FASTENERS Torque: 7-11 ft-lbs KIT, SEAL REPAIR PLATE, ARMATURE PLATE, ARMATURE, BD BEARINGS KIT, ROLLER [SET OF 24] ASM., ROLL CAGE [INCL.
Page 295: Operation, Front Gearcase (4Wdc)
FINAL DRIVE OPERATION, FRONT GEARCASE (4WDC) The active descent control front gearcase is designed to allow the vehicle to operate in 2x4, 4x4, or utilize the vehicles EBS to allow 4x4 ADC (active descent control) in the forward and reverse direction. IMPORTANT All-wheel drive ADC MUST be selected on the all-wheel drive / ADC switch to activate the ADC system.
Page 296: Disassembly / Inspection, Front Gearcase (Adc)
FINAL DRIVE DISASSEMBLY / INSPECTION, FRONT GEARCASE (ADC) 1. Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet 4. Remove the output hub assembly 2. Remove bolts retaining the outer cover plate assembly. 5.
Page 297 FINAL DRIVE 7. Remove the torsion spring retainer 10. Remove the LH output hub 8. Remove the torsion spring from the top of the ring 11. Inspect the bearing and contact surfaces of the output gear hub for signs of wear or damage. Replace component if found to be worn or damaged.
Page 298 FINAL DRIVE 13. Inspect the ring gear for inconsistent wear patterns or damage. The surfaces should be free of nicks or 16. Drill a hole in the input shaft seal and remove the burrs. seal using a pry bar or seal puller. 14.
Page 299: Reassembly, Front Gearcase (Adc)
FINAL DRIVE REASSEMBLY, FRONT GEARCASE (ADC) 1. Clean the gearcase housing of debris. 2. Replace all O-rings, seals, and worn components. 3. Inspect bearings on output and pinion shafts. To replace, press new bearing onto shaft. NOTE Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel.
Page 300 FINAL DRIVE 7. Install the torsion spring by wrapping each leg of the 11. Check the action of the torsion spring by rotating in spring around the dowel pin on the ring gear. both directions to ensure the spring and retainer are installed properly.
Page 301 FINAL DRIVE TORQUE Fill Plug: 8-10 ft-lbs (11-14 Nm) Drain Plug: 11 ft-lbs (15 Nm) 14. Install the cover plate assembly with a new o-ring onto the gearcase. NOTE Verify the square O-ring is placed flat on the cover surface. If the O-ring is twisted, fluid leaks may occur. 15.
Page 302: Troubleshooting, Front Gearcase (Adc)
FINAL DRIVE TROUBLESHOOTING, FRONT GEARCASE (ADC) Customer Complaint: ADC not functioning Verification of complaint: Drive vehicle with ADC switched on and off down a grade if possible to determine if ADC (Auto-lock is working correctly). May need to be in low range to tell in high traction areas. Make sure switch on handle bar is on ADC mode.
Page 303 FINAL DRIVE REPAIR REPAIR POTENTIAL DIAGNOSIS PROBLEM PROBLEM PROCEDURE DIAGNOSIS PROCEDURE VERIFICATION Hub Plate Hub Plate will be attached Plate should be flat. Plate Replace hub plate or hub Drive vehicle with ADC to output hub. Initially look should have even wear assembly with hub plate.
Page 304 FINAL DRIVE Symptom: AWD Will Not Engage 4. Check to make sure the coil is seated in the U- shaped insert that is pressed into the gearcase 1. Check the gearcase coil resistance. To test the cover . The top of the coil should be seated below gearcase coil resistance, use the coil harness (Grey the U-shaped insert.
Page 305: Rear Bearing Carrier
FINAL DRIVE REAR BEARING CARRIER INSPECTION / REMOVAL 6. Remove the rear wheel hub assembly. 1. Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 306: Bearing Replacement
FINAL DRIVE BEARING REPLACEMENT 9. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or Bearing Removal corrosion. 1. Remove outer retaining ring from the bearing carrier. NOTE Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel.
Page 307: Bushing Replacement
FINAL DRIVE BUSHING REPLACEMENT 3. Apply Loctite 603 retaining compound to the outer circumference of the new bearing race and carefully 1. Check bearing carrier bushings and shafts for press the new bearing into the bearing carrier excessive wear or damage. housing.
Page 308: Installation
FINAL DRIVE INSTALLATION 4. Install rear wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with 1. Install drive shaft axle through the backside of the domed side out. bearing carrier. Be sure bushings and pivot tubes are installed.
Page 309 FINAL DRIVE 6. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TORQUE Wheel Hub Castle Nut: 80 ft. lbs (108 Nm) 7. Install the rear wheel and (4) wheel nuts. Torque wheel nuts to specification.
Page 310: Rear Driveshaft
FINAL DRIVE REAR DRIVESHAFT REMOVAL 6. Remove the rear wheel hub assembly. 1. Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 311: Installation
FINAL DRIVE INSTALLATION 9. Grasp the rear drive shaft and pull sharply outward on the shaft to disengage it from the rear gearcase. 1. Install a new spring ring on the end of the drive shaft and apply an anti-seize compound to the splines. 10.
Page 312: Driveshaft Service
FINAL DRIVE DRIVESHAFT SERVICE DRIVE SHAFT / CV JOINT HANDLING TIPS OUTER CV JOINT / BOOT REPLACEMENT Care should be exercised during drive shaft removal or 1. Use a side cutters to cut and discard the boot clamps when servicing CV joints. Drive shaft components are precision parts.
Page 313 FINAL DRIVE 4. Place the drive shaft in a soft-jawed vise. Using a 7. Thoroughly clean the joint with an appropriate soft-faced hammer, or brass drift, strike the inner solvent and dry the joint to prevent any residual race of the joint to drive the joint off the drive shaft. solvent from being left in the joint upon reassembly.
Page 314: Inner Plunging Joint / Boot Replacement
FINAL DRIVE 13. Slide the joint onto the drive shaft splines and align 19. While pulling out on the CV shaft, fully extend the CV the circlip with the lead-in chamfer on the inner race joint and slide a straight O-ring pick or a small slotted of the joint.
Page 315 FINAL DRIVE 2. Remove the large end of the boot from the plunging 6. Remove the joint/cage from the shaft. Use a brass joint and slide the boot down the shaft. drift on the inner race only. 3. Clean the grease from the face of the joint. NOTE 4.
Page 316 FINAL DRIVE 14. Fully compress the joint and push the drive shaft 22. Position the boot lip in its groove. Install and tighten firmly into the inner race. the small clamp using the appropriate clamp tool. 15. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft.
Page 317: Rear Propshaft
FINAL DRIVE REAR PROPSHAFT REMOVAL INSTALLATION 1. Locate the rear propshaft through the right rear 1. Apply anti-seize compound to all splines. Slide wheel well. propshaft back onto the transmission output shaft, and then lift it up and align it with the rear gearcase input shaft coupler.
Page 318: Rear Gearcase
FINAL DRIVE REAR GEARCASE GEARCASE REMOVAL 11. Remove the left rear suspension and drive shaft from the vehicle as an assembly. 1. Position vehicle on a level surface and remove seat. 2. Drain the rear gearcase lubricant. 3. Remove the rear cab. 4.
Page 319 FINAL DRIVE 14. Remove the (4) through-bolts retaining the rear 17. Using your hand, press down on the inner PVT cover gearcase to the frame. and continue to rotate the gearcase down and forward until it is removed from the frame. NOTE 15.
Page 320: Gearcase Removal - Touring
FINAL DRIVE GEARCASE REMOVAL - TOURING 10. Remove the (3) through-bolt fasteners retaining the left rear upper and lower A-arms to the frame. 1. Position the vehicle on a level surface, remove the passenger seat and driver’s seat. 2. Remove the (6) T40 Torx-headed screws retaining the rear skid plate and remove the skid plate from the frame.
Page 321 FINAL DRIVE 12. Remove the through-bolt fastener retaining the right 15. Move the gearcase forward in the frame and remove rear upper A-arm to the bearing carrier. Pivot the the vent line from the gearcase. wheel hub and bearing carrier down to remove the drive shaft from the gearcase.
Page 322: Gearcase Disassembly And Inspection
FINAL DRIVE GEARCASE DISASSEMBLY AND 5. Inspect the ring gear teeth for chipped, worn, or broken teeth. INSPECTION NOTE Pinion and ring gear shimming information is NOT provided. The components are matched at the factory, which requires special OEM tooling in order to properly assemble and shim the gears.
Page 323: Gearcase Bearing And Seal Replacement
FINAL DRIVE GEARCASE BEARING AND SEAL 3. Remove the seal above the pinion shaft using a seal puller or other suitable method (see Figure 8-27). REPLACEMENT NOTE If the gearcase is assembled, perform the “Gearcase Disassembly and Inspection” procedure. 1. Remove the nut and lock washer from the pinion shaft (if necessary, hold the coupler in a vise to remove the nut).
Page 324 FINAL DRIVE 8. Remove the seals from each case half using a seal 12. Install the seals into the case halves using a puller or other suitable method (see Figure 8-28). standard seal installer or other suitable method. Seal depth should be approximately .110 in. (2.79 mm) from the main surface.
Page 325: Gearcase Assembly
TORQUE Cover Screws: GEARCASE ASSEMBLY 18 ft. lbs (25 Nm) 1. Grease all seals with Polaris All Season Grease (PN 2871322) upon assembly to prevent from 8. Proceed to “Gearcase Installation” before installing damaging seals. the coupler, lock washer and retaining nut. Doing so will allow you to properly torque the coupler retaining 2.
Page 326: Rear Gearcase Assembly View
FINAL DRIVE REAR GEARCASE ASSEMBLY VIEW REF# DESCRIPTION REF# DESCRIPTION Fill Plug with O-ring Ball Bearing Drain Plug with O-ring, Magnetic Main Case, Machined Cover, Machined Screw Pinion Shaft, 10T Straight Bevel Ring Gear, 37T Straight Bevel Lock Washer Dowel Pin Vent Tube Retaining Ring Coupler...
Page 327: Rear Gearcase Installation
FINAL DRIVE REAR GEARCASE INSTALLATION 5. Inspect the inner PVT cover for any signs of damage caused during removal or installation. If any burs are 1. Place the gearcase in the frame as shown by starting present, carefully clean them up with a flat hand file. the lower portion first.
Page 328 Aluminum Wheels: 75 ft. lbs (102 Nm) 11. Install the rear stabilizer bar onto the linkage rods. Torque the linkage retaining nuts to specification. 18. Add Polaris ATV Angle Drive Fluid to rear gearcase. Torque drain and fill plugs to specification. TORQUE...
Page 329: Rear Gearcase Installation - Touring
10. Install the rear wheels and torque wheel nuts to specification. 5. Install the rear upper shock through-bolts. Torque 11. Add Polaris ATV Angle Drive Fluid to the rear bolts to specification. gearcase. Torque drain and fill plugs to specification.
Page 330 FINAL DRIVE NOTES 7.74...
Page 331 STEERING / SUSPENSION CHAPTER 8 STEERING / SUSPENSION GENERAL INFORMATION................8.3 HANDLEBAR REMOVAL / REPLACMENT .
Page 332 STEERING / SUSPENSION FOX™ SHOCK SERVICE..................8.31 .
Page 333: General Information
STEERING / SUSPENSION GENERAL INFORMATION HANDLEBAR REMOVAL / REPLACMENT REMOVAL / REPLACEMENT (SPORTSMAN) INSTALLATION 1. Remove the upper and lower headlight pods from 1. Locate the alignment pin on the bottom side of the the handlebar bracket. upper block. The pin should line up with the alignment hole in the lower block and should face the NOTE front.
Page 334 STEERING / SUSPENSION 6. Reassemble the headlight pod. NOTE Make sure to route all vent lines, wire harness and throttle cable correctly into the lower headlight pod.
Page 335: Steering - Non-Eps
STEERING / SUSPENSION STEERING - NON-EPS STEERING ASSEMBLY VIEW - NON-EPS MODELS STEERING ASSEMBLY VIEW - NON-EPS REF. DESCRIPTION NOTES Tie Rod Assembly Jam Nut Torque: 12 ft-lbs (16 Nm) Cotter Pin Replace with new when removed. Tie Rod Flange Nuts 42 ft-lbs (57 Nm) Washers Flange Nuts...
Page 336: Steering Post Removal
STEERING / SUSPENSION STEERING POST REMOVAL 6. Remove the (2) bolts retaining the lower steering post bracket to the front gearcase. 1. Remove front rack and front cover. 2. Remove the headlight pods from the handlebar bracket. NOTE Take note of all vent line, wire harness and throttle cable routing for reassembly purposes.
Page 337: Steering Post Installation
STEERING / SUSPENSION STEERING POST INSTALLATION 1. Reverse the “Steering Post Removal” procedure to reinstall the steering post. See: NOTE Make sure to route all vent lines, wire harness and throttle cable correctly into the lower headlight pod. 2. When installing the headlight, be sure to install the O-rings prior to installing the headlight.
Page 338: Steering - Eps
STEERING / SUSPENSION STEERING - EPS STEERING ASSEMBLY VIEW - EPS MODELS...
Page 339 STEERING / SUSPENSION STEERING ASSEMBLY VIEW - EPS REF. DESCRIPTION NOTES Tie Rod Assembly Upper Steering Post Rod End Jam Nut 12 ft-lbs (16 Nm) Tie Rod Jam Nut 12 ft-lbs (16 Nm) Rod End Washers Cotter Pin Replace with new when removed. Flange Nuts 42 ft-lbs (57 Nm) Upper Steering Bracket...
Page 340: Upper Steering Post Removal
STEERING / SUSPENSION UPPER STEERING POST REMOVAL 7. Remove the (2) fasteners retaining the upper steering post bushing bracket. 1. Remove front rack and front cover. 2. Remove the upper and lower headlight pods from the handlebar bracket. NOTE Take note of all vent line, wire harness and throttle cable routing for reassembly purposes.
Page 341: Eps Unit Removal
STEERING / SUSPENSION 5. Refer to “Steering Exploded View (EPS Models)”. 7. Remove the (2) fasteners retaining the upper See: steering post bushing bracket. TORQUE Upper Steering Post Pinch Bolts: 14 ft. lbs (19 Nm) NOTE Make sure to route all vent lines, wire harness and throttle cable correctly into the lower headlight pod.
Page 342: Eps Unit Installation
STEERING / SUSPENSION EPS UNIT INSTALLATION 8. Position the upper steering post on the shaft so the pinch bolts are aligned with the recess in the power 1. Position the vehicle so the front hubs/brake discs are steering shaft. pointing straight forward. 2.
Page 343: Eps Unit Removal (Highlifter)
STEERING / SUSPENSION 12. Reinstall the upper steering post bushing bracket 2. Remove six screws holding on the front cover. and torque the (2) fasteners to specification. 3. Disconnect both fans and remove the radiator cover. 4. Remove both fuel tank guards. 5.
Page 344: Eps Unit Installation (Highlifter)
STEERING / SUSPENSION 14. Remove the lower steering post pinch bolt and nut. 4. Align the two marks and install the power steering unit onto the lower steering post assembly. 15. Remove the mounting fasteners and nuts that retain • Upper Steering Post the power steering unit and mount plate to the frame.
Page 345 STEERING / SUSPENSION 8. Position the upper steering post on the shaft so the TORQUE pinch bolts are aligned with the recess in the power Steering Post to Bulkhead Bolts: steering shaft. 18 ft. lbs (24 Nm) 13. Turn the ignition key to the “ON” position and move the handlebar from left to right several times to ensure the power steering doesn’t bind.
Page 346: Steering Tie Rods
STEERING / SUSPENSION STEERING TIE RODS TIE ROD / TIE ROD END REPLACEMENT • If replacing just the tie rod end, loosen the jam nut and remove the rod end Use the following procedure to replace the tie rod • Install new rod end and torque jam nuts to assembly or tie rod ends.
Page 347: Front Control Arms
STEERING / SUSPENSION FRONT CONTROL ARMS EXPLODED VIEW NOTE Image for Reference Only REF. DESCRIPTION NOTES Upper A-arm Lower A-arm Retaining Ring Ball Joint 28 ft-lbs Replace if loosened or removed. Bolt Grease Fitting Bushing Pivot Shaft Bolt 37 ft-lbs CV Shield Screw Washer...
Page 348: Removal / Replacement
STEERING / SUSPENSION REMOVAL / REPLACEMENT 7. Examine A-arm bushings and pivot shafts. Replace if worn and discard the hardware. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. CAUTION 1. Elevate and safely support the front of the vehicle The locking agent on the existing bolts was destroyed and remove the front wheel.
Page 349 STEERING / SUSPENSION 21. Install new lower A-arm assembly onto vehicle frame. Torque new bolts to specification. TORQUE A-Arm Assembly Bolts: 37 ft. lbs (50 Nm) 22. Insert lower A-arm ball joint end into bearing carrier. Install new pinch bolt and fastener hardware. Torque new pinch bolt to specification.
Page 350: Ball Joint Service
STEERING / SUSPENSION BALL JOINT SERVICE SERVICE PREPARATION BALL JOINT REMOVAL Service Preparation 1. Remove the retaining ring from the ball joint. NOTE Do not reuse a ball joint if it has been removed. If removed, it must be replaced. Use this removal procedure only when replacing the ball joint.
Page 351: Ball Joint Installation
STEERING / SUSPENSION 5. Tighten the Press Asm. screw and fully remove the 5. Tighten the Press Asm. screw and fully install the ball joint from the A-arm. ball joint into the arm. BALL JOINT INSTALLATION 6. After the new ball joint is fully installed into the A- arm, install a new retaining ring.
Page 352 STEERING / SUSPENSION 9. If needed, install new brake caliper mounting bolts and torque to specification. CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. TORQUE Front Caliper Mounting Bolts: 37 ft.
Page 353: Rear Controls Arms
STEERING / SUSPENSION REAR CONTROLS ARMS EXPLODED VIEW NOTE Image for reference only. REF. DESCRIPTION NOTES Bolt 37 ft-lbs (50 Nm) Bushing, LCA Upper A-arm Grease Fitting Pivot Shaft Bolt Lower A-arm Bolt Pivot Shaft, Upper Pivot Shaft, Lower Bushing, Lower Pivot Tube Bushing, UCA Bolt...
Page 354: Removal
STEERING / SUSPENSION REMOVAL 10. Remove the fastener retaining the stabilizer linkage to the lower A-arm. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. 1. Elevate and safely support the rear of the vehicle and remove the rear wheel.
Page 355 STEERING / SUSPENSION 5. Route brake line on top of lower A-arm and install retainer (if applicable). 6. Reinstall lower portion of shock and lower portion of stabilizer linkage to the lower A-arm. Torque shock mounting fastener (see Figure 10-19) specification.
Page 356: Rear Stabilizer Bar
STEERING / SUSPENSION REAR STABILIZER BAR ASSEMBLY VIEW REF. DESCRIPTION NOTE Bolt Stabilizer Bar Bracket Upper Bushings Torque: 20 ft-lbs (27 Nm) Stabilizer Bar Bushing Linkage Lower Bushings Torque: 37 ft-lbs (50 Nm) Bolts 8.26...
Page 357: Linkage Removal / Installation
STEERING / SUSPENSION LINKAGE REMOVAL / INSTALLATION STABILIZER BAR REMOVAL / INSTALLATION 1. Remove the upper linkage bushing from each side. Using an 5/16” open-end wrench, hold the linkage 1. Elevate the rear of vehicle and safely support rod and remove the lower linkage bushing. machine under the frame area.
Page 358 STEERING / SUSPENSION 4. Remove upper shock mounting fastener from the right rear shock and swing the shock out from the frame. 5. Carefully remove the stabilizer bar from the frame. 6. Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed.
Page 359: Shocks / Springs
STEERING / SUSPENSION SHOCKS / SPRINGS SHOCK EXPLODED VIEW - BASE MODEL 2. Remove the spring and adjusting cam from the existing shock and install components onto the new shock. 3. Compress the shock spring and install the spring retainer. 4.
Page 360: Shock Removal / Installation
STEERING / SUSPENSION SHOCK REMOVAL / INSTALLATION 1. Elevate the vehicle off the ground to relieve the suspension load. 2. Support under A-arm or trailing arm. 3. Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle. Discard nuts and replace with new upon installation.
Page 361: Fox™ Shock Service
STEERING / SUSPENSION FOX™ SHOCK SERVICE 7044135 SHOCK ASSEMBLY VIEW REF. DESCRIPTION REF. DESCRIPTION Body Cap Asm.-Piggyback Washer Shock Body Preload Ring Preload Ring Lock Shock Rod Eyelet Bushing Body/Bearing Cap Asm. Sleeve Bearing Cap Asm. Bushing Piston Valve Asm. Sleeve Retaining Ring Lock Nut...
Page 362: 7044080 / 7044081 Shock Assembly View
STEERING / SUSPENSION 7044080 / 7044081 SHOCK ASSEMBLY VIEW NOTE Rear FOX™ shocks on 2014 models are labeled “LEFT” and “RIGHT” to indicate placement on vehicle. DESCRIPTION NOTE DESCRIPTION NOTE Apply Loctite® 638™ / Primer Body Cap Asm. N™ to threads. Torque: 100 ft- Bumper lbs (136 Nm) Shock Body...
Page 363: 7044080 / 7044081 Shock Service Information
STEERING / SUSPENSION 7044135 SHOCK SERVICE INFORMATION 7044080 / 7044081 SHOCK SERVICE INFORMATION SHOCK DESIGN DETAILS Travel 4.86” SHOCK DESIGN DETAILS Extended Length 15.96” Travel 6.16” Extended Length 2.90” (73.6 mm) 19.44” IFP Location Factory Clicker Setting 2.90” (73.6 mm) IFP Location Factory Clicker Setting Nitrogen Pressure...
Page 364: General Service Information
1/2" Shock Rod Holding Tool 2871352 2201639 Shock Seal Protector Sleeve Bosch Automotive Service Solutions 1-800-328-6657 or www.polaris.service-solutions.com FOX™ SHOCK DISASSEMBLY 9. Remove the reservoir cap. NOTE To prevent damage or marks to the shock, the use of special tools and a soft jaw vise is recommended.
Page 365 STEERING / SUSPENSION 10. Use a small, flat-blade screwdriver to pry the bearing 18. Remove and discard the lock nut from the end of assembly cap out of the shock body. shock rod. NOTE Keep the rebound and compression valve stacks in the NOTE order they were removed.
Page 366: Fox™ Shock Body And Reservoir Service
STEERING / SUSPENSION FOX™ SHOCK BODY AND RESERVOIR 7. Use a 5/8" socket to remove the compression control assembly. SERVICE NOTE WARNING The compression control assembly is not serviceable. The following procedure involves the use of an open Replace assembly if required. flame.
Page 367 STEERING / SUSPENSION 4. Refer to the assembly instructions for component 8. Refer to the assembly instructions for component installation onto the shock asm. installation onto the shock asm. Bearing Assembly 9. Use a small pick to remove the U-cup seal (C), internal (D) and external (E) O-rings from the bearing assembly.
Page 368: Fox™ Shock Assembly
STEERING / SUSPENSION FOX™ SHOCK ASSEMBLY 5. Lubricate and install the body/bearing cap onto the shock rod. NOTE To prevent damage or marks to the shock, the use of special tools and a soft jaw vise is recommended. WARNING FOX™ shocks contain high pressure nitrogen gas. Extreme caution must be used while handling and working with FOX™...
Page 369 STEERING / SUSPENSION 9. Replace the o-ring on the piston valve and lubricate • Note the orientation of the bleed shim tabs as the with low temperature grease. Install the piston valve assembly would be installed on the shock shaft. as follows: •...
Page 370 14. Fill the remote reservoir 3/4 full with shock oil. the air bubbles out of the piston and piston ports. Polaris Gas Shock Oil - 5 wt. 24. Slide the bearing assembly partially into the shock PN 2870995 - qt.
Page 371 STEERING / SUSPENSION 31. Remove the IFP center screw and O-ring. 43. Use the Gas Fill Tool (PS-45259) and charge the shock to the recommended pressure for 10 seconds. 32. Pull upward on shock shaft until fully extended and seated against the bearing assembly retaining ring. Nitrogen Pressure: Reference shock specifications.
Page 372 STEERING / SUSPENSION NOTES 8.42...
Page 373 BRAKE SYSTEM CHAPTER 9 BRAKE SYSTEM GENERAL INFORMATION................9.3 .
Page 374 BRAKE SYSTEM BRAKE SYSTEM TROUBLESHOOTING ..............9.25 .
Page 375: General Information
1.500” / 38.1 mm 1.498” / 38.05 mm Caliper Bore Diameter 1.505” / 38.23 mm 1.507” / 38.28 mm SPECIAL TOOLS / BRAKE FLUID PART NUMBER TOOL DESCRIPTION Mity Vac 2870975 2872189 DOT 4 Brake Fluid Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com...
Page 376: Brake System Service Notes
Do not fill the reservoir beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.
Page 377: Brake System Assembly Views
BRAKE SYSTEM BRAKE SYSTEM ASSEMBLY VIEWS SPORTSMAN / SCRAMBLER 850 BRAKE SYSTEM...
Page 378: Sportsman / Scrambler 1000 Brake System
BRAKE SYSTEM SPORTSMAN / SCRAMBLER 1000 BRAKE SYSTEM...
Page 379: Sportsman / Scrambler International Brake System
BRAKE SYSTEM SPORTSMAN / SCRAMBLER INTERNATIONAL BRAKE SYSTEM BRAKE CALIPER EXPLODED VIEW...
Page 380: Hand Master Cylinder Exploded View
BRAKE SYSTEM HAND MASTER CYLINDER EXPLODED VIEW BRAKE HOSE ROUTING Retainers are indicated with a . The first image is the front routing, the second image is the rear.
Page 381 BRAKE SYSTEM...
Page 382: International Brake System Operation
BRAKE SYSTEM INTERNATIONAL BRAKE SYSTEM OPERATION HAND MASTER CYLINDER HYDRAULIC OPERATION FOOT MASTER CYLINDER HYDRAULIC OPERATION 9.10...
Page 383: Brake Fluid Bleeding
Do not allow brake fluid to come in contact with finished surfaces. This procedure should be used to change fluid or bleed brakes during regular maintenance. Polaris DOT 4 Brake Fluid 1. Clean reservoir cover thoroughly. PN: 2872189 2. Remove screws, cover and diaphragm from master cylinder reservoir.
Page 384: Rear Brake System Bleeding
BRAKE SYSTEM REAR BRAKE SYSTEM BLEEDING 6. Close bleeder screw and release brake lever. 1. Remove the front rack or front storage box and NOTE locate the foot brake fluid reservoir for the foot Do not release lever before bleeder screw is tight or air master cylinder.
Page 385 BRAKE SYSTEM 6. Install a box end wrench on the rear caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting. 7. Slowly pump the foot brake pedal until pressure builds and holds.
Page 386: Hand Brake Master Cylinder
1. Clean master cylinder and reservoir assembly. Make The hand master cylinder is a serviceable component. sure you have a clean work area to disassemble Polaris offers a number of service kits to rebuild this style brake components. of master cylinder. Refer to the Polaris Electronic Parts Catalog.
Page 387: Brake Switch Replacement
BRAKE SYSTEM 4. Follow brake bleeding procedures. Check all connections for leaks and repair if necessary. BRAKE SWITCH REPLACEMENT 1. Set the parking brake lock and locate the brake switch behind the hand brake lever. 2. Using a small screwdriver or similar tool, push up on the mounting tabs through the holes on the bottom side while rotating the switch to disengage the tabs from the holes.
Page 388: Foot Brake Master Cylinder
BRAKE SYSTEM FOOT BRAKE MASTER CYLINDER FOOT MASTER CYLINDER REMOVAL / BRAKE PEDAL REMOVAL / INSTALLATION INSTALLATION 1. Remove the RH mud guard and footwell. 1. Remove the RH mud guard and footwell. 2. Remove the through-bolt retaining the brake pedal to the mount bracket.
Page 389: Brake Pads
BRAKE SYSTEM BRAKE PADS PAD REMOVAL PAD INSPECTION 1. Loosen the (4) wheel nuts. 1. Measure the thickness of the pad material by taking two measurements. Measure the thickness of the 2. Elevate and support the side of the ATV in which the friction material and backing plate, then measure the caliper brake pads are being serviced.
Page 390: Brake Burnishing Procedure
BRAKE SYSTEM 3. Install the caliper and torque new mounting bolts to 7. Install the wheel (s) and wheel nuts. Torque wheel specification. nuts to specification. TORQUE TORQUE Brake Caliper Bolts Lug Nuts 37 ft. lbs (50 Nm) Aluminum Wheels: 75 ft. lbs (102 Nm) Steel Wheels: 45 ft.
Page 391: Brake Caliper Service
BRAKE SYSTEM BRAKE CALIPER SERVICE CALIPER REMOVAL CALIPER DISASSEMBLY 1. Loosen the (4) wheel nuts. 1. Push mount bracket inward and slip outer brake pad past the edge of the pin. Remove the inner brake 2. Elevate and support the side of the ATV in which the pad.
Page 392: Caliper Inspection
BRAKE SYSTEM 4. Clean the caliper body, piston, and mounting bracket 2. Inspect piston for nicks, scratches, wear or damage. with brake cleaner or denatured alcohol. Measure diameter and replace if damaged or worn beyond service limit. NOTE Be sure to thoroughly clean the seal grooves in the caliper body.
Page 393: Caliper Installation
BRAKE SYSTEM 5. Install the brake pads. 2. Install brake line with new seals, and torque the banjo bolt fitting to specification. 6. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. TORQUE CALIPER INSTALLATION Brake Line Banjo Fastener...
Page 394: Brake Disc Service
BRAKE SYSTEM BRAKE DISC SERVICE DISC INSPECTION 3. Mount a dial indicator and measure disc runout. Slowly rotate the disc and read total runout on the 1. Visually inspect brake disc for scoring, scratches, or dial indicator. Replace the disc if runout exceeds gouges.
Page 395: Disc Removal / Replacement
BRAKE SYSTEM DISC REMOVAL / REPLACEMENT 9. Install the new disc and press new wheel studs into the hub until they are flush with the mating surface. 1. Loosen the (4) wheel nuts. CAUTION 2. Elevate and support the side of the ATV in which the brake disc is being serviced.
Page 396 BRAKE SYSTEM 12. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TORQUE Wheel Hub Castle Nut: 80 ft. lbs (108 Nm) 13. Install the wheel and (4) wheel nuts. Torque wheel nuts to specification.
Page 397 BRAKE SYSTEM BRAKE SYSTEM TROUBLESHOOTING BRAKE SYSTEM TROUBLESHOOTING • Dirty/contaminated friction pads • Improper alignment • Worn disc • Worn caliper • Glazed brake pads Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned •...
Page 398 BRAKE SYSTEM BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet can be applied to the back of the pads.
Page 399 BODY / FRAME CHAPTER 10 BODY / FRAME GENERAL INFORMATION................10.2 .
Page 400: General Information
BODY / FRAME GENERAL INFORMATION DECAL REPLACEMENT PLASTIC PUSH RIVET REMOVAL Polaris ATVs use a two piece plastic push rivet to fasten WARNING most body components. Using the “Multi-Function Pliers” eases removal and prevents from damaging the push The following procedure involves the use of an open rivets and body components.
Page 401: 2018 850 / 1000 Sportsman
BODY / FRAME 2018 850 / 1000 SPORTSMAN HEADLIGHT POD ASSEMBLY 1. Install and electrical components removed form the HEADLIGHT POD pod. 2. Reconnect all electrical components. HEADLIGHT POD DISASSEMBLY 3. Route and refasten the wiring harnesses, vent lines, 1. Remove the screws retaining the front of the pod. and throttle cables as they were prior to disassembly.
Page 402: Seat
BODY / FRAME SEAT SEAT INSTALLATION 1. Align the seat with the tabs and pin. SEAT REMOVAL 1. Grasp the latch at the rear of the seat and squeeze. 2. Slide the seat forward and lower the rear. 2. Lift the rear of the seat and slide the seat rearward.
Page 403: Side Panels
BODY / FRAME SIDE PANELS SIDE PANEL INSTALLATION 1. With the side panel tipped as shown, insert the front SIDE PANEL REMOVAL tab begin to lower the rear 1. Remove the seat. 2. Remove the push rivets that retain the side panels. 2.
Page 404: Front Rack / Storage Box
BODY / FRAME FRONT RACK / STORAGE BOX 4. Remove the screws retaining the travel limiter cables FRONT RACK REMOVAL 1. Unlatch the front rack 5. Turn the quarter turns at the back of the storage tray to the unlock position. 2.
Page 405: Front Rack Installation
BODY / FRAME FRONT RACK INSTALLATION 4. Install the pins that retain the front rack. 1. Install the front storage tray by inserting the tabs at the front of the tray into the slots on the front cab, then lower the back of the tray. 5.
Page 406: Front Bumper
BODY / FRAME FRONT BUMPER FRONT BUMPER INSTALLATION 1. Install the upper bumper cover then install the FRONT BUMPER REMOVAL fasteners that retain the upper bumper cover 1. Remove the fasteners retaining the lower bumper cover. 2. Install the lower bumper cover then install the fasteners that retain the lower bumper cover 2.
Page 407: Mud Gaurds
BODY / FRAME MUD GAURDS MUD GUARD INSTALLATION 1. Align the mud guard with the mounting holes. MUD GUARD REMOVAL 2. Install the front top Tuflock fastener that retains the 1. Locate and remove the Tuflock fastener at the top mud guard front corner of the mud guard 3.
Page 408: Front Cab
BODY / FRAME FRONT CAB 7. Remove the center cover located under the pod. FRONT CAB REMOVAL 1. Remove the seat. 2. Remove the side panels. 3. Remove the front rack and storage compartment. 4. Remove the Tuflock fasteners and screws fastening the front cab to the fender flares and footwells.
Page 409: Front Cab Installation
BODY / FRAME FRONT CAB INSTALLATION 5. Install the diagnostic connector tree clip in the hole in the cab. 1. Place the front cab and align the mounting holes. 2. Place the center cover under the pod. 6. Remove the tape from the gas tank inlet. 7.
Page 410: Rear Rack / Storage Box
BODY / FRAME REAR RACK / STORAGE BOX REAR RACK INSTALLATION 1. Place the rear rack in place and align the mounting REAR RACK REMOVAL holes. 2. Loosely install the fasteners that retain the rear rack. 1. Open the rear storage compartment. 2.
Page 411: Rear Cab
BODY / FRAME REAR CAB REAR CAB REMOVAL 1. Remove the seat. 5. Remove the fasteners retaining the fender flares. 2. Remove the side panels. 6. Remove the fastener retaining the footwell sheild. 3. Remove the rear rack. 4. Remove the Tuflock fasteners retaining the rear cab.
Page 412: Rear Cab Installation
BODY / FRAME REAR CAB INSTALLATION 1. Place the rear cab and align the mounting holes. 2. Install the Tuflock fasteners that retain the rear cab. 3. Install the fasteners that retain the fender flares. TORQUE Fender Flare Fasteners: Until Fully Seated 4.
Page 413: Rear Bumper Cover
BODY / FRAME REAR BUMPER COVER REAR BUMPER COVER INSTALLATION 1. align the rear bumper cover with the mounting holes REAR BUMPER COVER REMOVAL and loosely install the fasteners 1. Open the rear storage lid and remove the rear rack. 2.
Page 414: Main Frame / Frame Supports
BODY / FRAME MAIN FRAME / FRAME SUPPORTS MAIN FRAME ASSEMBLY VIEW REF. DESCRIPTION NOTES Screw 30 ft-lbs (41 Nm) Screw 30 ft-lbs (41 Nm) Screw 10.16...
Page 415 ELECTRICAL CHAPTER 11 ELECTRICAL GENERAL INFORMATION................11.5 .
Page 416 ............11.39 POLARIS INTERACTIVE DIGITAL DISPLAY (PIDD) .
Page 417 ELECTRICAL ..............11.59 HEADLIGHT REPLACEMENT, POD .
Page 418 ELECTRICAL ................11.82 CAN TROUBLESHOOTING BREAKOUT WIRING DIAGRAMS .
Page 419: General Information
ELECTRICAL GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION Fluke™77 Digital Multimeter PV-43568 Test Relay PA-49466 PV-43526 Connector Test Kit Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com 11.5...
Page 420: Chassis Harness
ELECTRICAL CHASSIS HARNESS HARNESS RETENTION LOCATIONS Tie-strap retainers indicated by FRONT RETENTION POINTS REAR RETENTION POINTS 11.6...
Page 421: Harness Routing
ELECTRICAL HARNESS ROUTING NOTE If replacing the harness, noting routing during removal will aid in proper installation. 11.7...
Page 422: Electrical Diagnostics
• All associated circuits have no shorts to ground. , page DIGITAL MULTI-METER (DMM) NOTES 11.11 • All associated circuits have no shorts to voltage. , page Polaris advises to only use a high quality DMM that 11.12 meets the same standards as the Fluke™ 77 (PV-43568) for electrical testing.
Page 423: Connector Probing Guidelines
To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris NOTE machines can be tested using terminal test kit PV–...
Page 424: Testing Continuity/Resistance
ELECTRICAL TESTING CONTINUITY/RESISTANCE Testing using the Ohmmeter function of your DMM is one of the first things you will do when troubleshooting an electrical issue. It is especially convenient when the wiring diagram provides a resistance spec for the component in the circuit you are diagnosing. It can quickly give you a good idea if you simply need to replace a part, or if there might be another circuit issue.
Page 425: Testing For A Short To Ground
ELECTRICAL TESTING FOR A SHORT TO GROUND Shorts to ground happen when the current flowing in a given circuit bypasses the load. The current flowing from B+ finds an easier way to return to ground (B-), so much more of it can flow than the circuit is designed for. This causes the circuit’s protection device (either a fuse or circuit breaker) to open, protecting the circuit from damage.
Page 426: Testing For A Short To Voltage
ELECTRICAL TESTING FOR A SHORT TO VOLTAGE TESTING FOR INTERMITTENT CONDITIONS There are three possible short to voltage causes: Intermittent conditions are very difficult to diagnose, as when you are testing the circuit, you may not have the 1. Internal electronic component short. circuit failing to indicate where the issue is.
Page 427: Testing Current Flow (Amperage)
ELECTRICAL TESTING CURRENT FLOW (AMPERAGE) TESTING PARASITIC DRAW Performing a current flow test requires the meter leads Parasitic draw is when there is excessive current flow be inserted into the correct cavities in the meter, and be with the key off. placed in series in the circuit to be tested.
Page 428: Testing Voltage Drop
ELECTRICAL TESTING VOLTAGE DROP NOTE If you disconnect the connector at the load, and measure voltage with one lead on the power supply wire, and one to ground, you will be measuring available voltage. This is a static test and not dynamic voltage drop testing.
Page 429: Displays
ELECTRICAL DISPLAYS INSTURMENT CLUSTER INSTRUMENT CLUSTER OVERVIEW The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions. NOTE Some features are not applicable to all models. The use of a high pressure washer may damage the instrument cluster. Wash the ATV by hand or with a garden hose using mild soap.
Page 430: Rider Information Display - Sportsman / Scrambler
ELECTRICAL RIDER INFORMATION DISPLAY - SPORTSMAN / SCRAMBLER The rider information display is located in the instrument cluster. All segments will light up for 1 second at start-up. NOTE If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer.
Page 431: Information Display Area
ELECTRICAL INFORMATION DISPLAY AREA Tachometer (RPM) The LCD portion of the instrument cluster is the information display area. Information displayed in this area includes: odometer, trip meters, engine RPM, engine hours, service interval, clock, engine Diagnostic Trouble Codes (DTCs) and power steering DTCs. The reverse override button on the LH control acts as the MODE button when pressed and released quickly.
Page 432 ELECTRICAL Programmed Service Interval Clock The clock displays the time in a 12-hour or 24-hour The initial factory service interval setting is 50 hours. format. Refer to “Units of Measurement” to change the Each time the engine is started, the engine hours are format (Standard 12-hour / Metric-24 hour).
Page 433 ELECTRICAL 3. When the display flashes the distance setting, tap the Under / Over Voltage MODE button to advance to the desired setting. This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and a high electrical load is applied (lights, cooling fan or other accessories).
Page 434: Diagnostic Mode
ELECTRICAL DIAGNOSTIC MODE 3. A set of three numbers will appear in the information display area. The diagnostic mode is accessible only when the check • The first number (located far left) can range from 0 to engine MIL has been activated. 9.
Page 435 ELECTRICAL INSTRUMENT CLUSTER PINOUTS FUNCTION CAN High CAN Low Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input Fuel Level Sensor International Models Only Turn Signal Input, LH Turn Signal Input, RH 11.21...
Page 436: Insterment Cluster Troubleshooting
ELECTRICAL INSTERMENT CLUSTER TROUBLESHOOTING INSTRUMENT CLUSTER - KEY OFF / NO POWER 11.22...
Page 437: Instrument Cluster - Key On / No Power
ELECTRICAL INSTRUMENT CLUSTER - KEY ON / NO POWER 11.23...
Page 438: Instrument Cluster - No High Beam Indicator
ELECTRICAL INSTRUMENT CLUSTER - NO HIGH BEAM INDICATOR 11.24...
Page 439: Instrument Cluster - No / Incorrect Fuel Level
ELECTRICAL INSTRUMENT CLUSTER - NO / INCORRECT FUEL LEVEL 11.25...
Page 440: Message Center Gauge
Fuel Gauge activated. All segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can Service Indicator provide scheduled maintenance. See , page 11.36 for more information.
Page 441: Indicator Lamps
Check Engine Serious engine damage could result. Your authorized POLARIS dealer can assist. This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS EPS Warning (if equipped) dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.
Page 442: Display Area 1
ELECTRICAL DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 Speed Engine Temperature Ambient Temperature (Optional) 11.28...
Page 443: Display Area 2
ELECTRICAL DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 Engine Temperature Odometer Ambient Temperature Trip 1 (Optional) Trip 2 Voltage Speed Engine Hours Service Hours 11.29...
Page 444: Options Menu
ELECTRICAL OPTIONS MENU Press and hold the MODE button to enter the Options Menu. OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Units - Distance Select MPH or KPH Units - Temp Select between °F and °C Clock Select between 12H or 24H, and set time Backlight Color...
Page 445: Unit Selection Distance
ELECTRICAL UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Units-Distance” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 446: Unit Selection Temperature
ELECTRICAL UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 447: Clock
ELECTRICAL CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 448: Back Light Color
ELECTRICAL BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Backlight Color” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 449 ELECTRICAL BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Backlight Level” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 450: Service Hours
ELECTRICAL SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
Page 451: Diagnostic Code
ELECTRICAL DIAGNOSTIC CODE NOTE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2.
Page 452 ELECTRICAL INSTRUMENT CLUSTER PINOUTS FUNCTION CAN High CAN Low Constant Power (Vdc) Switched Power (Vdc) Ground Fuel Level Sensor 11.38...
Page 453: Polaris Interactive Digital Display (Pidd)
A printed copy of the manual was included with all ATV’s equipped with the IDD. If the manual is lost, a new one can be obtained through normal parts ordering channels. The manual can also be viewed by accessing the Polaris Owner’s Manual website. DOWNLOAD POLARIS OWNER’S...
Page 454: Idd - Usb Flash Drive Recommendations
ELECTRICAL IDD – USB FLASH DRIVE RECOMMENDATIONS Polaris recommends using a Scandisk® or similar USB flash drive with a minimum of 4 GB available memory. USB Flash Drive Notes / Troubleshooting • The flash drive must be formatted as FAT 32. Use Quick Format on the PC to format the drive as FAT 32.
Page 455: Interactive Digital Display (Pidd) Frozen Display Screen Recovery Methods
When the PIDD is turned on, the screen will display “Booting...”. After the PIDD completes the booting process, the screen will display the Polaris logo and then display the vehicle home screen. This concern is caused by the IDD being inadvertently left in diagnostics mode during manufacturing testing.
Page 456 ELECTRICAL PIDD screen does not display “Booting…” in the upper left corner of the screen immediately after the PIDD is turned on. ERROR 3 RECOVERY METHOD: 1. Verify there is power at the PIDD wire harness connector. Does the screen or buttons illuminate? 2.
Page 457: Interactive Digital Display (Pidd) Reset And Update Procedure
ELECTRICAL INTERACTIVE DIGITAL DISPLAY (PIDD) RESET After the PIDD is turned on, the screen immediately displays a white background with NO TEXT on the AND UPDATE PROCEDURE screen. 1. Log on to: https://www.riderx.com/en-us/home ERROR 4 RECOVERY METHOD: 2. Download the most current TRAILS UPDATE .zip file. 1.
Page 458: Gps Receiver Troubleshooting
ELECTRICAL GPS RECEIVER TROUBLESHOOTING Test the GPS Receiver Power Connector to identify why the receiver is not turning on. If the power connector Satellite / GPS Receiver Terminology: passes inspection, install a new receiver and re-test. DOP: Dilution of Precision (Position / Time Accuracy) No Satellite Reception (DOP Values All Zeros) HDOP: Horizontal Dilution of Precision VDOP: Vertical Dilution of Precision...
Page 459 ELECTRICAL GPS Receiver Power Connector Testing 1. Move the ATV to an outside area with a clear view of the sky. 2. Open the left side engine compartment panel. Disconnect the power connector from the GPS receiver. 3. Start the engine. 4.
Page 460: Switches / Controls
ELECTRICAL SWITCHES / CONTROLS BRAKE SWITCH Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and F. Applying the brakes closes a switch to activate the brake lamps. Use a multimeter to test for continuity when the brakes are applied.
Page 461: Off / Run Switch
ELECTRICAL If any of the tests fail, replace the RH throttle / switch assembly. OFF / RUN SWITCH Use a multimeter to test for continuity when the LH switch is moved to the RUN position. If the test fails, replace the LH control assembly. Move the switch to the RUN position and test.
Page 462: Left-Hand Switch Controls
ELECTRICAL LEFT-HAND SWITCH CONTROLS Use a multimeter to test for continuity for each of the LH switch functions. If any test fails, replace the LH control assembly. 11.48...
Page 463: Left-Hand Switch Controls - International
ELECTRICAL LEFT-HAND SWITCH CONTROLS - INTERNATIONAL Use a multimeter set to test for continuity for each of the left-hand control switch functions. If any test fails, replace the left-hand control assembly. 11.49...
Page 464: Reverse / Mode Button
ELECTRICAL REVERSE / MODE BUTTON HEADLAMP SWITCH Use a multimeter to test for continuity when pressing the Use a multimeter to test for continuity between the head Reverse Override / Mode button. If the test fails, replace lamp outputs in the LH control assembly. If any of the the LH control assembly.
Page 465: Throttle Release Switch (Trs)
ELECTRICAL THROTTLE RELEASE SWITCH (TRS) NOTE Machines with Electronic Throttle Control (ETC) will not have this switch. The Throttle Release Switch (TRS) is designed to close during throttle movement in the event the throttle cable sticks or breaks. When the throttle lever is at idle position, the TRS contacts should be closed (touching).
Page 466: Gear Selector Switch
ELECTRICAL GEAR SELECTOR SWITCH 1. Locate the gear selector switch on the transmission. Remove the wiring harness connector and insert the multimeter probes into the switch. 2. Move the gear selector handle to each of the 5 drive positions (HIGH, LOW, NEUTRAL, REV, or PARK). 3.
Page 467: Speed Sensor
ELECTRICAL SPEED SENSOR VEHICLE SPEED SENSOR The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear. Battery voltage is supplied to the sensor on the ORANGE circuit and is energized when the OFF/RUN and ignition switches are in the RUN and ON positions.
Page 468: All Wheel Drive (Awd) And Adc Coils
ELECTRICAL ALL WHEEL DRIVE (AWD) AND ADC COILS OPERATION OVERVIEW • Key on power is supplied to the AWD hub coil from terminal 23 in the fuse block, on the RED/GREEN wire. The AWD hub coil is engaged when ground is supplied on the BROWN/WHITE circuit for the AWD hub coil. •...
Page 469 ELECTRICAL • Verify that connector pins and grounds are undamaged, clean and connect properly. NOTE Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before suspecting a component failure. A high percentage of electrical issues are caused by bad/failed connections and grounds.
Page 470: Fuse / Relays
ELECTRICAL FUSE / RELAYS RELAY OVERVIEW FAN RELAY Relays use low current circuits to control high current The fan relay provides power to the following system: circuits. The low current circuit flows through a coil • Fan Motor winding, which magnetically attracts the contact to close the high current side, allowing that side of the circuit to COLOR FUNCTION...
Page 471: Start Solenoid Relay
ELECTRICAL START SOLENOID RELAY HIGH BEAM RELAY - INTERNATIONAL MODELS The start solenoid relay provides power to the following system: The high beam relay provides power to the high beam light on international models only. • Starter Motor Solenoid COLOR FUNCTION COLOR FUNCTION...
Page 472: Fuse / Relay Box Layout - Sportsman
To gain access, remove the front rack or storage box assembly by unlatching the two locking anchors. The cover label identifies the location of each relay and fuse. 7180678 - SPORTSMAN 850 / 850 SP / 1000 XP SPORTSMAN 850 / 1000 TOURING...
Page 473: Lights
ELECTRICAL LIGHTS HEADLAMPS WARNING Due to the nature of ATVs and where they are HEADLIGHT ADJUSTMENT, POD operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding 1. Place the vehicle on a level surface with the headlight with poor lighting can result in severe injury or death.
Page 474: Headlight Adjustment, Bumper
ELECTRICAL HEADLIGHT REPLACEMENT, BUMPER 7. Install front half of the pod. Torque fasteners until fully seated. Before replacing the lamp, use a digital multimeter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. HEADLIGHT ADJUSTMENT, BUMPER 1.
Page 475: Taillamps
ELECTRICAL TAILLAMPS 3. Remove the mounting fasteners Right Rear: TAIL / BRAKE LIGHT REPLACEMENT NOTE The LED tail lights are not serviceable and must be replaced as an assembly. 1. Turn the key to the off position. 2. Disconnect the tail light from the main wiring harness Right Rear: Left Rear: Left Rear:...
Page 476 ELECTRICAL 1. Open the rear storage lid ad remove the rear rack. 5. Connect the tail light to the Main Harness. 6. Install the rear rack. TORQUE Rear Rack Fasteners: Until Fully Seated 7. Verify proper operation. 2. Disconnect the tail light from the main wiring harness 3.
Page 477: Charging System
9. Remove the left footwell. NOTE VOLTAGE REGULATOR INSTALLATION This step is only required on 2017 sportsman 850/1000 (Applies to NON - High Lifter models only) 1-UP machines (excluding High Lifter) 1. Fasten the rope or cable used during regulator removal to the NEW regulator wiring harness.
Page 478: Voltage Regulator Removal
ELECTRICAL 3. Connect the regulator harness to the stator. 4. Remove the fasteners retaining the voltage regulator. 4. Install the left footwell. Torque to specification. TORQUE Footwell Fasteners: Torque Until Fully Seated 5. Install the side panel and seat. 6. Install the fasteners that retain the regulator. Torque to specification TORQUE Regulator Fasteners: 75 in-lbs (7Nm)
Page 479 ELECTRICAL 7. Remove the fasteners retaining the radiator shroud 18. Loosen the worm clamps that clamp the clutch duct connector inside of the left front wheel well. and fuse box Disconnect the clutch duct. 8. Disconnect the fans from the main wiring harness. 19.
Page 480: Voltage Regulator Installation, High Lifter
ELECTRICAL 22. Locate the stator wires and disconnect the Regulator 2. Draw the voltage regulator wiring harness through the from the stator. chassis as it was removed. NOTE Do not apply excessive force while installing the regulator wiring. Ensure the regulator harness routes correctly through the front cab support bracket.
Page 481: Current Draw - Key Off
ELECTRICAL CURRENT DRAW - KEY OFF 17. Install the radiator shroud cover. Engage the Lock & Ride fasteners. CAUTION 18. Install the fasteners that retain the voltage regulator. Do not connect or disconnect the battery cable or TORQUE ammeter with the engine running. Damage will occur to electrical components.
Page 482: Stator / Alternator Tests
ELECTRICAL STATOR / ALTERNATOR TESTS 2. Measure the resistance value of each of the stator legs to ground. Three tests can be performed using a multimeter to determine the condition of the stator (alternator). CONNECT OHMS TEST METER LEADS READING Open Line Battery Charge Y1, Y2, or Y3...
Page 483: Stator / Alternator Removal
ELECTRICAL STATOR / ALTERNATOR REMOVAL 8. Remove the (8) screws retaining the stator cover. 1. Remove the fuel tank.Fuel Tank Removal, page 4.9 2. Remove the (4) screws retaining the engine skid plate and remove the plate from the vehicle. 3.
Page 484: Stator / Alternator Installation
ELECTRICAL STATOR / ALTERNATOR INSTALLATION 5. Torque the (8) stator cover bolts to specification using the torque sequence provided. 1. Reverse the “Stator / Alternator Removal” procedure to reinstall the stator. 2. Use the following steps to ensure proper assembly. 3.
Page 485: Starter Motor
ELECTRICAL STARTER MOTOR STARTER / STARTER LOCKOUT SYSTEM 2. Disconnect the battery negative (-) cable. DIAGRAM 3. Clean the area around the starter motor. The starter and starter lockout system consists of: 4. Using an 8 mm allen socket, with an extension, •...
Page 486 ELECTRICAL 9. Be sure to install new O-rings on the starter motor bell housing. 10. Torque the mounting bolts to specification. TORQUE Starter Motor Mounting Bolts: 20 ft. lbs (27 Nm) 11.72...
Page 487: Battery Service
BATTERY SPECIFICATIONS 2. If the voltage is below 12.6 V, the battery will need to be recharged (see “Charging Procedure”). Charging BATTERY PN 4011496 Procedure , page 11.76 Polaris / Yuasa YTX20HL-BS Type NOTE Sealed - Maintenance Free Voltage Never attempt to add electrolyte or distilled water to a 12 Vdc Maintenance Free battery.
Page 488: Battery Installation (Non-High Lifter)
ELECTRICAL 3. Remove the nut retaining the hold-down strap 2. Place the battery into the ATV on its side with the near the rear portion of the battery and remove the positive (+) and negative (-) cable terminals strap. connected in the orientation shown. 3.
Page 489: Battery Installation (High Lifter)
Maintenance Free battery to determine its conductance measurement is calculated. Conductance condition: OCV Test and a Load Test. testing is more accurate than voltage, specific gravity, or load testing. Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries. 11.75...
Page 490: Charging Procedure
Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. Polaris MDX-610P SPX PN: PU-50296 CHARGING PROCEDURE If battery voltage is 12.6 Vdc or less, the battery may need recharging.
Page 491: Electronic Power Steering (Eps)
Key-On / Run Switch On to a normal mechanically coupled steering system. The ORANGE Battery Voltage / EPS Power system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the Battery Voltage vehicle’s diagnostic port. BROWN...
Page 492: Eps Troubleshooting
ELECTRICAL EPS TROUBLESHOOTING 11.78...
Page 493: Hand / Thumb Warmers
ELECTRICAL HAND / THUMB WARMERS HAND / THUMB WARMER RESISTANCE CHECKS The low heat element circuit in the element pad will always be the circuit with high resistance. The circuit with low re- sistance will be the high setting element. If an element pad’s circuit is out of range (either too high or too low), the oper- ator may notice a heat imbalance between the left and right warmers.
Page 494: Winch
ELECTRICAL WINCH WINCH ASSEMBLY VIEW CAUTION Disconnect battery prior to servicing winch. Always disconnect the negative (BLACK) cable from battery first during disassembly, and last during assembly. 11.80...
Page 495: Winch Contactor
ELECTRICAL WINCH ASSEMBLY VIEW REF. DESCRIPTION NOTES Winch Kit Assembly Winch Switch Screws Hand Tight - Do not Over-Torque Winch Bracket Winch Assembly Service Kit Latch Hook Fairlead Roller Winch Cable Wire, Yellow, 6 GA Connect at Yellow contactor / winch posts (NEG) Wire, Blue, 6 GA Connect at Blue contactor / winch posts (POS) Wire, Black, Ground, 6 GA...
Page 496: Controller Area Network (Can)
ELECTRICAL CONTROLLER AREA NETWORK (CAN) OVERVIEW This vehicle uses a Controller Area Network (CAN) to perform some functions. Similar to a computer network, CAN establishes a communication network between the ECM and several on-board components. The CAN network includes: • ECM •...
Page 497: Breakout Wiring Diagrams
ELECTRICAL BREAKOUT WIRING DIAGRAMS AWD (NON-ETC) AWD INPUT (ETC) COOLING FAN CRANKSHAFT POSITION SENSOR 11.83...
Page 498: Diagnostic Circuit/Can Bus
ELECTRICAL DIAGNOSTIC CIRCUIT/CAN BUS ENGINE TEMP. SENSOR EFI AND CHASSIS POWER IGNITION COIL (ETC) ELECTRONIC THROTTLE SIGNAL/INPUT IGNITION COIL (NON-ETC) ELECTRONIC THROTTLE OUTPUT INTAKE AIR TEMP SENSOR (ETC) 11.84...
Page 499: Intake Air Temp Sensor (Non-Etc)
ELECTRICAL INTAKE AIR TEMP SENSOR (NON-ETC) TMAP (ETC) THROTTLE POSITION SENSOR (NON-ETC) TMAP (NON-ETC) 11.85...
Page 500 ELECTRICAL NOTES 11.86...
Page 501 INDEX 7044080 / 7044081 Shock Service Information ....8.33 Sportsman / Scrambler International......9.7 Brake System Inspection ..........2.38 Brake System, Operation ..........9.4 Break-In Period............2.3 Breather Hose ............2.17 ADC, Coil Resistance..........7.31 Breather, Engine Adjustment Removal...............3.47 Valve Clearance.............2.18 Bumper Lights Relay..........11.56 Air Filter Service............2.14 Air Intake Assembly View ..........3.24 Assembly View, 7044080 / 7044081 Shocks ....8.32...
Page 502 INDEX Sealing ..............3.73 Crankcase (lower) Inspection.............3.59 ETC Learn Procedure ........4.25, 4.45 Crankcase Assembly View, Complete ......3.35 Replacement............4.45 Crankcase Assembly View, Lower.........3.38 ECU Connector Pinout ..........4.23 Crankcase Assembly View, Upper.........3.36 EFI Operation Overview..........4.20 Crankshaft EFI Priming / Starting Procedure........4.20 Inspection.............3.59 EFI Relay ..............
Page 503 INDEX Front Bumper Guide,Valve Installation ............10.8 Removal...............3.52 Front Bumper Removal..........10.8 Front Cab Installation ............10.11 Removal............. 10.10 Front Drive Shaft, Installation ........7.14 Hand / Thumb Warmers Front Drive Shaft, Removal .........7.13 Resistance Checks ..........11.79 Front Gearcase Hand Master Cylinder, Exploded View ......9.8 Hand Master Cylinder, Operation (INT’L Models)....9.10 Assembly View NON-ADC ............7.29...
Page 504 Valve ..............2.18 Plunging Joint / Boot Leakdown Test ............2.20 Replacement (Inner) ..........7.58 Left-Hand Controls Polaris Mobile Digital Wrench (PMDW) ....1.6, 4.48 International ............11.49 Power Steering Relay..........11.57 Left-hand Switch Controls ......... 11.48 Power Steering Unit Installation ........8.12 Low Beam Lights Relay, 2014 ........11.57 Power Steering Unit Removal ........
Page 505 INDEX Removal...............7.62 Start Solenoid Relay ..........11.57 Rear Gearcase, Assembly...........7.69 Starter Motor, Removal / Replacement......11.71 Rear Gearcase, Disassembly and Inspection ....7.66 Starter Ring Gear ............3.41 Rear Hubs Starter System............11.71 Assembly View ............7.8 Starter System, Troubleshooting......... 11.71 Rear Propshaft, Service..........7.61 Static ..............
Page 506 INDEX Transmission, Disassembly .......... 6.8 Transmission, Exploded View ........6.20 Transmission, Installation..........6.18 Transmission, Lubrication ..........6.2 Transmission, Removal ..........6.5 Transmission, Shaft Service ........6.10 Troubleshooting Front Gearcase (ADC)..........7.46 Troubleshooting, Brake Noise ........9.26 Troubleshooting, Clutching ..........5.29 Troubleshooting, Engine ..........3.80 Tube, Oil Passage .............3.68 Upper Crankcase Assembly .............
Page 507 2017-18 SPORTSMAN 850 XP WINCH EPS POWER (A) HARNESS: 2413823-01 FUNCTION SWITCH (HEADLIGHT BULB SERVICE P/N 4010253) SPEEDOMETER (HEADLIGHT BULB SERVICE P/N 4010253) (HEADLIGHT BULB SERVICE P/N 4010253) BATTERY (+) RIGHT HANDLEBAR SWITCH ASSEMBLY DIAGNOSTIC BATTERY (-) POD HEADLIGHT (P/N 2413427) SHEET NO.
Page 508 2017-18 SPORTSMAN 1000 XP ETC (HEADLIGHT BULB SERVICE P/N 4010253) HARNESS: 2413824 POWER STEERING ASSEMBLY (P/N 2411530) (HEADLIGHT BULB SERVICE P/N 4010253) (HEADLIGHT BULB SERVICE P/N 4010253) POD HEADLIGHT (P/N 2413427) SPEEDOMETER EPS POWER (A) FUNCTION RH BUMPER HEADLIGHT (P/N 2413433) LH BUMPER HEADLIGHT (P/N 2413432) WINCH DIAGNOSTIC...
Page 509 2017-18 SPORTSMAN 1000 XP ETC HARNESS: 2413824 HALL SENSOR SPEED SENSOR 100%%185 POWER IN PIN "A" 68%%185 V OUT WIRE COLOR LEGEND PIN "C" BEIGE (TAN) E = ENGINE GROUND BLACK 1000pf LIGHT BLUE COMMON DARK BLUE PIN "B" C = CHASSIS GROUND .01uf BROWN (LOCATED ON TRANSMISSION)
Page 510 2017-18 SPORTSMAN 850/1000 HIGH LIFTER HARNESS: 2413688-01 WINCH WINCH EPS POWER (A) FUNCTION SWITCH CONTACTOR SPEEDOMETER BATTERY (+) RIGHT HANDLEBAR SWITCH ASSEMBLY DIAGNOSTIC BATTERY (-) SHEET NO. 1 OF 2 POD LIGHT 2205636 4013465 1 2 3 4 5 6 7 8 EPS SENSOR (B) E246 BK (0.5)

This manual is also suitable for:

Sportsman 1000

Polaris Sportsman 850 Service Manual

Chapter 1 1 General Information

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling System

Chapter 4 Fuel System

Chapter 5 Pvt System

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Summary of Contents for Polaris Sportsman 850