Polaris 850 PRO-RMK 155 2020 Manual
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Polaris 850 PRO-RMK 155 2020 Manual

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Table of Contents

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2020-2021 850 AXYS™ Long Track
Snowmobile
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
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.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed October 2020 (PN 9850060 R02)
© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris 850 PRO-RMK 155 2020

  • Page 1 Publication Printed October 2020 (PN 9850060 R02) © Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation 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.
  • Page 4 12/03/2020 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
  • Page 5 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING / EXHAUST CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : FINAL DRIVE / BRAKE SYSTEMS CHAPTER 7 : PVT SYSTEM...

  • Page 7: Table Of Contents

    .....1.60 850 PRO-RMK 155/163/174 & RMK KHAOS 155 3.0 TRACK CLUTCH SETTINGS 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 8 ............1.119 POLARIS MOBILE DIGITAL WRENCH® (PMDW) .
  • Page 9 ............... . . 1.128 TESTING VOLTAGE DROP 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 10: Vehicle Identification

    The VIN (2) number is permanently stamped into the tunnel. The model number is embossed on the decal. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 11: Vehicle Identification Number Locations

    If the tunnel wrap doesn’t provide an opening for these labels, remove the section of wrap where the labels are located. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 12: Engine Serial Number Location

    GENERAL INFORMATION ENGINE SERIAL NUMBER LOCATION The engine serial number is located on the identification label on the engine case next to the recoil cover. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 13: Reference Information

    NOTICE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 14: Publication Part Numbers - 2021

    NOTICE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 15: 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 16 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.10 © Copyright Polaris Inc.
  • Page 17 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK 155/163 & RMK Khaos 155 Clutch Settings page 1.60 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.11 © Copyright Polaris Inc.
  • Page 18 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.12 © Copyright Polaris Inc.
  • Page 19 Maximum Stud Length For clutch settings; See 850 PRO-RMK 155/163/174 & RMK Khaos 155 3.0 Track Clutch Settings page 1.60 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.13 © Copyright Polaris Inc.
  • Page 20 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.14 © Copyright Polaris Inc.
  • Page 21 2.60 in. / 6.60 cm (Series 6 ) chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.15 © Copyright Polaris Inc.
  • Page 22 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.16 © Copyright Polaris Inc.
  • Page 23 3.0 in. / 7.62 cm (Series 7) later in this chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.17 © Copyright Polaris Inc.
  • Page 24 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.18 © Copyright Polaris Inc.
  • Page 25 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK 155/163 & RMK Khaos 155 Clutch Settings page 1.60 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.19 © Copyright Polaris Inc.
  • Page 26 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.20 © Copyright Polaris Inc.
  • Page 27 Maximum Stud Length For clutch settings; See 850 PRO-RMK 155/163/174 & RMK Khaos 155 3.0 Track Clutch Settings page 1.60 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.21 © Copyright Polaris Inc.
  • Page 28 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.22 © Copyright Polaris Inc.
  • Page 29 Maximum Stud Length For clutch settings; See 850 PRO-RMK 155/163/174 & RMK Khaos 155 3.0 Track Clutch Settings page 1.60 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.23 © Copyright Polaris Inc.
  • Page 30 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.24 © Copyright Polaris Inc.
  • Page 31 2.40 in / 6.10 cm (Series 5.1) 2.60 in. / 6.60 cm (Series 6) Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.25 © Copyright Polaris Inc.
  • Page 32 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.26 © Copyright Polaris Inc.
  • Page 33 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/165) Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.27 © Copyright Polaris Inc.

  • Page 34: 2021 850 Pro-Rmk 155 Qd2 2.75 Track

    46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.28 © Copyright Polaris Inc.
  • Page 35 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/165) Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.29 © Copyright Polaris Inc.
  • Page 36 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.30 © Copyright Polaris Inc.
  • Page 37 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/174) 3.0 Track Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.31 © Copyright Polaris Inc.
  • Page 38 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.32 © Copyright Polaris Inc.
  • Page 39 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/174) 3.0 Track Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.33 © Copyright Polaris Inc.
  • Page 40 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.34 © Copyright Polaris Inc.
  • Page 41 2.60 in. / 6.60 cm (Series 6 ) chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.35 © Copyright Polaris Inc.

  • Page 42: 2021 850 Rmk Khaos 155 Qd2 2.75 Track

    46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.36 © Copyright Polaris Inc.
  • Page 43 2.75 in. / 6.99 cm (Series 8) chapter. Track Tension 0.50 - 0.625 in / 1.3 - 1.6 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.37 © Copyright Polaris Inc.
  • Page 44 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.38 © Copyright Polaris Inc.
  • Page 45 3.0 in. / 7.62 cm (Series 7) in this chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.39 © Copyright Polaris Inc.
  • Page 46 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.40 © Copyright Polaris Inc.
  • Page 47 3.0 in. / 7.62 cm (Series 7) in this chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.41 © Copyright Polaris Inc.
  • Page 48 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.42 © Copyright Polaris Inc.
  • Page 49 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/165) Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.43 © Copyright Polaris Inc.
  • Page 50 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.44 © Copyright Polaris Inc.
  • Page 51 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/174) 3.0 Track Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.45 © Copyright Polaris Inc.
  • Page 52 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.46 © Copyright Polaris Inc.
  • Page 53 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/174) 3.0 Track Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.47 © Copyright Polaris Inc.
  • Page 54 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.48 © Copyright Polaris Inc.
  • Page 55 2.60 in. / 6.60 cm (Series 6 ) chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.49 © Copyright Polaris Inc.
  • Page 56 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.50 © Copyright Polaris Inc.
  • Page 57 3.0 in. / 7.62 cm (Series 7) in this chapter. Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.51 © Copyright Polaris Inc.
  • Page 58 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.52 © Copyright Polaris Inc.
  • Page 59 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/165) Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.53 © Copyright Polaris Inc.
  • Page 60 46.77 in / 118.8 cm Center Distance 11.5 in / 29 cm QUICKDRIVE Center Distance 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.54 © Copyright Polaris Inc.
  • Page 61 2.75 in. / 6.99 cm (Series 8) chapter. Track Tension 0.50 - 0.625 in / 1.3 - 1.6 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.55 © Copyright Polaris Inc.
  • Page 62 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.56 © Copyright Polaris Inc.
  • Page 63 Stud Protection Maximum Stud Length For clutch settings; See 850 PRO-RMK / RMK Khaos (155/163/174) 3.0 Track Clutch Settings page 1.61 later in this chapter. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.57 © Copyright Polaris Inc.
  • Page 64 7.76 in / 19.71 cm Gearing SEE CLUTCHING SETTINGS Polaris Synthetic (30W) Gear Lube Capacity 8 - 10 oz / 237 - 296 ml Reverse System Electronic Reverse 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.58 © Copyright Polaris Inc.
  • Page 65 2.40 in / 6.10 cm (Series 5.1) 2.60 in. / 6.60 cm (Series 6) Track Tension 0.625 - 0.75 in / 1.6 - 1.9 cm Stud Protection Maximum Stud Length 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.59 © Copyright Polaris Inc.

  • Page 66: Clutch Settings (Model Year 2020)

    Shaded cells indicate factory settings. Use 2 gram lighter shift weights when operating in temperatures above 40° F (5° C). * = INTL Stock Setting Drive Clutch Bolt Torque: 80 ft-lbs (108 Nm) Re-torque after running engine. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.60 © Copyright Polaris Inc.

  • Page 67: Clutch Settings (Model Year 2021)

    * = North American Low-Elevation and INTL Stock Setting ** = North American High-Elevation Stock Setting Drive Clutch Bolt Torque: 80 ft-lbs (108 Nm) Re-torque after running engine. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.61 © Copyright Polaris Inc.

  • Page 68: 850 Sks 155 Clutch Settings

    * = North American Low-Elevation and INTL Stock Setting ** = North American High-Elevation Stock Setting Drive Clutch Bolt Torque: 80 ft-lbs (108 Nm) Re-torque after running engine. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.62 © Copyright Polaris Inc.

  • Page 69: Misc Specifications And Charts

    (M10 x 1.50 x 127) threads prior to Exhaust Valve Base installation. Fasteners 9 ft-lbs (12 N·m) (M6 x 1.0 x 30) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.63 © Copyright Polaris Inc.
  • Page 70 ECU Mounting Fasteners 5 ft-lbs (7 Nm) Fasteners Front Seat Mount Torque Link Stud Nut 22 ft-lbs (30 Nm) 36 in-lbs (4 Nm) Fastener 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.64 © Copyright Polaris Inc.
  • Page 71 Ski Assembly Fastener 36 ft-lbs (50 Nm) Auxiliary Engine Stop 12 in-lbs (1.4 Nm) Switch Set Screw Control Arm Fastener 40 ft-lbs (54 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.65 © Copyright Polaris Inc.
  • Page 72 26 ft-lbs (35 Nm) Shaft Fastener Replace with new when removed. Rear Torque Arm 6 ft-lbs (8 Nm) Fastener Cast Clip Side Screws 9 ft-lbs (12 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.66 © Copyright Polaris Inc.
  • Page 73 Starter Motor Positive 8 ft-lbs (11 Nm) Cable Nut Starter Motor Pinion 7 ft-lbs (10 Nm) Fasteners Starter Motor Clip Bracket 8 ft-lbs (11 Nm) Fasteners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.67 © Copyright Polaris Inc.

  • Page 74: Conversion Table

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.68 © Copyright Polaris Inc.

  • Page 75: Sae Tap / Drill Sizes

    1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 3–4 7/16–14 2 3/4 7/16–20 25/64 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.69 © Copyright Polaris Inc.

  • Page 76: Decimal Equivalents

    0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 0.5938″ 19/32 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.70 © Copyright Polaris Inc.

  • Page 77: Fuel Recommendations

    Fuel System Deicers If you use non-ethanol fuel (sometimes labeled “non- oxygenated”), Polaris recommends the regular use of a isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent damage resulting from fuel system icing. Never use deicers or additives containing methanol.

  • Page 78: Service Precautions

    IMPORTANT necessary to tap the part into place, use a soft face hammer and tap lightly. Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines.

  • Page 79: General Diagnostics

    P1217 Sensor Over-Temp prevent damage. Can be caused by any failure Shutdown that would cause the engine to overheat. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.73 © Copyright Polaris Inc.
  • Page 80 Exhaust Over- Pipe Temperature caused by a Faulty Exhaust Temperature Sensor/ P1517 Temperature Sensor Connections or Lean Air/Fuel Ratio causing high Shutdown exhaust temperature. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.74 © Copyright Polaris Inc.
  • Page 81 Voltage. Can be caused by Damaged Wiring or P0916 Signal Low Connectors in the Gear Switch Circuit, a Damaged Switch or Faulty ECU /Connections. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.75 © Copyright Polaris Inc.
  • Page 82 1352 P1336 caused by Incorrect Fuel (low octane or Ethanol Limit Reached, content), Low Fuel Pressure or any other MAG Cylinder condition that can 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.76 © Copyright Polaris Inc.
  • Page 83 Open Circuit in the ECU Supply Can P1606 ECU Open be caused by a blown ECU Fuse or Open Circuit Circuit in the ECU power wiring. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.77 © Copyright Polaris Inc.
  • Page 84 This Trouble Code Sets if the Regulator has Regulator ECU detected an internal Low Voltage Condition Can 520377 P1619 Voltage Too be caused by damaged wiring/connections or Regulator/connections 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.78 © Copyright Polaris Inc.
  • Page 85 This Trouble Code Sets if the Accessory Relay Accessory Driver Circuit is Open. Can be caused by Relay Driver P1646 Damaged Wiring/Connections, a Accessory Circuit Open Ignition Relay or ECU 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.79 © Copyright Polaris Inc.
  • Page 86 Range (Mid) Exhaust Valve Position Out of 520327 P140C Range (Closed) Exhaust Valve Learn / Gauge EV Learn 520328 P140E Relay Short to Voltage 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.80 © Copyright Polaris Inc.
  • Page 87 This Trouble Code Sets if the Sled has been Ridiing With 520556 C2419 Brakes On driven with the brakes applied continuously for 20 seconds , 4500 RPM Most Severe 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.81 © Copyright Polaris Inc.

  • Page 88: Troubleshooting - Engine Will Not Start

    Wrench. Voltage must be 15.5 – 16 VDC. If the voltage is lower, inspect the stator system power coil and ORANGE wires at the ECU 26 PIN harness connector for damage. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.82 © Copyright Polaris Inc.

  • Page 89: Performance Troubleshooting Guide

    IMPORTANT Under no circumstance should a rider or Polaris service technician tamper with / modify the function of the E-VES actuator arm or push / pull cable for the sole purpose of setting the valves to the full-open position. Doing so may cause severe engine and / or E-VES actuator damage.
  • Page 90 Simple Green. The combination of this type of cleaner and belt dust creates a tacky film that causes the clutch bushings to stick. For this reason, Polaris only recommends cleaning clutches with compressed air. If chemicals are used, only use isopropyl alcohol to remove belt deposits from the sheaves.

  • Page 91: Digital Wrench Diagnostic Software Overview

    Digital Wrench Diagnostic Refer to Section 2, 3, and 4 in the Instruction Manual PU-47063–C provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your Digital Wrench Software: computer. PU-48731–A Interface Cable: PU-...

  • Page 92: Digital Wrench Software Version / 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. NOTICE You must already have the current version installed before adding an update.

  • Page 93: Digital Wrench® Communication Errors

    Do not "run" or "open" the file from where they are. troubleshooting information, FAQs, downloads and Select "save" and download them to your PC before software updates at: http://polaris.diagsys.com/. running the install. 8. When the update is complete, the version shown on the right side of the Digital Wrench start-up screen should match the update you just downloaded.

  • Page 94: Digital Wrench® Feature Map

    Perform specialized testing Run the Help System. and adjustment functions service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.88 © Copyright Polaris Inc.

  • Page 95: Digital Wrench - System Configurations

    Digital Wrench does not need to be connected to a vehicle to access this menu. DIGITAL WRENCH SYSTEM CONFIGURATION REF. DESCRIPTION Dealer Information – Enter the Polaris dealer name, dealer number, and address. These fields must be filled in with accurate information to submit Service Reports. Select preferred language.

  • Page 96: Digital Wrench - Diagnostic Trouble Codes (Dtcs) Display

    DTC. If guided diagnostic are available for the DTC, click on the icon to launch the feature. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.90 © Copyright Polaris Inc.

  • Page 97: Digital Wrench - Data List Display

    Click the save button to save the current view as a custom data map. Click the folder button to display more preset data lists or create a customized data list. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.91 © Copyright Polaris Inc.

  • Page 98: Digital Wrench - Data Trigger (Freeze Frame)

    (if trouble code is selected as the trigger) Enable or reset trigger recording In the example shown below, TPS Volts was selected as the Data Item Trigger. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.92 © Copyright Polaris Inc.

  • Page 99: Digital Wrench - Special Tests Menu

    The Special Tests Menu includes service procedures, component replacement procedures, and component recalibrations. Each of these functions has guided step by step instructions. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.93 © Copyright Polaris Inc.

  • Page 100: Digital Wrench - Output State Control Testing

    NOTICE Test items may appear different than what is shown and are vehicle-specific. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.94 © Copyright Polaris Inc.

  • Page 101: Digital Wrench - Service Report

    ECU monitors Polaris Unit Inquiry. on the vehicle. To submit a Service Report to Polaris, first create the The Service Report will also capture any current / historic report or open a report from the saved report location.

  • Page 102: Digital Wrench - Ecu / Injector / Oil Pump Replacement Menu

    2. Open the left engine compartment panel. 3. Connect the Next-Gen Service Power Harness to the diagnostic connector on the wiring harness. Next-Gen Service Power Harness: PS-52573 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.96 © Copyright Polaris Inc.
  • Page 103 13. After the new service ECU is installed and the wire / Oil Pump Replacement”. harness connectors are installed, reconnect the chassis power-up harness to the ECU PWR Test connector. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.97 © Copyright Polaris Inc.
  • Page 104 “Security Disabled”. Click on “Continue”. 2. Digital Wrench will notify the user that it is unable to communicate with the ECU. Click on “Done / Continue”. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.98 © Copyright Polaris Inc.
  • Page 105 Up harness and Digital Wrench SmartLink cables are connected to the vehicle. IMPORTANT Severe engine damage may occur if the wrong oil pump offset number code is entered. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.99 © Copyright Polaris Inc.

  • Page 106: Digital Wrench - Fuel Injector Replacement

    Place the battery on the floor next to the engine compartment. 6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.100 © Copyright Polaris Inc.
  • Page 107 Wait for 10 seconds and then reconnect the power connector. 13. Click “Continue”. Repeat steps 7 – 11 to verify the correct fuel injector color is set in the ECU. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.101 © Copyright Polaris Inc.

  • Page 108: Digital Wrench - Electronic Oil Pump Flow Offset

    ECU PWR and Critical PWR diagnostic test program the flow offset in Digital Wrench. The seven digit connectors on the Next-Gen Service Power Harness. number preceding the (-) is the Polaris part number and subject to change. 6. Connect the power up harness to the battery.
  • Page 109 10 and 11. 14. Write the offset value on the ECU label for future reference. 11. On the following screen, select “Oil Pump Replacement”. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.103 © Copyright Polaris Inc.

  • Page 110: Digital Wrench - Service Procedures Menu

    If using a stand-alone service battery, do not place the battery in the tunnel footwells. Place the battery on the floor next to the engine compartment. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.104 © Copyright Polaris Inc.
  • Page 111 8. Select the Special Tools (Tool Box) menu and then Service Procedures. 9. The next screen will prompt the user to select the desired operation. Select: Break-In Timer Reset. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.105 © Copyright Polaris Inc.

  • Page 112: Oil Pump Enrichment Mode Timer Reset

    PS-52573 4. Connect one of the Chassis Power Up harness leads to the ECU PWR diagnostic test connector on the Next-Gen Service Power Harness. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.106 © Copyright Polaris Inc.

  • Page 113: Ev Actuator Learn Procedure

    Place the battery on the floor next to the engine compartment. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.107 © Copyright Polaris Inc.
  • Page 114 Service Procedures. user to charge the battery. 9. The next screen will prompt the user to select the desired operation. Select: Exhaust Valve Learn. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.108 © Copyright Polaris Inc.
  • Page 115 14. If no faults are encountered, this screen will appear noting the procedure has successfully completed. Press the red X button to return to the main menu. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.109 © Copyright Polaris Inc.

  • Page 116: Gearing Change Reprogramming

    6. Connect the SmartLink cable to the vehicle and PC / laptop. 10. Select the track that is installed on the snowmobile. 7. Start Digital Wrench, and select the correct vehicle. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.110 © Copyright Polaris Inc.

  • Page 117: Electronic Oil Pump Prime Procedure

    19 – 26 and the bottom sprocket teeth numbers to 36 – accumulating in the crankcase. 45. Future Digital Wrench updates will limit the teeth numbers to match the Polaris-specified acceptable sprocket combinations. The Oil Pump Prime procedure is used to purge the engine oil supply lines of air and to verify the ECU can drive the oil pump.
  • Page 118 7. Start Digital Wrench, and select the appropriate vehicle. 8. Select the Special Tools (Tool Box) menu and then Service Procedures. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.112 © Copyright Polaris Inc.

  • Page 119: Digital Wrench - Ecu Reprogramming (Reflash)

    ECU, an Authorization Key must be obtained by entering a Request Code in the box provided on the Reflash Authorization site. The Request Code is automatically • Proceed to http://polaris.diagsys.com for specific generated by Digital Wrench during the reprogramming information and FAQs on how to troubleshoot process.
  • Page 120 Place the battery on the floor next to the engine compartment. 7. Connect the SmartLink cable to the vehicle and PC / laptop. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.114 © Copyright Polaris Inc.
  • Page 121 Digital Wrench screen. Click the 14. Enter or paste the Request Code into the box. ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.115 © Copyright Polaris Inc.

  • Page 122: Digital Wrench - Vehicle Identification Information

    If using a stand-alone service battery, do not place the battery in the tunnel footwells. Place the battery on the floor next to the engine compartment. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.116 © Copyright Polaris Inc.
  • Page 123 Special Tools menu, select “Vehicle Information”. Item is the vehicle serial number. Item is the Polaris part number of the ECU and should match the number in the vehicle’s parts catalog. Item is the ECU calibration software part number. This...
  • Page 124 When the cluster is an PIDD, this is the number used when registering the cluster with Ride Command. Item is the software program version number. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.118 © Copyright Polaris Inc.

  • Page 125: Polaris Mobile Digital Wrench® (Pmdw)

    Wrench® software. complete list of compatible vehicles. You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download. MINIMUM SPECIFICATIONS FOR ANDROID DEVICES •...

  • Page 126: Drive Belt

    • Replace the drive clutch spring and retest. • Inspect the spider rollers / bushings. • Inspect / adjust belt-to-sheave clearance. • Inspect the moveable / cover bushings. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.120 © Copyright Polaris Inc.

  • Page 127: Belt Wear / Burn Diagnostics

    Check for correct clutch components or damage on the Clutch malfunction clutch. Slow, easy belt engagement - easing on the throttle Use fast, effective throttle to engage the clutch. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.121 © Copyright Polaris Inc.

  • Page 128: Shock Analysis

    (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.122 © Copyright Polaris Inc.

  • Page 129: Electrical Service Notes

    • All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.126 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) DYNAMIC TESTING for electrical testing.

  • Page 130: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate Back probing is typically not advisable on sealed adapters is required. Most terminals used on Polaris connectors, as it can easily cause damage to the wire, machines can be tested using terminal test kit PV–...

  • Page 131: Testing Continuity / Resistance

    Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.126 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.125 © Copyright Polaris Inc.

  • Page 132: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.126 © Copyright Polaris Inc.

  • Page 133: Testing For Intermittent Conditions

    Failure to do so can lead to serious injury and/or damage to the machine. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.127 © Copyright Polaris Inc.

  • Page 134: Current Draw - Key Off

    IMPORTANT Charging system damage will occur if incompatible components are installed. Always reference the Polaris TESTING VOLTAGE DROP Electronic Parts Catalog for the proper part numbers. NOTICE If you disconnect the connector at the load, and...
  • Page 135 GENERAL INFORMATION For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.129 © Copyright Polaris Inc.
  • Page 136 GENERAL INFORMATION NOTES 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 1.130 © Copyright Polaris Inc.
  • Page 137 ..................2.32 INTAKE FILTERS 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 138 .................2.63 LUBRICATE THE PIVOTS 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 139 ................2.63 STORING THE SNOWMOBILE 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 140: Maintenance

    1. Open the left compartment door panel. NOTICE The speedometer may give wrong values at the existence of electromagnetic radiation >= 10 V/m. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 141 10. Rotate the spark plug wrench clockwise until it locks into place. 5. Pull the container out of the compartment. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 142: Vehicle Break-In

    Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All Polaris oils are compatible with each other. Drive with extra caution during the break-in period.

  • Page 143: Maintenance Program

    • Verify steering fasteners / linkage / handlebars for Chassis / Suspension proper torque and operation • Verify ski fasteners for proper torque • Inspect ski skags 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 144: Pre-Season Maintenance

    Throttle Lever / Throttle Cable Fuel / Vent Hoses Oil Hoses Air Box L = Lubricate I = Inspect or Adjust R = Replace C = Clean 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 145 Cooling Fins and Shroud Handlebar Centering Hood / Seat / Chassis / Engine Compartment L = Lubricate I = Inspect or Adjust R = Replace C = Clean 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 146: Periodic Maintenance Chart

    2000 miles (3200 km) intervals. 150 MILES (240 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE...
  • Page 147 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Ignition Timing BTDC Inspect or Adjust Spark Plugs...
  • Page 148 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Inspect or Adjust Drive / Driven Clutch Condition...
  • Page 149 MAINTENANCE 2000 MILES (3200 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Clutch Alignment / Offset...
  • Page 150 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Inspect or Adjust Rear Idler Wheel Bolts...

  • Page 151: Lubricants / Service Products

    Premium All Season Grease 14 oz. Tube 2871423 — Starter Grease 2871460 Carbon Clean — 2871326 (Will sub to 2881413 when discontinued.) — 5:1 Carbon Clean 2881413 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.15 © Copyright Polaris Inc.
  • Page 152 Mud Shield Pre-Treat 2830208 Never Rust Spray — 2830209 Cleaners / Polishes All Purpose Cleaner — 2830205 XP Spray Wash — 2830202 — XP Wash 2830203 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.16 © Copyright Polaris Inc.

  • Page 153: 50/50 Extended-Life Engine Antifreeze

    MAINTENANCE 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE All liquid-cooled Polaris vehicles use 50/50 Extended Life antifreeze, which has a 5-year service life. It’s important to note that conventional, 60/40 antifreeze can be mixed with 50/50 Extended Life antifreeze. However, mixing the two will affect the service interval. To receive the full 5-year service interval benefit, the cooling system must be fully drained and replenished with the Extended Life antifreeze.

  • Page 154: Hood / Side Panel Service

    3. Open the side panel, then pull the panel outward to release the tabs at the bottom. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.18 © Copyright Polaris Inc.

  • Page 155: Hood Removal / Installation

    3. Disconnect the hood wire harness connector 4. Remove the hood assembly from the vehicle. NOTICE Store the hood in a position that will not damage the brake cooler duct. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.19 © Copyright Polaris Inc.

  • Page 156: Engine Maintenance

    Verify that engine RPM does not increase as the handlebar is turned. If engine RPM increases, the throttle lever freeplay is too tight and must be readjusted. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.20 © Copyright Polaris Inc.

  • Page 157: Spark Plug Maintenance

    22 ft-lbs (30 N·m) tip indentation. NOTICE MAG and PTO coil wires will be labeled on wiring. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.21 © Copyright Polaris Inc.

  • Page 158: Cooling System Maintenance

    60/40. Polaris recommends the use of Polaris Extended Life Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water.

  • Page 159: Cooling System Bleeding

    9. Fill the coolant bottle to the COLD FILL mark. Reinstall the bottle cap securely. 10. Open the side panels and reinstall the hood. Close the side panels. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.23 © Copyright Polaris Inc.

  • Page 160: Drive Belt / Clutch Maintenance

    7. Turn the wrench clockwise until the sheaves open far enough to remove the belt. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.24 © Copyright Polaris Inc.

  • Page 161: Drive Belt Installation - Axys

    Always clean the drive belt using a mixture of warm, soapy water. Allow to air dry. When installing the belt, verify POLARIS or the part number can be read from the outside of the snowmobile. 1. Verify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves.

  • Page 162: Belt Deflection Inspection / Adjustment

    (decrease TORQUE deflection). Deflection Screw Jam Nut: 145 in-lbs (16 Nm) 6. Rotate the belt clockwise while removing the L- wrench 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.26 © Copyright Polaris Inc.

  • Page 163: Clutch Alignment / Offset - Ps-52666

    When installed into the drive clutch and placed on top of the driven clutch, the technician can immediately determine if any adjustments are required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.27 © Copyright Polaris Inc.

  • Page 164: Clutch Alignment / Offset - Ps - 47477 Lwt Tool

    2. Remove the drive belt. Push the driven clutch inwards. The drive / driven clutch offset specification on AXYS snowmobiles is different than other Polaris snowmobile 3. Install the PS-47477 alignment tool into the drive platforms. The driven clutch is mounted closer to the clutch.

  • Page 165: Clutch Alignment / Offset - Ps - 51607

    When installed into the drive clutch and placed on top of the driven clutch, the technician can immediately determine if any adjustments are required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.29 © Copyright Polaris Inc.

  • Page 166: Axys Clutch Offset / Float Adjustment

    Driven Clutch Bolt: 18 ft-lbs (25 Nm) 5. Apply a light film of Polaris Premium grease to the jackshaft. Install the driven clutch and push it tight toward the bulkhead. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.30...

  • Page 167: Clutch Cleaning

    IMPORTANT Do not lubricate the clutch bushings or any internal clutch components. Clutch bushings are self- lubricating. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.31 © Copyright Polaris Inc.

  • Page 168: Fuel / Air Intake / Exhaust Maintenance

    FUEL / AIR INTAKE / EXHAUST MAINTENANCE AXYS FUEL SYSTEM MAINTENANCE Fuel Recommendation For peak performance, POLARIS recommends the use WARNING of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel Gasoline is highly flammable and explosive under economy will decrease.

  • Page 169: Maintenance

    IMPORTANT When re-installing the exhaust system, the EGT sensor wires must be tied back to the designated retention points or wire failure may occur. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.33 © Copyright Polaris Inc.

  • Page 170: Drive System Maintenance

    6. Tighten the jam nut to specification while holding the adjuster bolt. TORQUE Drive Chain Tensioner Jam Nut: 21 ft-lbs (28 Nm) 7. Reinstall the side panels. Release the parking brake. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.34 © Copyright Polaris Inc.

  • Page 171: Chaincase Oil Change - Pump Method

    6. Using a funnel, slowly add the recommended oil until the fluid begins to overflow. FLUID CAPACITY Maximum Fluid Capacity: 10.5 oz. (310 ml) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.35 © Copyright Polaris Inc.
  • Page 172 10. Using a funnel, slowly add the recommended oil until the fluid begins to overflow. FLUID CAPACITY Maximum Fluid Capacity: 10.5 oz. (310 ml) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.36 © Copyright Polaris Inc.

  • Page 173: Quickdrive Low Inertia System

    • Do not pry on belt to remove • Store belt in original package - do not hang • Avoid contact with solvents, oils, or chemical cleaners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.37 © Copyright Polaris Inc.

  • Page 174: Brake System Maintenance

    Brake Caliper Brake Pad injury or death. Always have the brakes serviced at the first sign of spongiest. Brake Disc 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.38 © Copyright Polaris Inc.

  • Page 175: Brake Fluid

    Inspect the reservoir to be sure it contains the correct amount of fluid. Use only Polaris DOT 4 high During the bleeding procedure, keep the brake handle as temperature brake fluid. Change fluid every 2 years or level as possible.

  • Page 176: Steering / Suspension Maintenance

    6 in-lbs (0.7 Nm) Handlebar Clamp Screws / Bolts 7 ft-lbs (9.5 Nm) PERC Button Screw 35 in-lbs (4 Nm) Hand-Tight – Hand Guard Mounts (if applicable) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.40 © Copyright Polaris Inc.

  • Page 177: Handlebar Angle Adjustment

    Do not stretch wires while adjusting the controls. Stretching the wires could damage the hand warmers. 3. Tighten the bolts to specification. TORQUE Handlebar Mount Bolts: 7 ft-lbs (9.5 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.41 © Copyright Polaris Inc.

  • Page 178: Front Suspension Inspection

    • Skis, ski loops, ski stops, skags/carbides • Tie rods, rod ends, tie rod boots • Sway bar / sway bar linkage • Fasteners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.42 © Copyright Polaris Inc.
  • Page 179 40 ft-lbs (54 Nm) Ski Loop Rear Fasteners 6 ft-lbs (8 Nm) Ski Loop Front Fasteners 9 ft-lbs (12 Nm) Ski Skag Fasteners 7 ft-lbs (10 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.43 © Copyright Polaris Inc.

  • Page 180: Control Arm Pivot Adjustment

    3. While holding the pivot(s) in place, tighten the lock nuts. TORQUE Lower Control Arm Front Pivot Bolt / Nut: 40 ft-lbs (54 Nm) Control Arm Pivot Lock Nuts: 40 ft-lbs (54 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.44 © Copyright Polaris Inc.
  • Page 181 7. Steps 2 to 6 will align the skis with the track. At this point, verify the handlebar is centered with the skis. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.45 © Copyright Polaris Inc.

  • Page 182: Skag Replacement

    1. Raise and support the front of the snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag downward. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.46 © Copyright Polaris Inc.

  • Page 183: Rear Suspension Inspection

    • Rear idler wheels / shafts • Bogie / carrier wheels / shafts / fasteners • Front Torque Arm / Limiter Straps • Shocks • Rail Sliders • Track 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.47 © Copyright Polaris Inc.
  • Page 184 Rear Idler 55 ft-lbs (75 Nm) +/- 10% Upper Carrier Fasteners 46 ft-lbs (63 Nm) Rear Crank to Rear Pivot Fasteners 17 ft-lbs (23 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.48 © Copyright Polaris Inc.

  • Page 185: Rail Slider Inspection

    Apply spray lubricant to the rail beam. Use a small pry bar to drive the slider rearward until removed. NOTICE Replace rail sliders in pairs. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.49 © Copyright Polaris Inc.

  • Page 186: Track Alignment

    5. Tighten the locknuts. 6. Tighten the idler shaft bolts to specification. TORQUE Rear Idler Fastener Torque: 55 ft-lbs (75 Nm) +/- 10% 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.50 © Copyright Polaris Inc.

  • Page 187: Track Tension Adjustment

    6. Check track alignment and adjust as necessary. 7. Tighten the locknuts. 8. Tighten idler shaft fasteners to specification. TORQUE Rear Idler Fastener: 55 ft-lbs (75 Nm) +/- 10% 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.51 © Copyright Polaris Inc.

  • Page 188: Track Tension Specifications

    Series 7 (3 in) +/- 10% 1/2 - 5/8 in Series 8 (2.75 in) (1.3 - 1.6 cm) NOTICE Image for reference only. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.52 © Copyright Polaris Inc.

  • Page 189: Electrical System Maintenance

    / dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP charger and inspect the battery every 60 days. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.53 © Copyright Polaris Inc.

  • Page 190: Battery Removal

    3. Remove the plastic rivet securing the fender to the chassis. 8. Remove the battery shield 9. Remove the battery from the battery bracket. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.54 © Copyright Polaris Inc.

  • Page 191: Battery Installation

    5. Connect and tighten the RED (positive) cable first. 9. Reinstall the console using the two plastic rivets. 10. Reinstall the side panel. TORQUE Battery Cable Connector: 36 in-lbs (4 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.55 © Copyright Polaris Inc.

  • Page 192: Battery Activation (Electric Start Models Only)

    4. Press down evenly to break the foil seals and allow electrolyte to flow into the battery. NOTICE Air bubbles will begin to rise, indicating the flow of electrolytes. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.56 © Copyright Polaris Inc.
  • Page 193 7. Allow battery to stand for 1-2 hours. This allows the electrolyte to permeate the plates for optimal performance. 8. Charge the battery for 1 hour using a Polaris recommended charger. Polaris recommends using battery charger (PN 2830438), Battery MINDer 2012.

  • Page 194: Battery Tender Port

    NOTICE Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal discharge. Battery tenders can be...

  • Page 195: Axys Led Lights

    Turn the adjuster knob clockwise to lower the beam. Turn the adjuster counterclockwise to raise the beam. NOTICE Image for reference only. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.59 © Copyright Polaris Inc.

  • Page 196: Auxiliary Engine Stop Switch

    Do not start the engine again until the malfunction has been corrected. CAUTION Perform procedure in well-ventilated area. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.60 © Copyright Polaris Inc.

  • Page 197: Off Season Storage

    OFF SEASON STORAGE TREATING THE FUEL SYSTEM FOGGING THE ENGINE As the riding season draws to a close, Polaris Fogging the engine with Polaris fogging oil or similar recommends riders begin treating their snowmobile’s fuel commercial alternative is probably the most important...

  • Page 198: Battery/Electrical System Storage

    In addition, removing the battery allows access to other maintenance items, such as the chaincase chain tensioner bolt. 2. Connect a Polaris battery tender or equivalent commercially available tender to the battery. 3. Inspect the electrical connections and wire harnesses throughout the snowmobile.

  • Page 199: Cleaning The Snowmobile

    1. Wash the snowmobile with a garden hose and a 1. Use a grease gun and Polaris Premium All Season solution of soapy water. Note that if a pressure Grease. Reference the appropriate Owner’s Manual...
  • Page 200 MAINTENANCE NOTES 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 2.64 © Copyright Polaris Inc.
  • Page 201 .............3.59 ENGINE MOUNT ASSEMBLY VIEW 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 202 ................3.112 E-VES-II REMOVAL 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 203 ................3.154 EXHAUST INSTALLATION 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 204: General Information

    18 ft-lbs (24 N·m) Hold mount in place when (M8 x 1.25) torquing Water Pump Cover Fasteners 9 ft-lbs (12 N·m) (M6 x 1.0 x 20) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 205: Service Specifications

    (M7 x 1.0 x 63) lbs (20 N·m) Always discard fasteners and replace with new. Reed / Throttle Body 12 ft-lbs (16 N·m) Adapter Fasteners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 206: Important Engine Service Notes

    To perform the Electronic Oil Pump Prime procedure, see Electronic Oil Pump Prime Procedure page 1.111. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 207: Special Tools

    Heavy Duty Flywheel Puller E-VES Guillotine Alignment Tool PU-52602 PS-52573 Flywheel Holding Tool Next-Gen Service Power Harness PU-52497 2870390 33mm Drive Clutch Taper Reamer Piston Support Block 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 208 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 209: Electronic Oil Pump

    The part number label on the oil pump housing will have the three digit offset number printed on it. The seven digit number preceding the (-) is the Polaris part number and subject to change. NOTICE Image for reference only. Item is the manufacturing serial number and not used.
  • Page 210 In the image, there is one pin stamp in location . The flow code would be 001. OIL PUMP FLOW OFFSET CODE PIN STAMPS Offset Code 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.10 © Copyright Polaris Inc.

  • Page 211: Oil Pump Line Connections

    ENGINE / COOLING / EXHAUST OIL PUMP LINE CONNECTIONS Match the oil line and fittings as shown when installing the oil pump. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.11 © Copyright Polaris Inc.
  • Page 212 Perform Oil Pump Prime procedure in Digital Wrench if engine oil supply lines have air bubbles larger than 1 in (2.54 cm) or the lines are removed / replaced. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.12 © Copyright Polaris Inc.

  • Page 213: Oil Check Valve Fitting Hose Clamp Position

    9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.13 © Copyright Polaris Inc.

  • Page 214: Oil Supply Hose Routing

    1. From the electronic oil pump, route the oil supply hose up to the oil hose support and secure with a panduit strap 2. Continue routing the oil supply hose up to the oil tank fitting and secure with clamp 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.14 © Copyright Polaris Inc.

  • Page 215: Oil Injector Check Valves

    6 psi (41.4 kPa) or 17 psi (117.2 kPa) for the external center gallery check valve to open. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.15 © Copyright Polaris Inc.

  • Page 216: Cross Shaft Oil Gallery Outlet Check Valve

    PTO Oil Check Valve Ratchet Extension Fitting Check Valve Fitting Press Tool 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.16 © Copyright Polaris Inc.

  • Page 217: Cross Shaft Oil Gallery Outlet Check Valve Testing

    NOTICE The inner crankcase fasteners are longer than the outer crankcase fasteners. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.17 © Copyright Polaris Inc.
  • Page 218 Crankcase ring land damage in the area shown is caused by improper crankcase separation. 8. Finish removing the outer crankcase fasteners. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.18 © Copyright Polaris Inc.
  • Page 219 11. Discard the PTO and MAG crankshaft seals. IMPORTANT Be careful not to drip any Loctite on the inlet ports or outlet of the check valve fitting. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.19 © Copyright Polaris Inc.
  • Page 220 NOTICE Do not over-apply Loctite in oil injector area. Doing so may block the oil passage. Keep Loctite out of the snap ring groove. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.20 © Copyright Polaris Inc.
  • Page 221 Do not over-apply Loctite and keep Loctite off snap to installation. ring. NOTICE The inner crankcase fasteners are longer than the outer crankcase fasteners. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.21 © Copyright Polaris Inc.
  • Page 222 • Install the pistons. See Piston Installation page 3.97. • Install the cylinder. See Cylinder Installation page 3.98. • Install the cylinder head. See Cylinder Head Installation page 3.99. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.22 © Copyright Polaris Inc.

  • Page 223: Electronic Oil Pump - Resistance Check

    Verify the battery provides a minimum of 12.5 volts before attempting procedure. After performing this procedure 4–5 times, start the engine to prevent surplus oil from accumulating in the crankcase. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.23 © Copyright Polaris Inc.
  • Page 224 6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.24 © Copyright Polaris Inc.

  • Page 225: Electronic Oil Pump Manual Prime Procedure

    9. While pressing and holding the PERC button, press on the throttle lever inward enough to depress the throttle release switch. Hold for at least 15 seconds. Chassis Power Up Harness: PS-47296–B 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.25 © Copyright Polaris Inc.

  • Page 226: Digital Wrench - Electronic Oil Pump Flow Offset

    Digital Wrench. The seven digit connectors. If using a stand-alone service battery, do number preceding the (-) is the Polaris part number and not place the battery in the tunnel footwells. Place the subject to change.
  • Page 227 10 and 11. 14. Write the offset value on the ECU label for future reference. 11. On the following screen, select “Oil Pump Replacement”. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.27 © Copyright Polaris Inc.

  • Page 228: Electronic Oil Pump - Trouble Codes / Protection Mode

    This indicates the cross shaft oil seal was improperly installed or the water pump cross shaft oil gallery outlet valve is plugged and requires replacement. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.28 © Copyright Polaris Inc.

  • Page 229: Oil Tank

    OIL TANK OIL TANK ASSEMBLY VIEW Oil Cap Oil Level Switch Oil Tank Washer Oil Tank Mounting Fastener Fitting 7 ft-lbs (9 Nm) Flanged Grommet 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.29 © Copyright Polaris Inc.

  • Page 230: Oil Tank Removal

    4. Slide the oil tank forward and tilt it on its side to gain access to the oil line fitting 5. Slide the springband clamp down the oil line. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.30 © Copyright Polaris Inc.

  • Page 231: Oil Tank Installation

    6. Verify the oil tank has the specified amount of fluid. 3. Slide the oil tank rearward into the footrest slot. 7. Install the hood and side panels. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.31 © Copyright Polaris Inc.

  • Page 232: Engine Service

    6. Remove the recoil handle. 7. Remove the oil level sender connector NOTICE Place a rag under the fitting to catch any spilled oil. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.32 © Copyright Polaris Inc.
  • Page 233 20. Carefully remove the intake plenum. 14. Remove the push rivets retaining the intake tube to the intake plenum. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.33 © Copyright Polaris Inc.
  • Page 234 28. Remove the fasteners securing the PBR and remove the PBR. 24. Clean the area around the spark plugs to prepare for removal. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.34 © Copyright Polaris Inc.
  • Page 235 Turn the handlebar to the right. NOTICE If removal is difficult and additional space is needed, remove the ignition coils from the air box assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.35 © Copyright Polaris Inc.
  • Page 236 NOTICE Do not remove the cable ties securing the support to the coolant hose. NOTICE Remove any cable ties but note locations for installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.36 © Copyright Polaris Inc.
  • Page 237 See Starter Motor / Flex Drive Service page 10.91. 42. If cooling system was not previously drained, place a drain pan under the engine. 43. Remove the coolant bottle cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.37 © Copyright Polaris Inc.
  • Page 238 Pull the engine up and back slightly and remove it on the PTO side of the chassis. NOTICE Have an assistant help lift the engine. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.38 © Copyright Polaris Inc.

  • Page 239: Engine Installation

    8. If the throttle body was removed, see Throttle Body Installation page 5.11. NOTICE Ensure the clamps are properly oriented. See Component Orientation Views page 3.52. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.39 © Copyright Polaris Inc.
  • Page 240 15. If the vehicle is equipped with Electric start install the starter motor, pinion / pinion bracket assembly, and flex drive. See Starter Motor / Flex Drive Service page 10.91. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.40 © Copyright Polaris Inc.
  • Page 241 18. Route the fuel injector harness, oil pump jumper harness, and TPS harness into and along the side of the wire support securing the harness with new cable ties 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.41 © Copyright Polaris Inc.
  • Page 242 9 ft-lbs (12 N·m) Torque in sequence page 3.48 d. Verify the actuator cable is still installed on the actuator pin and properly retained in actuator bracket. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.42 © Copyright Polaris Inc.
  • Page 243 If the ignition coils were removed, reinstall the ignition coils and torque fasteners to specification. TORQUE Air Box Coil Fasteners: TORQUE 36 in-lbs (4 Nm) PBR Fasteners: 6 ft-lbs (8 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.43 © Copyright Polaris Inc.
  • Page 244 TORQUE Spark Plug: 22 ft-lbs (30 N·m) TORQUE Clutch Cover Nuts: 7 ft-lbs (10 Nm) 33. Carefully install the intake plenum into place. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.44 © Copyright Polaris Inc.
  • Page 245 43. Slide the rear of the oil tank into the profile at the rear of the clutch cover. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.45 © Copyright Polaris Inc.
  • Page 246 Installation page 3.154. NOTICE The strain relief retaining the wiring harness to the intake plenum will be installed with a new one during resonator installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.46 © Copyright Polaris Inc.

  • Page 247: 850 Engine

    MM (INCHES) 1.290 (0.051”) 0.145 (0.0057”) 0.40 (0.016”) 0.36 (0.014”) MINIMUM 0.9 (0.035”) ALL ENGINES NOMINAL 1.630 (0.064”) 0.155 (0.0061”) 0.50 (0.020”) 1.34 (0.052”) MAXIMUM 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.47 © Copyright Polaris Inc.

  • Page 248: Component Torque Sequences

    Certain engine components must be torqued in sequence. Refer to this section for fastener torque sequences while servicing the engine. CYLINDER HEAD MONOBLOCK CYLINDERS 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.48 © Copyright Polaris Inc.
  • Page 249 ENGINE / COOLING / EXHAUST ELECTRONIC VARIABLE EXHAUST VALVE COVER EXHAUST MANIFOLD 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.49 © Copyright Polaris Inc.
  • Page 250 ENGINE / COOLING / EXHAUST INTAKE CRANKCASE 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.50 © Copyright Polaris Inc.
  • Page 251 ENGINE / COOLING / EXHAUST RECOIL HOUSING WATERPUMP COVER 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.51 © Copyright Polaris Inc.

  • Page 252: Component Orientation Views

    ENGINE / COOLING / EXHAUST COMPONENT ORIENTATION VIEWS DET Sensor 60° ± 10° toward PTO Side Orient Throttle Body Clamps at 6 O’Clock ± 10° 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.52 © Copyright Polaris Inc.

  • Page 253: Crankcase Sealant Path

    . Doing so may block oil passages. Do not fill the MAG side Oil Gallery with case sealant. MEASUREMENT Maximum Sealant Bead Width .050 - .060 in (1.27 - 1.52 mm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.53 © Copyright Polaris Inc.
  • Page 254 The desired sealant coverage is when a very thin layer of sealant is covering the entire mating surface with ZERO sealant near the inner edges of the water pump cross shaft gallery (between the two seal grooves) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.54 © Copyright Polaris Inc.

  • Page 255: Cylinder Assembly View

    40 ft-lbs (54 N·m) Cylinder Head Apply VES oil under fastener head and to threads prior to installation. O-Ring Throttle Body Coolant Hose O-Ring Springband Clamp Cylinder 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.55 © Copyright Polaris Inc.

  • Page 256: Crankcase Assembly View

    Hollow Dowel Crankcase Fasteners (M8 x 1.25 x 50) 24 ft-lbs (32 N·m) Apply VES oil under fastener head and to threads prior to installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.56 © Copyright Polaris Inc.

  • Page 257: Piston & Crankshaft Assembly View

    Piston Ring Crankshaft Assembly Bearing (PTO) Snap Ring Piston Bearing (PTO) Piston Pin Bearing is slip fit Piston Circlip Bearing Bearing (MAG) Woodruff Key 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.57 © Copyright Polaris Inc.

  • Page 258: Stator / Flywheel Assembly View

    90 ft-lbs (122 N·m) Flywheel Stator Wire Retainer Recoil Starter Pulley Fasteners CPS Fasteners (M5 x 0.8 x 10) 10 ft-lbs (13 N·m) 53 in-lbs (6 N·m) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.58 © Copyright Polaris Inc.

  • Page 259: Engine Mount Assembly View

    Front MAG Engine Mount Bracket Mount Bracket to be retained while mount nut is torqued Mount Bracket to be retained while mount nut is torqued 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.59 © Copyright Polaris Inc.

  • Page 260: Water Pump Assembly View

    9 ft-lbs (12 N·m) Water Pump Driven Shaft Water Pump Impeller Ensure cross shaft turns and indexes with crankshaft during assembly Ball Bearing D-Washer 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.60 © Copyright Polaris Inc.
  • Page 261 ENGINE / COOLING / EXHAUST 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.61 © Copyright Polaris Inc.

  • Page 262: Reed Valve Assembly View

    ENGINE / COOLING / EXHAUST REED VALVE ASSEMBLY VIEW Reed / Throttle Body Adapter Fasteners Throttle Body Adapter 12 ft-lbs (16 N·m) Gear Clamps Reed Assemblies 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.62 © Copyright Polaris Inc.

  • Page 263: Flywheel Removal / Inspection

    The recoil fan is balanced and can only be installed on the flywheel one way because of an asymmetrical hole pattern. 7. Remove the Flywheel Holding tool. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.63 © Copyright Polaris Inc.

  • Page 264: Stator Removal / Inspection

    9. Turn the puller center bolt in until the flywheel “pops” off of the crankshaft. 4. Remove the three fasteners securing the stator. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.64 © Copyright Polaris Inc.

  • Page 265: Stator Installation

    4. Install the stator wire retainer STATOR INSTALLATION 1. Carefully install the magneto/stator into the crankcase. NOTICE The stator wires will be pulled through the cutout in the crankcase. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.65 © Copyright Polaris Inc.

  • Page 266: Flywheel Installation

    Do not use an impact wrench to install the flywheel nut. NOTICE Ensure the key aligns with the notch in the flywheel during installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.66 © Copyright Polaris Inc.
  • Page 267 TORQUE Recoil Housing Fasteners: 9 ft-lbs (12 N·m) Torque in sequence page 3.48 6. Reinstall the exhaust silencer and pipe. See Exhaust Installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.67 © Copyright Polaris Inc.

  • Page 268: Reed Valve Inspection

    4. Measure the air gap between the fiber reed and the reed block. The air gap should not exceed specification. VForce3 Reeds: MEASUREMENT Reed Valve Air Gap Limit: 0.015 in (.381 mm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.68 © Copyright Polaris Inc.

  • Page 269: Reed Petal Replacement Inspection

    Inspect each reed petal. There should be no cracks or chipping on any of the petals. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.69 © Copyright Polaris Inc.

  • Page 270: Reed Petal Removal

    5. Remove and discard the two inner reed petals 6. Thoroughly clean the inner and outer cages. Do not reuse if damage is found. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.70 © Copyright Polaris Inc.

  • Page 271: Reed Petal Installation

    8. Install the two outer reed petals onto the cage making sure the slots engage the cage tabs. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.71 © Copyright Polaris Inc.
  • Page 272 10. When installing each reed assembly back into the engine, verify the model number is at the bottom and “MOTOTASSINARI” is at the top. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.72 © Copyright Polaris Inc.

  • Page 273: General Information - Top End

    Clean the fastener threads to remove any thread are serviced / replaced. locking residue. CAUTION Always allow the engine to cool before servicing the vehicle. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.73 © Copyright Polaris Inc.

  • Page 274: Cylinder Head Inspection

    Replace cylinder head if warping exceeds specification. 6. Inspect the cylinder head / combustion domes for any damage. Measure cylinder head flatness. Replace cylinder head if required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.74 © Copyright Polaris Inc.

  • Page 275: Cylinder Removal

    6. Inspect the cylinder walls. Nicasil cylinders can only be lightly honed. Damage that cannot be removed with a light hone requires cylinder replacement or rechroming. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.75 © Copyright Polaris Inc.

  • Page 276: Cylinder Inspection

    Taper = Top Y - Bottom Y and Top X - Bottom X MEASUREMENT MEASUREMENT Taper Limit: Out-of-Round Limit: 0.002 in (0.051 mm) 0.002 in (0.051 mm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.76 © Copyright Polaris Inc.

  • Page 277: Cylinder Honing

    Rinse thoroughly, dry with studs. compressed air, and oil the bore immediately with 3. Place hone in cylinder and tighten stone adjusting Polaris Premium 2 Cycle Lubricant. knob until stone contacts the cylinder walls (DO NOT OVERTIGHTEN). NOTICE 4.

  • Page 278: Piston Removal

    IMPORTANT Do not apply heat to the piston ring. The ring may lose radial tension. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.78 © Copyright Polaris Inc.

  • Page 279: Piston Markings

    0.98 in (25 mm) from the bottom of the piston skirt Subtract this measurement from the minimum cylinder measurement (90° to the pin). If clearance exceeds the service limit piston/cylinder overhaul may be required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.79 © Copyright Polaris Inc.

  • Page 280: Piston Ring Markings

    1. Position the ring 0.79 in (20 mm) from the top of the cylinder using the piston to push it squarely into place. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.80 © Copyright Polaris Inc.

  • Page 281: Piston Needle Bearing

    8. Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement. If play or roughness is evident with a new pin and bearing, replace the connecting rod. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.81 © Copyright Polaris Inc.

  • Page 282: General Information - Bottom End

    1. Remove the ten inner crankcase fasteners from the locations indicated below. NOTICE The inner crankcase fasteners are longer than the outer crankcase fasteners. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.82 © Copyright Polaris Inc.

  • Page 283: Crankshaft Removal

    6. Thoroughly clean the two crankcase mating surfaces with acetone. Flush out the crankcase galleries after the crankshaft and water pump shaft have been removed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.83 © Copyright Polaris Inc.

  • Page 284: Lower Crankcase Cross Shaft Gallery Inspection

    VES oil, drain, and set aside. NOTICE This bearing is not pressed on the crankshaft and is designed to easily be removed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.84 © Copyright Polaris Inc.

  • Page 285: Lower Connecting Rod Bearing Inspection

    LOWER CONNECTING ROD BEARING MAIN BEARING INSPECTION INSPECTION Clean the crankshaft, oil main, and connecting rod bearings thoroughly with Polaris engine oil. Carefully Measure the side clearance for the big end of the check each main bearing on the crankshaft.

  • Page 286: Pto Bearing Inspection

    3. Inspect the snap ring for damage. If slip fit bearing passes inspection, clean cured green Loctite 603 from outer race using acetone 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.86 © Copyright Polaris Inc.

  • Page 287: Crankshaft Truing

    High at point If point measures high, squeeze the crankshaft as shown. High at point If point measures high, spread the crankshaft as shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.87 © Copyright Polaris Inc.

  • Page 288: Crankshaft Runout Inspection

    ENGINE / COOLING / EXHAUST CRANKSHAFT RUNOUT INSPECTION CRANKSHAFT INDEX Polaris crankshafts are pressed together. The connecting The Crankshaft must be true for optimal performance rod journal center lines are indexed 180° apart from each and engine longevity. Use the procedure bellow to other.

  • Page 289: Water Pump Removal

    3. Discard the water pump cover seal Water Pump Seal Remover: PS-52664 NOTICE The seal remover body halves have a large end and a tapered end. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.89 © Copyright Polaris Inc.
  • Page 290 Carefully disassemble any remaining pieces of the mechanical seal until just the mechanical seal body is remaining. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.90 © Copyright Polaris Inc.
  • Page 291 Do not pry on the water pump mating surface or bore as crankcase damage may occur. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.91 © Copyright Polaris Inc.

  • Page 292: Water Pump Installation

    Apply water to cross-shaft prior to seal assembly at seal / shaft interface. IMPORTANT Use care during installation to prevent damaging the water pump bore. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.92 © Copyright Polaris Inc.
  • Page 293 7. Install new water pump seal on water pump cover. NOTICE Ensure the seal tab aligns with the notch in the water pump cover. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.93 © Copyright Polaris Inc.

  • Page 294: Crankshaft Installation

    NOTICE Do not over-apply Loctite in oil injector area. Doing so may block the oil passage. Keep Loctite out of the snap ring groove. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.94 © Copyright Polaris Inc.
  • Page 295 VES / VES Extreme oil. ring. 4. Apply VES / VES Extreme oil into the two connecting rod bearings 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.95 © Copyright Polaris Inc.

  • Page 296: Crankcase Assembly

    During installation, make sure the outer race of the PTO gallery high-flow check valves. bearing is against the standoff feature of the seal. Do NOT allow the bearing to slide against the crankshaft. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.96 © Copyright Polaris Inc.

  • Page 297: Piston Installation

    3. Install the piston pin into piston. 4. Install the piston circlips in the correct orientation. 5. Install the cylinder. See Cylinder Installation page 3.98. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.97 © Copyright Polaris Inc.

  • Page 298: Cylinder Installation

    2. Prior to installation of cylinder, liberally coat the inside TORQUE of each cylinder and the outside of each piston with Cylinder Fasteners: Polaris two-stroke engine oil. 40 ft-lbs (54 N·m) 3. Carefully install the cylinder . Squeeze the piston Torque in sequence page 3.48...

  • Page 299: Cylinder Head Installation

    Apply lube as required to retain o-rings during cylinder head and slide the springband clamp up to secure head installation. the coolant hose. 2. Install the cylinder head 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.99 © Copyright Polaris Inc.

  • Page 300: Recoil Assembly View

    Slide Plate Recoil Ratchet Recoil Spring Friction Plate Recoil Reel Washer Recoil Friction Plate Fastener Recoil Return Spring 15 ft-lbs (20 N·m) Recoil Washer 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.100 © Copyright Polaris Inc.

  • Page 301: Recoil Housing Removal

    If the recoil assembly is severely damaged, consider replacing the complete recoil housing assembly as a service part. The new service part assembly is completely assembled with the rope. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.101 © Copyright Polaris Inc.

  • Page 302: Recoil Housing Assembly

    The outer spring loop fits on the pin in the housing. NOTICE Note the orientation of these components during removal. 2. Lubricate the center shaft and spring with Polaris 7. Remove the recoil spacer , recoil washer , and Premium grease.
  • Page 303 12. Verify the recoil friction spring tang fits in the notch on the ratchet. 13. Install the friction plate 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.103 © Copyright Polaris Inc.

  • Page 304: Recoil Housing Installation

    The coolant hose support is secured by one of the recoil housing fasteners. TORQUE Recoil Housing Fasteners: 9 ft-lbs (12 N·m) Torque in sequence page 3.48 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.104 © Copyright Polaris Inc.

  • Page 305: E-Ves-Ii Overview

    NOTICE protrudes into the exhaust ports and when the lower valves engage the upper valves. Polaris recommends using Polaris VES or VES Extreme Synthetic Two-Stroke engine oil. The E-VES system operates in three stages: Never mix different brands of engine oil.
  • Page 306 Exhaust valve stage positions given at approximate engine RPMs. Actual E-VES position is determined by current engine RPM, throttle position, barometric pressure, and diagnostic conditions. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.106 © Copyright Polaris Inc.

  • Page 307: E-Ves-Ii Assembly View

    Exhaust Valve Base Fasteners (M6 x 1.0 x 50) Lower Exhaust Valve Guillotine 9 ft-lbs (12 N·m) Exhaust Valve Base Fasteners (M6 x 1.0 x 30) 9 ft-lbs (12 N·m) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.107 © Copyright Polaris Inc.

  • Page 308: E-Ves-Ii Operation Notes

    • The exhaust valve base shaft bushings are not serviceable. • The exhaust valve base seals must be inspected when the assembly is removed from the engine and replaced if damaged or worn. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.108 © Copyright Polaris Inc.
  • Page 309 E-VES learn procedure. Performing the Push / Pull Cable Travel Test can be done to ensure the E- VES system is functioning as designed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.109 © Copyright Polaris Inc.
  • Page 310 The two photos are of a guillotine assembly removed from an engine with over 5,000 miles (8,046 KM) on it. The engine oil used during break-in and subsequent driving was VES oil. Top View: 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.110 © Copyright Polaris Inc.
  • Page 311 IMPORTANT Never use harsh abrasives, wire brushes, or files to clean any type of Polaris exhaust valve. Doing so may scratch the valve surfaces and create friction between the components. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.111...

  • Page 312: E-Ves-Ii Removal

    ECU. seals . If no damage is present reuse the seals. 1. Remove the four exhaust valve base fasteners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.112 © Copyright Polaris Inc.

  • Page 313: E-Ves-Ii Inspection

    E-VES-II DISASSEMBLY 1. Remove the E-VES assembly from the cylinder. See E-VES-II Removal page 2. Remove the exhaust valve tiebar fasteners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.113 © Copyright Polaris Inc.

  • Page 314: E-Ves-Ii Assembly

    3. Torque the exhaust valve tie bar fasteners to specification. TORQUE Exhaust Valve Tiebar Fasteners: 14 ft-lbs (19 N·m) 4. Remove E-VES Guillotine Alignment Tool. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.114 © Copyright Polaris Inc.

  • Page 315: E-Ves-Ii Installation

    3. Install the four exhaust valve base fasteners cover screws to hand tightness. NOTICE The shorter exhaust valve base fasteners should be positioned in the outer mounting holes. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.115 © Copyright Polaris Inc.

  • Page 316: E-Ves Diagnostic Trouble Codes (Dtcs)

    Out of • Verify smooth valve operation by operating the Range cable by hand through its full travel (Mid) • Relearn EV If no problem 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.116 © Copyright Polaris Inc.
  • Page 317 • Actuator power (Red/Black) removed P1408 Abnormal • Command wire (Dark Blue/White) short to Rate of +12V Change • Command wire (Dark Blue/White) short to 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.117 © Copyright Polaris Inc.
  • Page 318 Actuator Fails to Learn This can be caused by a Actuator P1318 faulty Exhaust Valve Actuator, Broken Cable or Feedback Broken Exhaust Valve Assembly Calibration Fault 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.118 © Copyright Polaris Inc.

  • Page 319: Electronic Exhaust System (E-Ves-Ii) - Cable Travel Test

    5. Hold the actuator cable as shown. NOTICE The mid port position can be felt when the bottom blades make contact with the upper blades. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.119 © Copyright Polaris Inc.
  • Page 320 12. Install cable staked nut into bracket. Verify the staked nut hex is seated in bracket 13. Install nut and torque to specification. TORQUE E-VES Actuator Cable Jam Nut: 13 ft-lbs (18 N·m) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.120 © Copyright Polaris Inc.

  • Page 321: E-Ves-Ii - Using Digital Wrench Data Display

    ECU to the EV actuator to command the valve position. NOTICE Create a custom data list display to show the E-VES data items. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.121 © Copyright Polaris Inc.

  • Page 322: Ev Actuator Learn Procedure

    Place the battery on the floor next to the engine compartment. 6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.122 © Copyright Polaris Inc.
  • Page 323 The actuator will also be heard moving back and forth as the ECU sets the travel limits. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.123 © Copyright Polaris Inc.
  • Page 324 Typically, the fault will be caused by a partially- charged battery or loose wire connector as noted by this error screen. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.124 © Copyright Polaris Inc.

  • Page 325: Ev Actuator Mounting

    Install the jam nuts into the actuator cable bracket Torque to specification. TORQUE E-VES Actuator Cable Jam Nut: 13 ft-lbs (18 N·m) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.125 © Copyright Polaris Inc.

  • Page 326: Ev Actuator Wire Harness Connector

    E-VES system or if the EV Learn Procedure fails due to insufficient battery voltage and the battery is suppling at least 12.5 volts. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.126 © Copyright Polaris Inc.

  • Page 327: Cooling System

    Mounted on recoil housing Mounted to upper crankcase half Hose Clamp Hose, Bottle / Tunnel 5 ft-lbs 7 Nm Hose / Electrical Wires Support 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.127 © Copyright Polaris Inc.

  • Page 328: Cooling System Assembly (Sks)

    Mounted on recoil housing Hose Support Hose, Bottle / Tunnel Mounted to upper crankcase half Hose Clamp Hose / Electrical Wires Support 5 ft-lbs 7 Nm 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.128 © Copyright Polaris Inc.

  • Page 329: Coolant Bottle Assembly View

    Coolant Bottle Vent Line Plastic Push Rivet Coolant Bottle Bracket Connector Placement Bracket Edge Clip Rivet Coolant Bottle Bracket Fasteners 7 ft-lbs (9 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.129 © Copyright Polaris Inc.

  • Page 330: Cooling Hose - Hot Side Routing / Retention

    COOLING HOSE - HOT SIDE ROUTING / RETENTION Cooling hose is secured in 2 locations as shown Cooling hose is secured in 2 locations as shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.130 © Copyright Polaris Inc.
  • Page 331 / throttle Orientation of panduit strap on the stator wire cable support should be pointing toward downward. support should be pointing toward upside. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.131 © Copyright Polaris Inc.

  • Page 332: Cooling Hose - Cold Side Routing / Retention (Pro-Rmk)

    Cooling hoses are secured in 4 locations with springband clamps as shown. Cooling hoses are secured in 2 locations with springband clamps and 1 location with a panduit strap as shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.132 © Copyright Polaris Inc.
  • Page 333 1 location with a hose clamp as shown. COOLING HOSE - COLD SIDE ROUTING / RETENTION CONTINUED Cooling hose is secured in 3 locations as shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.133 © Copyright Polaris Inc.

  • Page 334: Cooling Hose - Cold Side Routing / Retention (Sks)

    COOLING HOSE - COLD SIDE ROUTING / RETENTION (SKS) Cooling hoses are secured in 4 locations as shown Cooling hoses are secured in 3 locations as shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.134 © Copyright Polaris Inc.
  • Page 335 COOLING HOSE - COLD SIDE ROUTING / RETENTION CONTINUED Cooling hoses are secured in 2 locations as shown Cooling hose is secured in 2 locations as shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.135 © Copyright Polaris Inc.
  • Page 336 ENGINE / COOLING / EXHAUST COOLING HOSE - COLD SIDE ROUTING / RETENTION CONTINUED Cooling hose is secured in 3 locations as shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.136 © Copyright Polaris Inc.

  • Page 337: Coolant Bottle / Thermostat Removal

    8. Remove the two plastic rivets connector placement bracket. 5. Remove the brake caliper mounting fasteners move the brake caliper to the side. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.137 © Copyright Polaris Inc.

  • Page 338: Coolant Bottle / Thermostat Installation

    2. Connect all the cooling hoses and slide the springband clamps down to secure the coolant hoses. TORQUE Coolant Bottle Bracket Fasteners: 7 ft-lbs (9 Nm) 5. Install the fuel tank. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.138 © Copyright Polaris Inc.
  • Page 339 8. Fill coolant bottle with coolant and follow coolant bleeding procedure. 9. Install the resonator. See Exhaust Installation page 3.154. 10. Install hood and side panels. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.139 © Copyright Polaris Inc.

  • Page 340: Coolant Bottle Overflow Line Routing

    ENGINE / COOLING / EXHAUST COOLANT BOTTLE OVERFLOW LINE ROUTING NOTICE Image for reference only. 1. Secure the coolant overflow line routing in the locations shown below. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.140 © Copyright Polaris Inc.

  • Page 341: Thermostat Location

    Replace the thermostat if it tests outside of specification. NOTICE If thermostat replacement is required, the coolant bottle must be replaced. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.141 © Copyright Polaris Inc.

  • Page 342: Air Intake

    Lower Plenum Fasteners Air Box 3 ft-lbs (4 Nm) 1/4 Turn Clip Lower Intake Foam Plenum Support Bracket Seal Foam Narrow Band Clamp Rivet 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.142 © Copyright Polaris Inc.

  • Page 343: Air Intake Plenum Removal

    Image for reference only. Console configuration may vary slightly based on model. 3. Remove the push rivets retaining the intake tube to the intake plenum. 6. Remove the intake plenum 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.143 © Copyright Polaris Inc.

  • Page 344: Air Intake Plenum Installation

    Image for reference only. Console configuration may vary slightly based on model. TORQUE Upper Plenum Fasteners: 7 ft-lbs (10 Nm) 6. Install the side panels and hood. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.144 © Copyright Polaris Inc.

  • Page 345: Air Intake Tube Removal

    4. Remove the fastener retaining the lower intake tube. 5. Remove the push rivets retaining the intake tube to the intake plenum. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.145 © Copyright Polaris Inc.

  • Page 346: Air Intake Tube Installation

    3. Install the fastener retaining the lower intake tube. Torque the fastener to specification. TORQUE Lower Intake Tube Fastener: 3 ft-lbs (4 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.146 © Copyright Polaris Inc.

  • Page 347: Air Box Removal

    11. Remove the air box from the clutch-side of the removal much easier. vehicle. 8. Remove the fasteners and ignition coils from the air box assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.147 © Copyright Polaris Inc.

  • Page 348: Air Box Installation

    Air Box Throttle Body Gear Clamps: 12. Install the hood assembly and left / right engine 11 in-lbs (1.24 Nm) compartment side panels. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.148 © Copyright Polaris Inc.

  • Page 349: Exhaust

    EGT sensor(s) from the wiring harness. DO NOT REMOVE the EGT probe from the resonator or pipe if it is not necessary. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.149 © Copyright Polaris Inc.

  • Page 350: Exhaust Manifold Assembly View

    EXHAUST MANIFOLD ASSEMBLY VIEW Exhaust Manifold Fasteners First Pass: 11 ft-lbs (15 N·m) Exhaust Manifold Gasket Second Pass: 22 ft-lbs (30 N·m) Exhaust Manifold 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.150 © Copyright Polaris Inc.

  • Page 351: Exhaust Removal

    8. Remove the exhaust spring connecting the tuned pipe to the chassis. 4. Remove the exhaust spring connecting the rear of the resonator to the chassis. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.151 © Copyright Polaris Inc.
  • Page 352 13. Remove the tuned pipe. NOTICE An extended length exhaust spring tool aids in lower exhaust spring removal. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.152 © Copyright Polaris Inc.

  • Page 353: Exhaust Manifold Removal

    Discard the Exhaust Manifold gasket Torque in sequence page 3.48 NOTICE Image for reference only. 3. Proceed to exhaust Installation. See Exhaust Installation page 3.154. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.153 © Copyright Polaris Inc.

  • Page 354: Exhaust Installation

    NOTICE Ensure the resonator is properly positioned on the resonator mounts. NOTICE Stainless steel (grey) springs connect the tuned pipe to the exhaust manifold. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.154 © Copyright Polaris Inc.
  • Page 355 12. Install the exhaust spring fastening the right side sensor wire to the main harness with a new cable ties on the tuned pipe in place. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.155 © Copyright Polaris Inc.
  • Page 356 TORQUE EGT Sensor: 32 ft-lb (44 Nm) Apply Loctite® 767-64 Anti-Seize as required. 17. Install the hood and side panels. 18. Verify proper operation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 3.156 © Copyright Polaris Inc.
  • Page 357 POLARIS ELECTRONIC REVERSE CONTROL (PERC) ........

  • Page 358: General Information

    If fuel system is leaking or open, disconnect fuel pump prime connection ‘before’ powering up critical power connection 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 359: Engine Protection Features

    Verify vehicle is not overloaded during operation (high Vehicle use load/high engine RPM and low ground speed) Verify track is not missing lugs. Set correct track tension Track condition/tension 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 360: Detonation (Det) Protection Modes

    Standard Gauge (DET) Display PIDD Gauge (DET) Display NOTICE The PIDD display will alert the operator as to which cylinder is experiencing detonation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 361: Detonation (Det) Troubleshooting

    NOTICE If equipped with an PIDD, the gauge will remain on because the key is in the ON position. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 362: Cleanfire Fuel Injection (Cfi) System

    Fuel Pump Supplies fuel to the fuel injectors. Power to the fuel pump is supplied by the PBR. The ECU can communicate with the Polaris Digital Wrench® software and can be re-flashed, Diagnostic Connector monitored and will display trouble codes.

  • Page 363: Exhaust Gas Temperature (Egt) Sensor

    EXHAUST TEMPERATURE SENSOR 349.5Ω @ 392° F (200° C) Resistance 767.3Ω @ 1562° F (850° C) Values 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 364: Air Temperature / Pressure Sensor (T-Map)

    @ 68 °F (20 ° 2400 - 8200Ω Pins 3 to 4 (Pressure) 3400 - 8200Ω WHT – WHT/RED Two-Tooth 190 Ω +/- 15% GRN – WHT/GRN Five-Tooth 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 365: Crankshaft Position Sensor Air Gaps

    If there is no drag felt on the feeler gauge, the CPS must be adjusted. 3. To adjust a CPS, use an 8 inch pry bar to carefully deflect the sensor. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 366: Ignition Coil Packs

    The high tension wires are not serviceable. If the wires are damaged, replace the complete coil pack. ECT Sensor Cylinder Head ECT Sensor Jumper TORQUE ECT Sensor: 18 ft-lbs (24 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.10 © Copyright Polaris Inc.

  • Page 367: Knock (Det) Sensor

    168 in-lbs (19 Nm) NOTICE Install screw clean and dry. If fuel sensor replacement is required, the return fuel line must be replaced as an assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.11 © Copyright Polaris Inc.

  • Page 368: Electronic Control Unit (Ecu)

    Exhaust Valve Position PWM Splice, Critical Power #1 Critical PWR 5V Sensor Supply #3 Speed Sensor PWR OG/WH Splice, Chassis Sensor Ground #2 BK/DB Sensor GND 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.12 © Copyright Polaris Inc.

  • Page 369: Ecu (Cnb) 34 Pin Connector Pinout

    CAN Hi Splice, CAN Low CAN Low Splice, Sensor Power #2 5V Sensor Supply Power #2 RD/WH Splice, Chassis Sensor Ground #3 BK/DB Sensor GND 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.13 © Copyright Polaris Inc.

  • Page 370: Ecu Label Information

    ECU. This label will have the base ECU part material, clean with a dry cloth. Use of harsh cleaners number on it. Use the appropriate Polaris parts manual / or solvents will erase the ink from the label.
  • Page 371 ECU to the intake plenum. Remove the ECU from the vehicle. 5. Reconnect Digital Wrench to the vehicle and finish the ECU replacement procedure. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.15 © Copyright Polaris Inc.

  • Page 372: Throttle Position Sensor (Tps) Testing

    • All engine management sensors/switches must be connected to obtain accurate TPS voltage readings. • Use a fully charged 12VDC battery to power the engine management system. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.16 © Copyright Polaris Inc.

  • Page 373: Tps Wire Routing

    Always secure the wire lead to the TPS as shown with a cable tie Route and retain the rest of the wire lead as shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 4.17 © Copyright Polaris Inc.

  • Page 374: Polaris Electronic Reverse Control (Perc)

    ENGINE ELECTRICAL POLARIS ELECTRONIC REVERSE CONTROL (PERC) PERC OVERVIEW 4. Slowly apply throttle until the sled starts to move in reverse, and carefully direct the sled in the direction The operation of the electronic reverse system is that you want.
  • Page 375 ................5.31 FUEL LINE ROUTING 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 376: General Information

    E85 fuels. All fuel injectors must share the same color code (Yellow, Blue, or Red). Always verify the fuel injector part number prior to installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 377: Fuel Pump Prime Procedure

    If using a stand-alone service battery, do not place the battery in the tunnel footwells. Place the battery on the floor next to the engine compartment. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 378: Fuel Type Selection - Standard Gauge

    EXIT appears in the information display area. 6. Press and release the SET button to exit. The fuel type being displayed is the active fuel type. 5. Select FUEL TYPE. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 379 6. Use the UP or DOWN keypad buttons to select the current fuel type (E10 Ethanol or 91 Premium) to match what is in the fuel tank. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 380: Fuel Injectors / Fuel Rail / Throttle Body

    O- Return Quick Connect Fittings (BLUE) rings and bushing are serviceable. O-Ring Foam Block Replace with new when removed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 381: Fuel Hose Quick Disconnect Fittings

    Do not apply excessive pressure to fuel fittings or clips. Verify proper operation of the fitting and clip by lightly pulling on fitting to ensure it is secure before completing repair. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 382 13. Carefully remove the intake plenum. 8. Remove the ziptie securing the upper intake tube to the chassis. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 383 19. Carefully remove the air box. NOTICE If removal is difficult and additional space is needed, remove the ignition coils from the air box assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 384 27. Remove the throttle body from the vehicle. 23. Disconnect the TPS harness connector. NOTICE Note the cable tie position and TPS harness routing prior to disconnecting the TPS. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.10 © Copyright Polaris Inc.

  • Page 385: Throttle Body Installation

    NOTICE Turn the throttle cable in-line adjuster to full length (clockwise) prior to cable installation. TORQUE Throttle Cable Lock Nut: 44 in-lbs (5 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.11 © Copyright Polaris Inc.
  • Page 386 If the ignition coils were removed, reinstall the ignition coils and torque fasteners to specification. TORQUE Air Box Coil Fasteners: 36 in-lbs (4 Nm) TORQUE PBR Fasteners: 6 ft-lbs (8 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.12 © Copyright Polaris Inc.
  • Page 387 Ensure the intake tube is properly seated to the air box and properly aligned with the intake plenum. 15. Install the diagnostic connector into the cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.13 © Copyright Polaris Inc.
  • Page 388 • Drive Belt Installation - AXYS page 2.25 24. Install the hood assembly and left / right engine compartment side panels. TORQUE Clutch Cover Nuts: 7 ft-lbs (10 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.14 © Copyright Polaris Inc.

  • Page 389: Fuel Injectors

    PINS INJECTOR ANCE COLOR VALUE YE/WH 12 Ω RD/DB DB/WH 12 Ω RD/DB IMPORTANT Do not apply excessive pressure to fuel fittings or clips. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.15 © Copyright Polaris Inc.
  • Page 390 NOTICE Note that the fuel injector harness is secured to the throttle body at the white tape marks with routing clips / cable ties. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.16 © Copyright Polaris Inc.
  • Page 391 Verify proper operation of the fitting and clip by lightly TORQUE pulling on fitting to ensure it is secure before completing repair. Air Box Throttle Body Gear Clamps: 11 in-lbs (1.24 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.17 © Copyright Polaris Inc.
  • Page 392 18. Reinstall the support brace. Torque fasteners to specification. TORQUE Left Support Brace Fastener: 22 ft-lbs (30 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.18 © Copyright Polaris Inc.

  • Page 393: Fuel Injector Service

    2. Install replacement o-rings onto top and bottom of injectors. PART ITEM POSITION NUMBER Top of Injector 1500198 Bottom of 5412891 Injector — 5436287 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.19 © Copyright Polaris Inc.

  • Page 394: Fuel Tank / Fuel Pump Service

    Fuel Pump Flange (PFA) Gasket Bolt Fuel Pump Flange Nut 28 ft-lbs (38 Nm) Fuel Tank / Tunnel Foam Pads Install new PFA gasket when nut is removed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.20 © Copyright Polaris Inc.

  • Page 395: Fuel Tank Removal - Rmk

    Disconnect the switch harness during removal. Do not untie the recoil handle. Lay the console to the side of the vehicle. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.21 © Copyright Polaris Inc.
  • Page 396 9. Disconnect the fuel pump wire harness. 10. Remove the nuts and washers fastening the rear of the tank. Discard the nuts. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.22 © Copyright Polaris Inc.

  • Page 397: Fuel Tank Installation - Rmk

    Fuel Tank Rear Mounting Screw: 9.5 ft-lbs (13 Nm) IMPORTANT DO NOT OVER-TORQUE Do not apply excessive pressure to fuel fittings or clips. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.23 © Copyright Polaris Inc.
  • Page 398 The fuel pump wire harness routes under the supply fuel line and connects to the fuel pump connector. 9. Install the three push darts securing the console. IMPORTANT Ensure proper routing. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.24 © Copyright Polaris Inc.

  • Page 399: Fuel Pump Specifications

    When using standby 12V battery, verify battery is fully charged and can supply required voltage to fuel pump. PICKUP FILTER MEDIA • Primary Screen = 200 Microns • Filter = 10 Microns 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.25 © Copyright Polaris Inc.

  • Page 400: Fuel Pump Removal / Service

    3. Carefully extract the fuel pump out of the fuel tank. Manipulate the pickup assembly to fit through the tank opening. Do not kink the fuel pickup hose during this process. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.26 © Copyright Polaris Inc.

  • Page 401: Fuel Pump Installation

    Do not damage the gasket during pump installation. 6. Reinstall the fuel cap. PFA Nut Socket: PS-48459 TORQUE Fuel Pump Flange Nut: 28 ft-lbs (38 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.27 © Copyright Polaris Inc.
  • Page 402 5 lbs. of force. IMPORTANT Connections should NOT disengage during push/pull test. 12. Make sure the gas cap is firmly installed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.28 © Copyright Polaris Inc.
  • Page 403 19. If no leaks are detected, the tank assembly is adequately sealed and ready for installation into the snowmobile. 20. Complete the installation process by following the Fuel Tank Installation procedure. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.29 © Copyright Polaris Inc.

  • Page 404: Fuel Pump Harness Routing

    2. Connect the fuel pump wire harness connector to the fuel pump connector on the main harness. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.30 © Copyright Polaris Inc.

  • Page 405: Fuel Line

    2. Both fuel lines should be routed behind, and rest against the fuel line bracket / retainement point Image is shown from above with arrow pointing toward the front of the vehicle. Handlebar and other parts removed for visibility. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.31 © Copyright Polaris Inc.
  • Page 406 3. The fuel supply line should route down the front of the fuel tank. The supply line should be secured in the foam block and connect to the corresponding line from the fuel rail in the locations shown below. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.32 © Copyright Polaris Inc.
  • Page 407 2. Both fuel lines should be routed behind, and rest against the fuel line bracket / retainement point Image is shown from above with arrow pointing toward the front of the vehicle. Handlebar and other parts removed for visibility. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.33 © Copyright Polaris Inc.
  • Page 408 3. The fuel return line should route down the front of the fuel tank. The return line should be secured in the foam block and connect to the corresponding line from the fuel rail in the locations shown below. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 5.34 © Copyright Polaris Inc.
  • Page 409 ............... . .6.36 BRAKE SYSTEM BLEEDING 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 410 ..................6.44 TRACK STUDDING 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 411: General Information

    42T, 3/4W, 15 SPL, HYVO, PM 43T, 3/4W, 15 SPL, HYVO, PM 3221188 44T, 3/4W, 15 SPL, HYVO, PM 3222239 45T, 3/4W, 15 SPL, HYVO, PM 3222146 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 412: Chaincase Sprocket Ratio Speed Chart - Axys (7.764 Cd)

    7T / 2.86P 7T / 3.00P 1.67 1.68 1.68 1.72 1.73 1.73 1.74 1.78 1.79 1.80 1.81 1.83 1.86 1.86 1.89 1.91 1.91 1.95 1.95 1.96 2.00 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 413: Gearing Stock Settings - 2020

    Use the Gearing Stock Settings when making gearing changes with Digital Wrench. If the upper and lower sprockets on the snowmobile do not match the model specifications in the table, Digital Wrench must be used to re-calibrate the speedometer offset. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 414: Gearing Stock Settings - 2021

    Use the Gearing Stock Settings when making gearing changes with Digital Wrench. If the upper and lower sprockets on the snowmobile do not match the model specifications in the table, Digital Wrench must be used to re-calibrate the speedometer offset. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 415: Gearing Change Reprogramming

    6. Connect the SmartLink cable to the vehicle and PC / laptop. 10. Select the track that is installed on the snowmobile. 7. Start Digital Wrench, and select the correct vehicle. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 416 Digital Wrench limits the top sprocket teeth numbers to 19 – 26 and the bottom sprocket teeth numbers to 36 – 45. Future Digital Wrench updates will limit the teeth numbers to match the Polaris-specified acceptable sprocket combinations. IMPORTANT Entering incorrect top and bottom sprocket values will result in inaccurate vehicle speed display.

  • Page 417: Chaincase Service

    Install sharp edge facing out. 21 ft-lbs (28 Nm) Adjuster Bolt (M10 x 1.5 x 70) Bearings Cover Finger tight, then back-off 1/2 turn. 2& Spacer Dowel Tensioner 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 418: Drive Chain Tension Adjustment

    6. Tighten the jam nut to specification while holding the adjuster bolt. TORQUE Drive Chain Tensioner Jam Nut: 21 ft-lbs (28 Nm) 7. Reinstall the side panels. Release the parking brake. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.10 © Copyright Polaris Inc.

  • Page 419: Chaincase Oil Change - Pump Method

    6. Using a funnel, slowly add the recommended oil until the fluid begins to overflow. FLUID CAPACITY Maximum Fluid Capacity: 10.5 oz. (310 ml) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.11 © Copyright Polaris Inc.

  • Page 420: Chaincase Cover Gasket Orientation

    10. Using a funnel, slowly add the recommended oil until the fluid begins to overflow. FLUID CAPACITY Maximum Fluid Capacity: 10.5 oz. (310 ml) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.12 © Copyright Polaris Inc.

  • Page 421: Chaincase Cover Torque Pattern

    • Draining chaincase oil using the Cover Method • Removing chaincase cover • Removing chaincase assembly IMPORTANT Do not hang the brake caliper by the brake hose. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.13 © Copyright Polaris Inc.
  • Page 422 15. Inspect the cover gasket for damage. Inspect the bearing and seal in the cover. Replace bearing if it no longer rolls smoothly. Replace the seal if damaged. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.14 © Copyright Polaris Inc.
  • Page 423 Inspect the chain for frozen links and damage. Replace as required. 21. Clean the inside of the chaincase housing. 18. Remove the spacer on the jackshaft. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.15 © Copyright Polaris Inc.

  • Page 424: Chaincase Cover Service

    6. Tighten the tensioner adjuster bolt until there is 1/8 inch (3.175 mm) chain deflection on the backside of the drive chain. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.16 © Copyright Polaris Inc.
  • Page 425 If the fender is secured to the chaincase housing, remove the two screws. Removing the screws will allow more room for the cover to rotate into place. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.17 © Copyright Polaris Inc.

  • Page 426: Chaincase Housing Removal

    There are two domed washers on the brake disc bolt. 15. Clean the brake disc with brake cleaner and then install on to jackshaft. TORQUE Brake Disc Bolt: 18. Fill-to-spill the chaincase with Polaris Synthetic Chaincase Lubricant (SCL). Tighten fill plug to specification. TORQUE Chaincase Fill Plug: 4 ft-lbs (6 Nm) 19.
  • Page 427 6. Remove the rivets securing the bulkhead floor and fender to the chaincase housing. 10. Allow the housing to cool completely. Inspect the bearing seals, and bearings. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.19 © Copyright Polaris Inc.
  • Page 428 Discard the bearings and oil seals. 14. Install new bearings using an Arbor press. Only press on outer race of bearings. Do not press on the inner race. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.20 © Copyright Polaris Inc.

  • Page 429: Chaincase Housing Installation

    9 ft-lbs (12 Nm) Chaincase Housing Cooler / Bulkhead Fasteners: 26 ft-lbs (35 Nm) 6. Reinstall the chaincase components. 7. Reinstall the right fender assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.21 © Copyright Polaris Inc.

  • Page 430: Chaincase Vent Line Routing

    2. Route the chaincase vent line under the recoil roller and behind the coolant bottle. The chaincase vent line should be tucked between the mounting bracket and coolant bottle as shown below. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.22 © Copyright Polaris Inc.

  • Page 431: Quickdrive Low Inertia Drive System

    Screw (M10 x 1.25 x 45) Bearings 44 ft-lbs (60 Nm) Use new fasteners during assembly Snap Rings QuickDrive Belt Upper Sprocket Lower Sprocket 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.23 © Copyright Polaris Inc.

  • Page 432: Quickdrive Drive Belt / Sprocket Removal

    If snowmobile is equipped with electric start, remove the battery and battery support brackets. IMPORTANT Disconnect BLACK (NEGATIVE) battery cable first, and then the RED (POSITIVE) cable. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.24 © Copyright Polaris Inc.

  • Page 433: Quickdrive Drive Belt / Sprocket Installation

    NOTICE If sprockets will not slide down the splines, the belt is binding. Pull up slightly on the sprockets to re-align belt. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.25 © Copyright Polaris Inc.
  • Page 434 8. Connect the RED (POSITIVE) battery cable first, and then the BLACK (NEGATIVE) cable. 9. Tip snowmobile back onto it skis. Reinstall the fender. Reinstall the right side engine compartment door. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.26 © Copyright Polaris Inc.

  • Page 435: Quickdrive Backer Plate Assembly View

    Screws (M8 x 1.25 x 25) Washers 26 ft-lbs (35 Nm) Nuts Screws (M8 x 1.25 x 25) 9 ft-lbs (12 Nm) 22 ft-lbs (30 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.27 © Copyright Polaris Inc.

  • Page 436: Quickdrive Backer Plate Removal

    3. Remove the brake caliper from the backer plate. Secure caliper to over structure. Remove brake disc from jackshaft. 4. Remove speed sensor from backer plate. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.28 © Copyright Polaris Inc.

  • Page 437: Quickdrive Backer Plate Installation

    10. Follow the procedure for installing the drive belt and sprockets. Apply adhesive along the black lines shown. Use a 4 mm diameter bead. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.29 © Copyright Polaris Inc.

  • Page 438: Driveshaft Service

    Press on inner race until fully seated. Driveshaft Assembly, Tubular W/ Collar Flangette - 52MM Seat, 72 MM Not Serviceable Flangette W/ Clinch Nuts 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.30 © Copyright Polaris Inc.

  • Page 439: Driveshaft Removal

    When installing a new bearing, press bearing on inner race until fully seated against step in driveshaft. 6. Remove the bearing cover 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.31 © Copyright Polaris Inc.

  • Page 440: Driveshaft Installation

    Driveshaft Bearing Cover / Flangette Fasteners: 18 ft-lbs (25 Nm) 7. Reinstall the rear suspension. 8. Follow the procedure for chaincase reassembly. 9. Reinstall the driven clutch assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.32 © Copyright Polaris Inc.

  • Page 441: Jackshaft Service

    FINAL DRIVE / BRAKE SYSTEMS JACKSHAFT SERVICE JACKSHAFT ASSEMBLY VIEW Screws (M8 x 1.25 x 15) Bearing 18 ft-lbs (25 Nm) Flangette, 3 Bolt, Offset, Out Jackshaft Asm. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.33 © Copyright Polaris Inc.

  • Page 442: Jackshaft Removal

    5. Reinstall the driven clutch assembly. 6. Follow the procedure for chaincase reassembly or drive belt/sprocket/backer plate reassembly. 6. Extract the jackshaft out of the tunnel. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.34 © Copyright Polaris Inc.

  • Page 443: Brake System

    9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.35 © Copyright Polaris Inc.

  • Page 444: Brake System Bleeding

    8. Reinstall the gasket and cover. Torque cover fasteners to specification. TORQUE Brake Reservoir Cover Fasteners: 6 - 8 in-lbs (0.7 - 0.9 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.36 © Copyright Polaris Inc.
  • Page 445 6. Install the brake pads back into the caliper. 7. Reinstall the retaining pin. 8. Test brake system prior to returning vehicle to service. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.37 © Copyright Polaris Inc.
  • Page 446 4″ to 5″. 15. Inspect both brake pads prior to installation. If they are within the pad wear specification, reinstall into caliper. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.38 © Copyright Polaris Inc.
  • Page 447 7. Reinstall the brake caliper. Apply Loctite 242 to caliper fasteners and torque to specification. TORQUE Brake Caliper Fasteners: 18.4 ft-lbs (25 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.39 © Copyright Polaris Inc.
  • Page 448 2. Continue to route the brake line upward along the over structure tube. Secure the brake line to the main harness at the retention tape location shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.40 © Copyright Polaris Inc.
  • Page 449 4. Finish routing by routing the brake line up to the brake master cylinder and secure with banjo bolt 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.41 © Copyright Polaris Inc.
  • Page 450 2. Continue to route the brake line upward along the over structure tube. Secure the brake line to the main harness at the retention tape location shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.42 © Copyright Polaris Inc.
  • Page 451 4. Finish routing by routing the brake line up to the brake master cylinder and secure with banjo bolt 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.43 © Copyright Polaris Inc.
  • Page 452 FINAL DRIVE / BRAKE SYSTEMS TRACK STUDDING / LUG HEIGHT TRACK STUDDING IMPORTANT Do not install track studs on any deep snow model. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 6.44 © Copyright Polaris Inc.
  • Page 453 ............... . .7.26 DRIVEN CLUTCH REMOVAL 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 454 ..................7.34 CLUTCH CLEANING 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 455: General Information

    RPM speed. The shift out RPM should come down to the or https://polaris.service-solutions.com desired operating RPM, but never below, after the driven clutch begins to open. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 456: Shift Out Rpm

    A compression spring (Team driven / P2) or torsional Low ratio is the mechanical position when the drive belt spring (Polaris P-85 driven clutch) works in conjunction is all the way down into the drive clutch, and all the way with the helix, and controls the shift rate of the driven out on the driven clutch.
  • Page 457 Springs listed as color - #### will have the last four digits of the part number painted on the spring coil. Tag each spring with the part number and spring force when not in use. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 458: Spring Free Length

    1321589 10-56 1321684 10-58 1321588 10-60 1321587 10-62 1321586 10-64 1321585 10-66 1321584 10-68 1322427 10-70 1322414 10-72 1322428 10-74 1322429 10-76 1322585 10-78 1322586 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 459: Perc Team Lwt Driven Helixes

    The last number (C) is the transition distance (in numbers. inches) between the starting and finish angles. IMPORTANT Do not install a non-ER helix on a PERC-equipped snowmobile where the engine changes directions. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 460: Team Driven Springs

    Team driven springs listed with a color - ### / ### will have the beginning and ending spring rates painting on the spring coils. Tag each spring with the part number when not in use. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 461: Drive Belt

    Always take time to warm up the belt and driveline prior to operating the snowmobile. Free track and skis from the ground before engaging throttle. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 462: Drive Belt Removal - Axys

    7. Turn the wrench clockwise until the sheaves open far enough to remove the belt. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.10 © Copyright Polaris Inc.

  • Page 463: Drive Belt Installation - Axys

    Always clean the drive belt using a mixture of warm, soapy water. Allow to air dry. When installing the belt, verify POLARIS or the part number can be read from the outside of the snowmobile. 1. Verify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves.

  • Page 464: Drive Clutch

    , clutch spider , and the stationary sheave should line up when the clutch is assembled. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.12 © Copyright Polaris Inc.

  • Page 465: Drive Clutch Assembly View

    Starter Ring Gear Fasteners (Applicable to electric start models) Washers 165 in-lbs (19 Nm) Apply Loctite® 271™ to Threads in hole of Stationary Sheave Roller and Bushing 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.13 © Copyright Polaris Inc.

  • Page 466: Drive Clutch Removal

    4. Obtain the Drive Clutch Puller. Drive Clutch Puller: 2872085 5. Apply a light film of Polaris Premium Grease to the puller threads. Tighten the puller into the clutch. If the clutch does not come off, strike the clutch puller head with a hammer.
  • Page 467 Place the pin inside the weight to check the flyweight bushing and pin surface for wear by rocking the weight back and forth. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.15 © Copyright Polaris Inc.

  • Page 468: Roller Removal

    NOTICE When required, button shims are installed on the trailing (right) side of the spider leg as viewed from the front of the spider. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.16 © Copyright Polaris Inc.

  • Page 469: Roller Installation

    5. Add shims beneath each trailing side spider button to obtain the specified button-to-tower clearance when assembled at each spider leg. MEASUREMENT Button-To-Tower Clearance: .001 - .002 in (0.025 - 0.05 mm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.17 © Copyright Polaris Inc.

  • Page 470: Bushing / Insert Replacement

    5. Turn the sheave counterclockwise until the bushing is fully seated. 6. Remove the rod nut and installation tool and repeat the step to install the new insert. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.18 © Copyright Polaris Inc.

  • Page 471: Cover Bushing

    6. Turn the clutch cover counterclockwise until the bushing is removed and the cover comes free. 7. Remove the tools and discard the bushing. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.19 © Copyright Polaris Inc.

  • Page 472: Drive Clutch Assembly

    Spider Tool: 5. Place the moveable sheave onto the stationary 2870341 sheave. TORQUE Spider Torque: 280-300 ft-lbs (380-406 Nm) Apply Loctite® 243™ to Threads 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.20 © Copyright Polaris Inc.
  • Page 473 Do not allow the side loading or misalignment of the 11. Place the drive spring on the shaft. cover or the bushing may become damaged. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.21 © Copyright Polaris Inc.

  • Page 474: Drive Clutch Installation

    Dry completely prior to clutch installation. Do not use harsh cleaners which may cause clutch taper to corrode, or damage the crank seal. 4. Slide clutch onto crankshaft taper. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.22 © Copyright Polaris Inc.

  • Page 475: Spider Indexing

    (s). To decrease the clearance, remove or install thinner washer (s). Either way, the belt-to- sheave clearance adjustment most often requires the spider to be “re-indexed”. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.23 © Copyright Polaris Inc.
  • Page 476 (25.4 mm) after final assembly and torquing. When assembling a new clutch with all of the same components, it is not uncommon for the marks not to line up. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.24 © Copyright Polaris Inc.

  • Page 477: Driven Clutch

    145 in-lbs (16 Nm) Stationary Sheeve Washer Deflection Spacer Retaining E-Ring Snap Ring Moveable Sheeve Spring Cup Helix Helix Fasteners Spring 110 in-lbs (12 Nm) Spider 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.25 © Copyright Polaris Inc.

  • Page 478: Driven Clutch Removal

    Note the number and location of the offset washers / bushing located behind the driven clutch. 5. Inspect the jackshaft and driven clutch splines for damage. Replace components as required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.26 © Copyright Polaris Inc.

  • Page 479: Driven Clutch Assembly

    NOTICE Apply Loctite 243 to 3235592 helix fasteners. 4. Install and torque helix fasteners to specification. TORQUE Helix Fasteners: 110 in-lbs (12 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.27 © Copyright Polaris Inc.

  • Page 480: Driven Clutch Installation

    1. Verify the same number of offset washers / bushings are installed on the jackshaft that were present when the clutch was removed. 2. Apply a light film of Polaris Premium Grease to the jackshaft splines and shaft. 3. Install the driven clutch.

  • Page 481: Pvt System Adjustments

    (decrease TORQUE deflection). Deflection Screw Jam Nut: 145 in-lbs (16 Nm) 6. Rotate the belt clockwise while removing the L- wrench 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.29 © Copyright Polaris Inc.

  • Page 482: Clutch Alignment / Offset - Ps-52666

    When installed into the drive clutch and placed on top of the driven clutch, the technician can immediately determine if any adjustments are required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.30 © Copyright Polaris Inc.

  • Page 483: Clutch Alignment / Offset - Ps - 47477 Lwt Tool

    2. Remove the drive belt. Push the driven clutch inwards. The drive / driven clutch offset specification on AXYS snowmobiles is different than other Polaris snowmobile 3. Install the PS-47477 alignment tool into the drive platforms. The driven clutch is mounted closer to the clutch.

  • Page 484: Clutch Alignment / Offset - Ps - 51607

    When installed into the drive clutch and placed on top of the driven clutch, the technician can immediately determine if any adjustments are required. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.32 © Copyright Polaris Inc.

  • Page 485: Axys Clutch Offset / Float Adjustment

    Driven Clutch Bolt: 18 ft-lbs (25 Nm) 5. Apply a light film of Polaris Premium grease to the jackshaft. Install the driven clutch and push it tight toward the bulkhead. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.33...

  • Page 486: Clutch Cleaning

    IMPORTANT Do not lubricate the clutch bushings or any internal clutch components. Clutch bushings are self- lubricating. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 7.34 © Copyright Polaris Inc.
  • Page 487 ............8.39 REAR SUSPENSION INSTALLATION 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 488 ..........8.94 WALKER EVANS PIGGYBACK SHOCK ASSEMBLY 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 489: General Information

    Make notes of the direction a bolt goes through a part, what type of nut is used in an application, etc. Always use genuine Polaris parts and hardware when replacing front end components. Review steering adjustment guidelines before making adjustments.

  • Page 490: Rod End Engagement

    FRONT SUSPENSION SETTING SPECIFICATIONS FRONT SUSPENSION TOE OUT (IN. / MM) (AT RIDE HEIGHT / OVERALL) AXYS React 1/8″ – 1/4″ (3.0 – 6.0 mm) RMK Assault 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 491: Steering / Front Suspension Assembly Views

    Ski Assembly Fastener (M10X1.5X155) Upper Shock Fastening Nut (M10X1.5) 36 ft-lbs (50 Nm) 36 ft-lbs (50 Nm) Ski Assembly Fastener Nut (M10X1.5) 36 ft-lbs (50 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 492: Upper Steering Post Assmbly - Axys React

    Handlebar Mount, Upper Strap Handguard Mount, Upper Handlebar Mount, Lower Handlebar Mount Fastening Nut Handguard Mount, Lower 7 ft-lbs (9.5 Nm) - Tighten Gap Evenly 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 493: Lower Steering Assembly - Axys React

    Washer (8.4X16.0X0.91) 37 ft-lbs (50 Nm) Idler Assembly Fastener (M8X1.25X85) Steering Post 30 ft-lbs (41 Nm) Steering Post Bushing Spacer Idler Assembly Grease Before Assembly 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 494: Front Sway Bar Assembly - Axys React

    Sway Bar Link 18 ft-lbs (25 Nm) Upper Sway Bar Link Fastener Sway Bar 18 ft-lbs (25 Nm) Sway Bar Bushing Washer Sway Bar Bushing Clamp 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 495: Steering / Front Suspension Service

    6. Remove the flange nut securing the upper steering 9. Remove the steering post from the vehicle. post to the steering tie rod. Discard the flange nut. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 496 1. Remove the flange nut securing the lower steering post to the steering tie rod. Discard the flange nut. 4. Remove the lower steering shaft mounting nut. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.10 © Copyright Polaris Inc.

  • Page 497: Steering Post Installation

    3. Assemble the lower steering post bushings spacers to the lower steering post mount. Apply a REF. DESCRIPTION light film of Polaris Premium Grease to the bushings. Bushings Torque screws to specification. Do not over-torque the two screws. Spacers TORQUE...
  • Page 498 STEERING / SUSPENSIONS 4. Reconnect the lower steering post to the steering tie 2. Apply a light film of Polaris Premium Grease to the rod and fixed rack link using a new flange nuts. bushings Torque flange nuts to specification.
  • Page 499 9. Verify Proper Operation. The steering should move freely without excessively stressing the wires, cables, and hoses. Start the engine and repeat to ensure proper installation. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.13 © Copyright Polaris Inc.

  • Page 500: Spindle Removal

    3. Remove the steering tie rod end from the spindle. Note the position of the washer under the rod end. Discard the flange nut. 6. Remove the spindle. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.14 © Copyright Polaris Inc.

  • Page 501: Spindle Installation

    TORQUE Upper / Lower Control Arm Spindle Nuts: 40 ft-lbs (54 Nm) TORQUE Ski Fastener Flange Nuts: 37 ft-lbs (50 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.15 © Copyright Polaris Inc.

  • Page 502: Upper Control Arm Service

    TORQUE Control Arm Pivot Nuts: 40 ft-lbs (54 Nm) 2. Reinstall the ski. Refer to Ski Assembly Service page 8.45. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.16 © Copyright Polaris Inc.
  • Page 503 18 ft-lbs (25 Nm) 4. Reinstall the ski. Refer to Ski Assembly Service page 8.45. 5. Reinstall the spindle. Refer to Spindle Removal page 8.14. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.17 © Copyright Polaris Inc.

  • Page 504: Control Arm Pivot Service

    When installing or adjusting the control arm pivots, push 6. Reinstall the lower control arm. the rear pivots forward prior to tightening the control arm pivot flange nuts. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.18 © Copyright Polaris Inc.

  • Page 505: Rear Susupension Assembly Views

    Lubrication Fitting Wave Washers 55 ft-lbs (75 Nm) Flange Nut (M6 x 1.0) 2& Screws (M10 x 1.5 x 250) Washers 6 ft-lbs (8 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.19 © Copyright Polaris Inc.

  • Page 506: Rmk Rail Assembly View

    Head of screw to be on same side of rail as adjuster block Screw (M6 x 1.0 x 20) Rail Beam 4 ft-lbs (6 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.20 © Copyright Polaris Inc.

  • Page 507: Rmk Rail Beam Detail

    Front Torque Arm Mount Limiter Strap Shaft Bumper Screw Bumper Screw Rear Torque Arm Mount Front Shock Shaft Rail Brace Shaft / Screws Adjuster Block Rivets Scratcher 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.21 © Copyright Polaris Inc.

  • Page 508: Rmk Khaos Rail Assembly View

    Head of screw to be on same side of rail as adjuster block Screw (M6 x 1.0 x 20) Rail Beam 4 ft-lbs (6 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.22 © Copyright Polaris Inc.

  • Page 509: Rmk Khaos Rail Beam Detail

    Front Torque Arm Mount Limiter Strap Shaft Bumper Screw Bumper Screw Rear Torque Arm Mount Front Shock Shaft Rail Brace Shaft / Screws Adjuster Block Rivets Scratcher 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.23 © Copyright Polaris Inc.

  • Page 510: Rmk Front Torque Arm Assembly View

    Replace with new when removed. Limiter Strap Lubrication Fittings Install with free ends facing forward. Stock position is tight. — Front Track Shock Washers Shock Pivot 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.24 © Copyright Polaris Inc.

  • Page 511: Rmk 174" Rear Suspension Pivot / Brace Shaft Assembly View

    Rear Torque Arm Brace Bogie Wheel Front Torque Arm Brace Washer Screw Inside Spacer Shaft 55 ft-lbs (75 Nm) +/- 10% Wave Washer Screw 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.25 © Copyright Polaris Inc.

  • Page 512: Rmk 174" Rail Assembly View

    14 ft-lbs (19 Nm) +/- 20% Rail Slider Head of screw to be on same side of rail as adjuster block Screw Rail Beam 4 ft-lbs (6 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.26 © Copyright Polaris Inc.

  • Page 513: Rmk 174" Rail Beam Detail

    Rear Pivot Front Track Shock Shaft Rail Brace Shaft / Screws Scratcher Rail Brace Shaft / Screws Front Torque Arm Mount Adjuster Block Rivets 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.27 © Copyright Polaris Inc.

  • Page 514: Rmk 174" Front Torque Arm Assembly View

    Flange Nuts Screw 17 ft-lbs (23 Nm) Domed Washers Torque Arm Install dome-side out. Lubrication Fittings Limiter Strap — Front Track Shock Washers Tube 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.28 © Copyright Polaris Inc.

  • Page 515: Rmk Rear Torque Arm Assembly View

    Screw (M8 x 1.25 x 150) Spring Washer 17 ft-lbs (23 Nm) Bogie Wheel Asm. Shaft Hollow Shaft Shock Rod Rear Torque Arm — Rear Track Shock 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.29 © Copyright Polaris Inc.

  • Page 516: Sks Rear Suspension Pivot / Brace Shaft Assembly View

    55 ft-lbs (75 Nm) +/- 10% Lubrication Fitting Screws (M10 x 1.5 x 250) Washers 2& Bogie Wheels / Mounts Inner Shaft Rear Idler Shaft 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.30 © Copyright Polaris Inc.

  • Page 517: Sks Rail Assembly View

    Rail Slider Screw (M6 x 1.0 x 20) Bogie Wheels 4 ft-lbs (6 Nm) Screw (M6 x 1.0 x 70) 10 ft-lbs (14 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.31 © Copyright Polaris Inc.

  • Page 518: Sks Rail Beam Detail

    Front Torque Arm Mount Adjuster Block Rivets Bogie Wheel Mounts Mount to outside of each rail. Left Rail: Forward Holes Right Rail: Rear Holes 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.32 © Copyright Polaris Inc.

  • Page 519: Sks Front Torque Arm Assembly View

    Replace with new when removed. Limiter Strap Lubrication Fittings Install with free ends facing forward. Stock position is tight. — Front Track Shock Washers Shock Pivot 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.33 © Copyright Polaris Inc.

  • Page 520: Rear Suspension Service

    4. Install the snap ring. IMPORTANT Ensure the snap ring is fully seated. INSTALLATION 1. Install the bogie wheel , spring washer , and spacer 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.34 © Copyright Polaris Inc.
  • Page 521 2. Raise the suspension up to the chassis and install the two washers , spring lock washers , and fasteners . Torque to specification. TORQUE Upper Carrier Fasteners: 46 ft-lbs (63 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.35 © Copyright Polaris Inc.

  • Page 522: Front Track Shock (Fts) Service

    6. Slide the FTS/ cross shaft assembly rearward and at an angle to remove the rail beams. NOTICE The cross shaft washers will stay in the rail beams. Do not misplace these washers. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.36 © Copyright Polaris Inc.

  • Page 523: Rear Track Shock (Rts) Service

    33 ft-lbs (45 Nm) Shock Rod – Front Torque Arm Lock Nut: 33 ft-lbs (45 Nm) Limiter Strap Lock Nuts: 17 ft-lbs (23 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.37 © Copyright Polaris Inc.

  • Page 524: Rear Suspension Removal

    Push the rear idler shaft / idler wheel assembly forward. 3. Remove the two upper carrier fasteners. 6. Remove the rear suspension from the track. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.38 © Copyright Polaris Inc.

  • Page 525: Rear Suspension Installation

    Upper Carrier Fasteners: 46 ft-lbs (63 Nm) 6. Perform the Track Alignment and Track Tension Adjustment procedures. 3. Loosely install the front torque-arm-to tunnel mount bolts 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.39 © Copyright Polaris Inc.

  • Page 526: General Setup / Adjustments - All Models

    6 in-lbs (0.7 Nm) Handlebar Clamp Screws / Bolts 7 ft-lbs (9.5 Nm) PERC Button Screw 35 in-lbs (4 Nm) Hand-Tight – Hand Guard Mounts (if applicable) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.40 © Copyright Polaris Inc.

  • Page 527: Handlebar Angle Adjustment

    Do not stretch wires while adjusting the controls. Stretching the wires could damage the handwarmers. 3. Tighten the bolts to specification. TORQUE Handlebar Mount Bolts: 7 ft-lbs (9.5 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.41 © Copyright Polaris Inc.

  • Page 528: Two Piece Throttle Control Installation

    . Note the orientation of the switch during removal. 6. Slide the lower block out of the upper block Remove the throttle blocks from the handlebar. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.42 © Copyright Polaris Inc.

  • Page 529: Ski Alignment / Toe Adjustment

    7. Steps 2 to 6 will align the skis with the track. At this point, verify the handlebar is centered with the skis. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.43 © Copyright Polaris Inc.

  • Page 530: Control Arm Pivot Adjustment

    3. While holding the pivot(s) in place, tighten the lock nuts. TORQUE Lower Control Arm Front Pivot Bolt / Nut: 40 ft-lbs (54 Nm) Control Arm Pivot Lock Nuts: 40 ft-lbs (54 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.44 © Copyright Polaris Inc.

  • Page 531: Ski Assembly Service

    3. Install a new flange nut and torque to specification. TORQUE Ski Bolt Fastener Torque: 37 ft-lbs (50 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.45 © Copyright Polaris Inc.

  • Page 532: Skag Replacement

    1. Raise and support the front of the snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag downward. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.46 © Copyright Polaris Inc.

  • Page 533: Rail Slider Inspection

    Apply spray lubricant to the rail beam. Use a small pry bar to drive the slider rearward until removed. NOTICE Replace rail sliders in pairs. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.47 © Copyright Polaris Inc.

  • Page 534: Track Alignment

    5. Tighten the locknuts. 6. Tighten the idler shaft bolts to specification. TORQUE Rear Idler Fastener Torque: 55 ft-lbs (75 Nm) +/- 10% 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.48 © Copyright Polaris Inc.

  • Page 535: Track Tension Adjustment

    6. Check track alignment and adjust as necessary. 7. Tighten the locknuts. 8. Tighten idler shaft fasteners to specification. TORQUE Rear Idler Fastener: 55 ft-lbs (75 Nm) +/- 10% 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.49 © Copyright Polaris Inc.

  • Page 536: Track Tension Specifications

    Series 7 (3 in) +/- 10% 1/2 - 5/8 in Series 8 (2.75 in) (1.3 - 1.6 cm) NOTICE Image for reference only. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.50 © Copyright Polaris Inc.

  • Page 537: Limiter Strap Adjustment

    The front torque arm limiter strap is set at position #1. Polaris recommends leaving the limiter strap length at position #1 to maintain the optimum ride characteristics of the snowmobile. Riders who desire less ski pressure and more weight transfer toward the rear of the snowmobile can lengthen the limiter strap by changing to position #2.

  • Page 538: General Setup / Adjustments - 155" Or Longer

    Always adjust the clicker at least one click below full stiff (full clockwise) or shock damage will occur. Test ride the snowmobile and continue making spring and clicker adjustments until you achieve the perfect ride. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.52 © Copyright Polaris Inc.

  • Page 539: Pro-Rmk And Sks Shock Locations

    PRO-RMK AND SKS SHOCK LOCATIONS NOTICE Image for reference only. IFS = Front Shocks FTS = Front Track Shock RTS = Rear Track Shock 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.53 © Copyright Polaris Inc.

  • Page 540: Front Suspension (Ifs) Factory Spring Settings

    PRO-RMK 10.25” (26 cm) 9.75” (24.8 cm) Monotube 10.25” (26 cm) 9.75” (24.8 cm) RMK KHAOS SKS/PRO-RMK 10.25” (26 cm) 9.75” (24.8 cm) w/Clicker 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.54 © Copyright Polaris Inc.

  • Page 541: Front Track Shock (Fts) Factory Spring Settings

    6.25” (15.9 cm) 8.375" (21.3 cm) 8.2" (20.8 cm) Low Speed Adjustment FACTORY CLICKER SETTING (FROM FULL MODEL STIFF) Low-Speed: 6 RMK KHAOS High-Speed: 4 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.55 © Copyright Polaris Inc.

  • Page 542: Rear Track Shock (Rts) Factory Spring Settings

    *Factory Setting For Optional 250 lb./in. Stiff Springs 250-300 lbs. 113-136 kg 10.25" 26 cm 10" (25.4 cm) 300-350 lbs. 136-159 kg 10" 25.4 cm 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.56 © Copyright Polaris Inc.

  • Page 543: Rear Track Shock (Rts) Factory Clicker Settings

    CLICKER SETTING MODEL (FROM FULL STIFF) PRO-RMK w/clicker High-Speed: 4 RMK KHAOS Low-Speed: 6 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.57 © Copyright Polaris Inc.

  • Page 544: Shocks

    PS-45259-1 Shock Body Holding Tool (2 1/8”) Shock Rod Holding Tool 1/2" Shock Rod Holding Tool 5/8" PS-45281 Diameter Rod Diameter Rod 2871352 2872429 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.58 © Copyright Polaris Inc.
  • Page 545 IFP Depth Tool (Fox/Walker Evans) Tool PS-45908 2871351 2870803 FOX Air Assist Bearing Wrench Commercially Available (FOX P/N 398-00-644) Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.59 © Copyright Polaris Inc.

  • Page 546: 2020 Shock Specifications

    6.03 5.77 6.03 (inches) Shock Rod .500 .500 .500 .500 (inches) IFP Depth 6.20 2.00 2.00 1.26 (inches) Oil Volume Full Full Full Full 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.60 © Copyright Polaris Inc.
  • Page 547 6ID x .30 x 15 6ID x .30 x 12 6ID x .30 x 12 6ID x .30 x 11 6ID x .30 x 11 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.61 © Copyright Polaris Inc.
  • Page 548 3.540 3.540 3.790 (inches) Shock Rod .500 .500 .500 .625 (inches) IFP Depth 4.04 4.04 4.04 1.50 (inches) Oil Volume Full Full Full Full 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.62 © Copyright Polaris Inc.
  • Page 549 6ID x .30 x 15 6ID x .30 x 12 6ID x .30 x 12 6ID x .30 x 11 6ID x .30 x 11 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.63 © Copyright Polaris Inc.
  • Page 550 11.395 (inches) Stroke 5.70 5.70 5.705 (inches) Shock Rod .500 .500 .500 (inches) IFP Depth 6.00 2.00 2.00 (inches) Oil Volume Full Full Full 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.64 © Copyright Polaris Inc.
  • Page 551 6ID x .30 x 12 6ID x .30 x 9 6ID x .30 x 9 6ID x .30 x 9 6ID x .30 x 9 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.65 © Copyright Polaris Inc.

  • Page 552: 2021 Shock Specifications

    6.03 5.77 6.03 (inches) Shock Rod .500 .500 .500 .500 (inches) IFP Depth 6.20 2.00 2.00 1.26 (inches) Oil Volume Full Full Full Full 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.66 © Copyright Polaris Inc.
  • Page 553 6ID x .30 x 15 6ID x .30 x 12 6ID x .30 x 12 6ID x .30 x 11 6ID x .30 x 11 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.67 © Copyright Polaris Inc.
  • Page 554 3.540 3.540 3.790 (inches) Shock Rod .500 .500 .500 .625 (inches) IFP Depth 4.04 4.04 4.04 1.50 (inches) Oil Volume Full Full Full Full 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.68 © Copyright Polaris Inc.
  • Page 555 6ID x .30 x 15 6ID x .30 x 12 6ID x .30 x 12 6ID x .30 x 11 6ID x .30 x 11 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.69 © Copyright Polaris Inc.
  • Page 556 11.395 (inches) Stroke 5.70 5.70 5.705 (inches) Shock Rod .500 .500 .500 (inches) IFP Depth 6.00 2.00 2.00 (inches) Oil Volume Full Full Full 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.70 © Copyright Polaris Inc.
  • Page 557 6ID x .30 x 12 6ID x .30 x 9 6ID x .30 x 9 6ID x .30 x 9 6ID x .30 x 9 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.71 © Copyright Polaris Inc.

  • Page 558: General Information

    The Body Holder Tool, Internal Floating Piston (IFP), and Shock Rod Holding Tool are not included in the Recharging Kit and must be ordered separately. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.72 © Copyright Polaris Inc.

  • Page 559: Walker Evans Shock Valve Part Numbers - 3/8" I

    .015 1800070 1.100 1800380 1.200 1800071 1.250 1800072 1.300 1800090 1.000 1800091 1.100 .025 1800092 1.200 1800093 1.300 1800050 .625 .065 1800204 .875 .090 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.73 © Copyright Polaris Inc.

  • Page 560: Walker Evans Shock Valve Part Numbers - 7/16" I

    1.450 1800258 1.500 1800259 1.550 1801120 .600 1801115 .700 1801119 .800 1800260 .900 1800261 1.000 .015 1800262 1.100 1800263 1.200 1800264 1.300 1800265 1.450 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.74 © Copyright Polaris Inc.
  • Page 561 STEERING / SUSPENSIONS PART NUMBER SIZE THICKNESS 1800266 1.500 1800267 1.550 1800268 1.000 .090 (WASHERS) 1800269 1.100 1800270 1.250 1800271 1.300 .025 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.75 © Copyright Polaris Inc.

  • Page 562: Walker Evans Piston Valve Arrangement

    The rebound and compression valve stacks will always be positioned as shown in the illustration, regardless of how the shock assembly is installed on the snowmobile. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.76 © Copyright Polaris Inc.

  • Page 563: Walker Evans Piggyback Shock Ifp Depth

    Piggyback shocks, measure from the top of the reservoir to the Internal Floating Piston (IFP) using a Vernier Caliper. Reference the shock specification tables in this chapter for measurement (A). 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.77 © Copyright Polaris Inc.

  • Page 564: Walker Evans Piggy Back (Low Speed Adj.)

    STEERING / SUSPENSIONS WALKER EVANS PIGGY BACK (LOW SPEED ADJ.) WALKER EVANS PIGGYBACK SHOCK ASSEMBLY VIEW 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.78 © Copyright Polaris Inc.
  • Page 565 End Cap / Service Port Replace service port assembly after fifth charging. Snap Ring Clicker Stud 3& Clicker Piston Clicker Bolt Slotted Spring Retainer Snap Ring Washer 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.79 © Copyright Polaris Inc.

  • Page 566: Walker Evans Piggyback Shock - Disassembly

    2. Remove the spring and spring retainers. 3. Remove the shock bushings and spacer. 6. Depressurize the shock by installing the gas fill tool into the bleed port. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.80 © Copyright Polaris Inc.
  • Page 567 Place shock back into vise. 14. Remove the shock from the vise and pour residual shock oil into an approved container. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.81 © Copyright Polaris Inc.
  • Page 568 Discard the O-ring. 17. Remove the piston valve and compression valve stack from the shock rod. Remove the bearing cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.82 © Copyright Polaris Inc.
  • Page 569 25. Discard all O-rings and wear bands from removed components. 26. Clean the shock components with parts cleaner. Blow dry with compressed air. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.83 © Copyright Polaris Inc.

  • Page 570: Walker Evans Piggyback Shock - Assembly

    Clicker Assembly Nut: 10 ft-lbs (14 Nm) Clicker Adjuster Assembled: 3. Install a new O-ring onto the clicker stud. Reinstall back into body cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.84 © Copyright Polaris Inc.
  • Page 571 Reinstall reservoir tube and O- ring. 6. Reinstall the snap ring. 9. If the shock is equipped with a needle and it was removed, reinstall the needle assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.85 © Copyright Polaris Inc.
  • Page 572 Shock Body Cap / Tube: 30 ft-lbs (41 Nm) 12. Assemble the bearing cap. Coat a new bearing cap O-ring with new shock oil. Install into bearing cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.86 © Copyright Polaris Inc.
  • Page 573 The side of valve with the greater number of relief ports is the rebound side. Install with rebound side facing up. 17. Install a new O-ring onto the bearing cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.87 © Copyright Polaris Inc.
  • Page 574 25. After the air has been bled, set the IFP so it is approximately 1.5" (3.8 cm) from the top of the reservoir. Remove the T-handle tool and install the O- ring and bleed screw. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.88 © Copyright Polaris Inc.
  • Page 575 31. Verify there is shock oil above the IFP in the reservoir. 32. Slowly pull the shock rod out till the shock is fully extended. 33. Remove the bleed screw and O-ring from the IFP. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.89 © Copyright Polaris Inc.

  • Page 576: Walker Evans Piggy Back (High/Low Speed Adj.)

    7. Loosen and remove the bearing cap from the shock. 3. Insert safety needle carefully and depressurize the shock. 8. Remove the used oil from the shock body. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.90 © Copyright Polaris Inc.
  • Page 577 Inspect the valve shims for damage and 11. Remove and discard the lock nut. Remove the replace as required. rebound valve stack as an assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.91 © Copyright Polaris Inc.
  • Page 578 17. Remove the bearing cap O-ring and discard. The body / reservoir cap. spring is held in place with set screws. Remove the set screws to remove the spring. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.92 © Copyright Polaris Inc.
  • Page 579 Discard the brass ball. 3. Apply heat to the area where the eyelet screws onto the rod. Remove the eyelet from the rod. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.93 © Copyright Polaris Inc.

  • Page 580: Walker Evans Piggyback Shock Assembly

    7. Inspect all components for wear and replace as required. Clean parts with parts cleaner and blow dry using compressed air or lint free towel. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.94 © Copyright Polaris Inc.
  • Page 581 Install the rebound piston on rebound rod into the bottom of the shock rod. 5. Install a new bearing cap O-ring. Install the spring. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.95 © Copyright Polaris Inc.
  • Page 582 The brass ball and set screw are designed to crush against the rod threads and prevent the rod from loosening. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.96 © Copyright Polaris Inc.
  • Page 583 6. If the jounce bumper was removed from the rod, reinstall it. 9. Remove the 5/8″ shock rod seal protector. Install the rebound valve stack and a new lock nut. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.97 © Copyright Polaris Inc.
  • Page 584 2. Hold the plug and turn the high speed adjuster main body counter-clockwise to install the plug. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.98 © Copyright Polaris Inc.
  • Page 585 TORQUE High / Low Speed Adjuster Torque: 10 ft-lbs (14 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.99 © Copyright Polaris Inc.
  • Page 586 Install IFP bleeder screw, do not tighten. 9. With the cylinder head assembly pushed down against the valve piston, dip the piston assembly in shock oil. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.100 © Copyright Polaris Inc.
  • Page 587 10 ft-lbs (14 Nm) 17. Charge the shock to the specified pressure. 18. Clean the shock of all oil reside and check for any leaks. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.101 © Copyright Polaris Inc.
  • Page 588 STEERING / SUSPENSIONS 19. Install button screw onto the reservoir cap. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 8.102 © Copyright Polaris Inc.
  • Page 589 ............9.36 BULKHEAD CLIP INSTALLATION, RIGHT 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 590: General Information

    (20 °C). Do not move the snowmobile outside (colder temperature) while the adhesive is curing. • Do not place the vehicle into service until the adhesive has completely cured (24 hours). 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 591: Chassis Assembly Views

    26 ft-lbs (35 Nm) Replace with new when removed. Right Bulkhead Clip Assembly Chaincase Housing Fastener (M8 x 1.25 x 45) 26 ft-lbs (35 Nm) Replace with new when removed. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 592: Left Bulkhead / Side Support Assembly View

    26 ft-lbs (35 Nm) Replace with new when removed. Flanged Nut (M8 x 1.25) Nut Plate 26 ft-lbs (35 Nm) Replace with new when removed. Side Support Cross Tube Left Bulkhead Clip 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 593: Clutch Guard / Foot Supports Assembly View

    CHASSIS CLUTCH GUARD / FOOT SUPPORTS ASSEMBLY VIEW Flange Nuts (M6 x 1.0) Right Footrest 7.5 ft-lbs (10 Nm) Rivets Left Footrest Clutch Guard 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 594: Over Structure Assembly View

    Spacer Tube Airbox Support Bracket Rear Frame (Over Structure) Rivet Flange Nut (M6 x 1.0) Front Frame (Over Structure) 9 ft-lbs (12 Nm) Rivet Foil 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 595: Recoil Roller Assembly View

    CHASSIS RECOIL ROLLER ASSEMBLY VIEW Pulley Tube Support Rope Guide Pulley Support Roller Bushing Recoil Roller Fastener Recoil Roller Pulley Support Fasteners 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 596: Tunnel Assembly View

    9 ft-lbs (12 Nm) Pop-Rivet Front Running Board Support Acorn Nut (M5) Nut (M6 x 1.0) 16 in-lbs (1.8 Nm) 9 ft-lbs (12 Nm) Toe Stop Rivet Closeoff 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 597: Body Assembly Views

    CHASSIS BODY ASSEMBLY VIEWS HOOD ASSEMBLY VIEW Hood 1/4 Turn Stud Retainer 1/4 Turn Retainer Upper Hood Vent Middle Screen Storage Lid Front Screen 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 598: Hood Foam Assembly View

    RH Lower Hood Foam Center Hood Foam Round Patch Fabric RH Upper Hood Foam LH Lower Hood Foam Kit (All Pieces Included) Center Lower Hood Foam 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.10 © Copyright Polaris Inc.

  • Page 599: Nosepan / Fender Assembly View

    NOSEPAN / FENDER ASSEMBLY VIEW Push Rivet Washer Right Fender Left Fender Rubber Strap Exhaust Outlet Boot Fasteners (M5 x 0.8 x 15) Nosepan 36 in-lbs (4 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.11 © Copyright Polaris Inc.

  • Page 600: Side Panel Assembly View

    CHASSIS SIDE PANEL ASSEMBLY VIEW Right Side Panel Latch Grommets Left Side Panel Washer 1/4 Turn Latch 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.12 © Copyright Polaris Inc.

  • Page 601: Console Assembly View

    CONSOLE ASSEMBLY VIEW Console Recoil Bracket Foam, Console – LH Screws (10 x 5/8) Foam, Console – RH Upper Plastic Rivets Foam, Console – RH 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.13 © Copyright Polaris Inc.
  • Page 602 3. When the console is mated correctly with the air intake plenum, the bottom of the console will rest in a dedicated recess molded into the fuel tank here 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.14 © Copyright Polaris Inc.

  • Page 603: Seat Assembly View

    CHASSIS SEAT ASSEMBLY VIEW Seat Assembly Washer Seat Support Seat Support Fasteners 7 ft-lbs (10 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.15 © Copyright Polaris Inc.

  • Page 604: Bumper Assemby Views

    FRONT BUMPERS STOCK BUMPER Flange Nut Front Bumper 7 ft-lbs (10 Nm) Screw Bolt 7 ft-lbs (10 Nm) Pipe / Chassis Bracket Lower Bumper Support 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.16 © Copyright Polaris Inc.

  • Page 605: Monarch Bumper

    CHASSIS MONARCH BUMPER Flange Nut Front Bumper 7 ft-lbs (10 Nm) Screw Bolt 7 ft-lbs (10 Nm) Pipe / Chassis Bracket Lower Bumper Support 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.17 © Copyright Polaris Inc.

  • Page 606: Rear Bumper / Closeoff Assembly View

    17 ft-lbs (23 Nm) Apply Loctite 263 Acorn Nuts Closeoff Taillight Cover Rivets Nuts Snow Flap 17 ft-lbs (23 Nm) Apply Loctite 263 Bumper Cap Rivets 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.18 © Copyright Polaris Inc.

  • Page 607: Bonded Component Service

    9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.19 © Copyright Polaris Inc.

  • Page 608: Bonded Component Service

    NOTICE New bonded parts should be washed with warm, soapy water and allowed to dry completely before the adhesive is applied. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.20 © Copyright Polaris Inc.
  • Page 609 CHASSIS ADHESIVE APPLICATOR KITS The Lord 406/19 Repair Kit (2204171) is supplied with an Polaris offers a repair kit, individual adhesive cartridges, adapter sleeve and a plunger adapter designed to work and replacement needle packs. It is recommended to with a standard size, caulk gun. A smooth rod-type caulk leave the product unopened until needed.
  • Page 610 2. Attach a new mixer needle to the cartridge. Do not manually mix the adhesive and accelerator. Always use a mixing needle to apply the adhesive. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.22 © Copyright Polaris Inc.

  • Page 611: Adhesive Application Patterns

    CHASSIS ADHESIVE APPLICATION PATTERNS Reference the following illustrations showing the exact patterns for each bonded component when applying the adhesive. BULKHEAD FLOOR 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.23 © Copyright Polaris Inc.
  • Page 612 CHASSIS CHAINCASE REAR TABS 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.24 © Copyright Polaris Inc.
  • Page 613 CHASSIS RIGHT BULKHEAD CLIP / CHAINCASE SUPPORT SPAR MATING SURFACE 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.25 © Copyright Polaris Inc.
  • Page 614 CHASSIS RIGHT BULKHEAD CLIP FRONT CORNER 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.26 © Copyright Polaris Inc.
  • Page 615 CHASSIS LEFT SUPPORT MATING SURFACE 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.27 © Copyright Polaris Inc.
  • Page 616 CHASSIS LEFT BULKHEAD CLIP / SUPPORT SPAR MATING SURFACE 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.28 © Copyright Polaris Inc.
  • Page 617 CHASSIS LEFT BULKHEAD CLIP FRONT CORNER 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.29 © Copyright Polaris Inc.
  • Page 618 CHASSIS FRONT BULKHEAD COOLER 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.30 © Copyright Polaris Inc.

  • Page 619: Bulkhead Floor Plate Removal

    Installation page 4. Insert the blade of a flat blade screwdriver into one of the plate’s corners. Pry the plate away from the chassis. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.31 © Copyright Polaris Inc.

  • Page 620: Front Tunnel Bulkhead Cooler Removal

    4. Remove the cooler from the chassis. 5. Remove any residual adhesive from the tunnel and/or cooler if it is going to be re-used. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.32 © Copyright Polaris Inc.

  • Page 621: Support Brace Removal, Right

    Do not apply heat to areas of adhesive where bond line separation is not needed. Doing so will require removing the part, removing adhesive, and then re-applying new adhesive. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.33 © Copyright Polaris Inc.

  • Page 622: Bulkhead Clip Installation, Left

    • Tie rod boot NOTICE Allow the adhesive to cure for 24 hours at 68° F (20° C) before placing the snowmobile back into service. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.34 © Copyright Polaris Inc.

  • Page 623: Bulkhead Clip Removal, Right

    3. Remove the tie rod boot and tie-rod if not already removed. 4. Wearing heat resistant gloves, use a propane gas torch to heat the adhesive between the two components 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.35 © Copyright Polaris Inc.

  • Page 624: Bulkhead Clip Installation, Right

    • Engine assembly (See Engine Installation page NOTICE Allow the adhesive to cure for 24 hours at 68° F (20° C) before placing the snowmobile back into service. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 9.36 © Copyright Polaris Inc.
  • Page 625 ............... . 10.39 BATTERY LOAD TEST 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.1 © Copyright Polaris Inc.
  • Page 626 ..................10.72 PBR OVERVIEW 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.2 © Copyright Polaris Inc.
  • Page 627 ..............10.101 THUMB WARMER DIAGNOSTICS 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.3 © Copyright Polaris Inc.
  • Page 628 ..............10.103 12V ACCESSORY RCA ADAPTER 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.4 © Copyright Polaris Inc.

  • Page 629: General Information

    When disconnecting the battery, remove the negative (-) black cable first, and then remove the positive (+) red cable. Reverse steps when connecting battery. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.5 © Copyright Polaris Inc.

  • Page 630: Diagnostic Power Connector

    If fuel system is leaking or open, disconnect fuel pump prime connection ‘before’ powering up critical power connection 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.6 © Copyright Polaris Inc.

  • Page 631: Electrical Harness

    Diagnostic Connector TPS Sensor EGT Sensor Ground Speed Sensor 2& Diagnostic Power Ground Speed Capacitor Oil Level Electric Start Load Center Fuel Sensor EV Actuator 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.7 © Copyright Polaris Inc.

  • Page 632: Chassis Harness Routing / Retention

    BATTERY / ELECTRICAL CHASSIS HARNESS ROUTING / RETENTION ROUTING 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.8 © Copyright Polaris Inc.
  • Page 633 BATTERY / ELECTRICAL RETENTION POINTS • Secure the harness at the points shown below. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.9 © Copyright Polaris Inc.

  • Page 634: Handlebar Connectors

    BATTERY / ELECTRICAL HANDLEBAR CONNECTORS Tether Switch Soft Stop Thumbwarmer RCA Accessory Power Reverse Switch Left Handwarmer Brake Switch Right Handwarmer Hard Stop 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.10 © Copyright Polaris Inc.

  • Page 635: Handlebar Harness Locations

    All wiring is routed on the front side of the handlebar. Retention straps should be indexed down or toward the outside of the handlebar. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.11 © Copyright Polaris Inc.

  • Page 636: Handlebar Harness Retention

    All wiring is routed on the front side of the handlebar. Retention straps should be indexed down or toward the outside of the handlebar. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.12 © Copyright Polaris Inc.

  • Page 637: Rear Harness Routing / Retention

    BATTERY / ELECTRICAL REAR HARNESS ROUTING / RETENTION ROUTING NOTICE Route the rear harness as shown above to avoid harness damage. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.13 © Copyright Polaris Inc.
  • Page 638 BATTERY / ELECTRICAL RETENTION POINTS NOTICE Secure the rear harness at the retention points 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.14 © Copyright Polaris Inc.

  • Page 639: Egt Sensor Routing

    2. Take up some slack in the EGT sensor wire harness and secure to the load center bracket with a routing clip 3. Connect the EGT sensor connector to the main harness connector. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.15 © Copyright Polaris Inc.
  • Page 640 4. Take up the EGT sensor wire harness slack and secure the slack, EGT sensor connector, and main harness with a panduit strap NOTICE Orientation of panduit strap should be pointing down like shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.16 © Copyright Polaris Inc.

  • Page 641: Speed Sensor Harness Routing (Chaincase)

    The recoil roller and bracket is removed in the images. The harness should be routed under and behind the recoil rope and secured to the inside of the bracket. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.17 © Copyright Polaris Inc.

  • Page 642: Speed Sensor Harness Routing (Quick Drive)

    The recoil roller and bracket is removed in the images. The harness should be routed under and behind the recoil rope and secured to the inside of the bracket. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.18 © Copyright Polaris Inc.

  • Page 643: Knock (Det) Sensor Harness Routing

    4. Secure the knock (DET) sensor connector and harness slack to the main harness with a panduit as shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.19 © Copyright Polaris Inc.

  • Page 644: Engine Coolant Temperature (Ect) Sensor Harness Routing

    2. The ECT sensor jumper harness should route upward. Connect the ECT jumper harness connector to the main harness connector. NOTICE Ensure the ECT sensor jumper harness slack is secured with a panduit strap as shown. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.20 © Copyright Polaris Inc.

  • Page 645: Ignition Coil Harness Routing

    3. Route the PTO coil harness down to the spark plug support and secure the harness with a panduit strap 4. Install spark plug cap on PTO side spark plug. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.21 © Copyright Polaris Inc.
  • Page 646 1. Connect the MAG coil connector (white connector) from the main harness to the coil pack. Connect the PTO coil connector (blue connector) from the main harness to the coil pack. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.22 © Copyright Polaris Inc.

  • Page 647: Fuel Injector Harness Routing

    3. Route the fuel injector upward towards the coolant bottle and secure on the outside of the hose/electrical support with a panduit 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.23 © Copyright Polaris Inc.
  • Page 648 Secure the fuel injector harness connector to the inside of the connector placement bracket using the Christmas tree clip on the connector. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.24 © Copyright Polaris Inc.

  • Page 649: Oil Pump Jumper Harness Routing

    Secure the oil pump jumper harness connector to the inside of the connector placement bracket using the Christmas tree clip on the connector. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.25 © Copyright Polaris Inc.

  • Page 650: Load Center

    Power Out Coil Low Power In ECM Power 10A Fuse Power Out Power In Headlight 10A Fuse Power Out EV Control 5A Fuse Power In 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.26 © Copyright Polaris Inc.
  • Page 651 Power Out Power In Rear Acc 10A Fuse Power Out Power In Accessory 10A Fuse Power Out Power In Drive Chassis 10A Fuse Power Out 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.27 © Copyright Polaris Inc.

  • Page 652: Relay / Fuse Details

    RD / WH Fused Drive Chassis Power Drive Chassis 10A Fuse Busbar Chassis Load Center Bus — Not Applicable Fan 10A Breaker — Not Applicable 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.28 © Copyright Polaris Inc.

  • Page 653: Load Center Location

    The load center is located on a bracket secured to the front cross tube. NOTICE To access the fuse box, remove the side panels and hood. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.29 © Copyright Polaris Inc.

  • Page 654: Battery

    5. Disconnect the red (positive) cable last. 6. Pull the fender away from the battery compartment to gain better access. 7. Remove the Battery hold down strap 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.30 © Copyright Polaris Inc.

  • Page 655: Battery Installation

    1. Ensure that the battery is fully charged. 2. Carefully place the battery in the battery bracket. 3. Place the battery shield on the battery bracket. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.31 © Copyright Polaris Inc.

  • Page 656: Battery Identification

    8. Secure the right fender using the plastic rivet. 9. Reinstall the console using the two plastic rivets. 10. Reinstall the side panel. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.32 © Copyright Polaris Inc.

  • Page 657: Battery Activation (Electric Start Models Only)

    ACTIVATION 1. Remove the sealing strip on top of the battery. IMPORTANT Do not remove the sealing strip until ready to activate the battery. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.33 © Copyright Polaris Inc.
  • Page 658 4. Press down evenly to break the foil seals and allow electrolyte to flow into the battery. NOTICE Air bubbles will begin to rise, indicating the flow of electrolytes. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.34 © Copyright Polaris Inc.
  • Page 659 7. Allow battery to stand for 1-2 hours. This allows the electrolyte to permeate the plates for optimal performance. 8. Charge the battery for 1 hour using a Polaris recommended charger. Polaris recommends using battery charger (PN 2830438), Battery MINDer 2012.

  • Page 660: Dry Shipped Agm Battery Charging And Testing

    To charge a Dry Shipped AGM battery, do the following: maintain the Absorbent Glass Mat (AGM) battery with the BatteryMINDer® 2012 AGM - 2 AMP charger. 1. Charge the battery for 1 hour using the Polaris recommended charger. BatteryMINDer® 2012 AGM - 2 AMP battery charger...

  • Page 661: Agm Low Maintenance Battery Charging

    AGM batteries discharged to a voltage of 3 volts or less CHARGING may not be recognized by the recommended automatic Polaris recommends using the BatteryMINDer® 2012 battery charger. (The minimum voltage threshold AGM - 2 AMP battery charger to charge and maintain recognized by other battery chargers may be as high as Absorbent Glass Mat (AGM) batteries.

  • Page 662: Agm Low Maintenance Battery Testing

    If the tester indicates a test result other than “Good Battery,” follow the steps below before replacing the Authorized Polaris dealers / distributors are required to battery: use the conductance analyzer when testing 12V Polaris batteries.

  • Page 663: Battery Open Circuit Voltage Test (Ocv)

    9.5 volts. If the beginning voltage is 12.6 volts or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.39 © Copyright Polaris Inc.

  • Page 664: Battery Tender Port

    NOTICE charger using the battery tender port Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal discharge. Battery tenders can be...

  • Page 665: Digital Instrument Cluster / Security

    Always allow the engine to properly warm to normal operating temperature before applying full throttle. Polaris Interactive Digital Display: If the snowmobile is equipped with a Polaris Interactive Digital Display (PIDD), the screen will alert the rider when the cold engine protection mode is active.

  • Page 666: Overview

    The instrument cluster is powered by the RED/WHT chassis power 12 VDC circuit. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.42 © Copyright Polaris Inc.

  • Page 667: Rider Information Center

    4. Odometer/Engine Hour Display - This area displays the odometer, Trip A, Trip B and engine hours. To change the display, see Odometer/Engine Hour Display Area page 10.43. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.43 © Copyright Polaris Inc.

  • Page 668: Indicator Lamps

    REVERSE INDICATOR The reverse indicator flashes when the transmission is in reverse. SECURITY INDICATOR The security indicator illuminates when the security system is activated. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.44 © Copyright Polaris Inc.

  • Page 669: Mode / Set Switch

    Fuel Level - VT/WHT (If applicable) LH Set Switch - WHT/BLK LH Mode Switch - WHT/RED NOTICE CAN wires are twisted together and must remain twisted to prevent interference. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.45 © Copyright Polaris Inc.

  • Page 670: Diagnostic Display Mode

    PLAYBACK FUNCTION The diagnostic display mode is for informational The playback function allows the rider to record and play purposes only. Your POLARIS dealer can perform all back engine speed, vehicle speed and throttle position major repairs. sensor information for up to three minutes.

  • Page 671: Fuel Selector Mode

    Options Menu. 6. Press and release the SET button to exit. The fuel type being displayed is the active fuel type. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.47 © Copyright Polaris Inc.

  • Page 672: Interactive Digital Display (Pidd) Connector Pinouts

    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 MANUALS WEBSITE: http://www.polaris.com/en-us/company/owners-manual.

  • Page 673: Interactive Digital Display (Pidd) Hood Bracket

    The PIDD hood bracket kit contains one bracket , two screws , and detailed installation instructions. Torque screws to specification. TORQUE PIDD Bracket Screws: 6 ft-lbs (8 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.49 © Copyright Polaris Inc.

  • Page 674: Idd - Usb Flash Drive Recommendations

    PIDD USER NOTES / TROUBLESHOOTING RECOMMENDATIONS User Notes: Polaris recommends using a Scandisk® or similar USB ORV Icons Displayed on Screen: flash drive with a minimum of 4 GB available memory. • PIDD has not been initialized with the vehicle’s ECU.

  • Page 675: Pidd - Using A Service Battery

    8. The PIDD will go into bootloader mode. Use the PIDD key buttons to select the update file on the flash drive and install. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.51 © Copyright Polaris Inc.

  • Page 676: 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 677 This concern is caused by mis-formatted or corrupted memory which can be caused by a failed or corrupted software update file download. Perform PIDD Reset Procedure and Update Procedure. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.53 © Copyright Polaris Inc.

  • Page 678: Interactive Digital Display (Pidd) Reset And Update Procedure

    BATTERY / ELECTRICAL ERROR 4: PIDD DISPLAY IS WHITE WITH NO TEXT 1. Log on to: https://ridecommand.polaris.com/en-us/ home 2. Download the most current vehicle TRAILS + MAP UPDATE .zip file. 3. Extract the contents of the TRAILS + MAP UPDATE .

  • Page 679: Gps Receiver Troubleshooting

    When this occurs, the GPS receiver is either not receiving power, missing CAN communications, or the receiver is faulty. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.55 © Copyright Polaris Inc.
  • Page 680 7. If either of the CAN data signals are out of range, but Sensor Ground (-) not 0, check possible ECU or PIDD CAN communication failures. Voltage Supply (B+) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.56 © Copyright Polaris Inc.

  • Page 681: Security System - Enable

    ECU, Digital Wrench will display “Security Setting Already Enabled.” Click on the red “X” to return to the main menu. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.57 © Copyright Polaris Inc.
  • Page 682 15. After the reflash process is complete, cycle the power by disconnecting the Chassis Power-Up Harness, waiting for 10 seconds, and then re-connecting the power. Click the FINISH button. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.58 © Copyright Polaris Inc.

  • Page 683: Security System: Disable Procedure

    MIL LEDs will flash. 6. After the reset pass code process is complete, click on the RETURN button to return to the main screen. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.59 © Copyright Polaris Inc.

  • Page 684: Security System - Axys User Notes

    Next-Gen Service Power Harness to • Security system activation requires an authorized access Vehicle Security Settings on the IDD. Security Polaris dealer using Digital Wrench to enable security cannot be accessed if the ECU is not powered. in the ECU.

  • Page 685: Security System (Ignition Lock System)

    2nd digit. SYSTEM) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended.
  • Page 686 5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit. 6. Press and release the SET button to increase the 3rd digit. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.62 © Copyright Polaris Inc.
  • Page 687 Your new code is now set. The system is NOT locked. 8. Record your new security code in a safe place for future reference. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.63 © Copyright Polaris Inc.

  • Page 688: Locking The System With Your Personal Security Code

    7. Press and release the SET button to increase the 2nd digit. 8. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.64 © Copyright Polaris Inc.

  • Page 689: Unlocking The System With Your Personal Security Code

    5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit. 6. Press and release the SET button to increase the 3rd digit. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.65 © Copyright Polaris Inc.

  • Page 690: Changing To A New Security Code

    Allows user to change security code. While SECURITY OFF is shown on the information display area, simultaneously Press and hold the MODE and SET button. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.66 © Copyright Polaris Inc.

  • Page 691: Idd Security: Locking

    4. Select Lock. 6. After the correct code has been entered, the following screen will appear when the engine is running (ECU powered). 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.67 © Copyright Polaris Inc.

  • Page 692: Idd Security: Unlocking

    1. Start the engine and allow the IDD to boot. 2. Select the IDD Main Menu. 3. Select Vehicle Settings. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.68 © Copyright Polaris Inc.
  • Page 693 7. Record the new security code in a safe place (Owner’s Manual or Customer R.O.) for future reference. NOTICE If an incorrect pass code is entered, the following screen will appear. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.69 © Copyright Polaris Inc.

  • Page 694: Led Headlight / Tail Light

    Reference the above image when determining if all of the LEDs are illuminating and when each set receives power. If an LED is not illuminating, replace the headlight assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.70 © Copyright Polaris Inc.

  • Page 695: Led Tail Light Overview / Service

    (Pins A and C). If battery voltage is present at either connector, replace the component that will not turn on and re-test. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.71 © Copyright Polaris Inc.

  • Page 696: Power Boosting Regulator (Pbr)

    Connectors may be difficult to remove. Do not remove 3-phase power to ground. connectors by pulling the wires or damage may occur. TORQUE PBR Mounting Fasteners: 6 ft-lbs (8 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.72 © Copyright Polaris Inc.

  • Page 697: Pbr Details

    Chassis Power #1 Splice Red / White Chassis Power Injector Power Splice Injector Power Sense Red / Dark Blue Critical Power #2 Splice Critical Power 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.73 © Copyright Polaris Inc.

  • Page 698: Pbr Circuit

    The PBR is a smart regulator that is CAN capable. If the PBR has an issue it will report a Diagnostic Trouble Code. NOTICE Using the trouble codes listed below, follow the primary course of action to diagnose the issue. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.74 © Copyright Polaris Inc.

  • Page 699: Pbr Diagnostic Trouble Code List

    Check sled for Condition no engagement loads on ECU (injector) P1607 ECU overload 520367 electrical longer exists of PBR power line voltage modifications connectors 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.75 © Copyright Polaris Inc.
  • Page 700 Test battery connectors battery with Polaris tester Check Chassis Chassis Condition no engagement P1610 520369 voltage above None overvoltage longer exists of PBR connectors 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.76 © Copyright Polaris Inc.

  • Page 701: Pbr Update / Replacement

    If using a stand-alone service battery, do not place the battery in the tunnel footwells. Place the battery on the floor next to the engine compartment. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.77 © Copyright Polaris Inc.

  • Page 702: Stator

    BATTERY / ELECTRICAL STATOR STATOR CIRCUIT / ARCHITECTURE 3-Phase AC Coils Crankshaft Position Sensor - 2 Crankshaft Position Sensor - 5 Tooth Tooth 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.78 © Copyright Polaris Inc.

  • Page 703: Stator Testing

    ‘leg’ of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3). 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.79 © Copyright Polaris Inc.

  • Page 704: Stator Harness Routing

    4. Route the stator harness upward along the air box and secure to the routing clip on the air box. Connect the 3 pin connector to the PBR and the 6 pin connector to the main harness. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.80 © Copyright Polaris Inc.

  • Page 705: Ferrite Suppressor

    This suppressor reduces high frequency noise on ECU CPS input circuit. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.81 © Copyright Polaris Inc.

  • Page 706: Controllers / Converters

    E-VES system or if the EV Learn Procedure fails due to insufficient battery voltage and the battery is suppling at least 12.5 volts. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.82 © Copyright Polaris Inc.

  • Page 707: Electronic Oil Pump - Resistance Check

    Place the meter probes on pins 1 and 2 on the oil pump connector. Compare the measurement with specification. Electronic Oil Pump Resistance: 1.8Ω +/- 15% 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.83 © Copyright Polaris Inc.

  • Page 708: Switches

    If both of the original keys are lost, the ignition switch PIN CONTINUITY assembly must be replaced. SWITCH CONTINUITY FUNCTION POSITION BETWEEN Down BK/BLU and Shutdown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.84 © Copyright Polaris Inc.

  • Page 709: Throttle Release Switch

    Released Above Idle The tether switch connects to the main wire harness at the handlebar wire connector location under the upper steering post assembly. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.85 © Copyright Polaris Inc.

  • Page 710: Fuses / Diodes / Resistors

    The circuit breaker will reset after voltage to the PIDD and GPS puck when the ignition key it is allowed to cool. is in the ON position. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.86 © Copyright Polaris Inc.

  • Page 711: Relays

    EV Actuator GY / YE Relay Control NOTICE If relay is removed for service, re-install with a drop of NyoGel on each connector blade. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.87 © Copyright Polaris Inc.

  • Page 712: Starter Solenoid

    Apply battery voltage to the connector terminals. Verify there is continuity between the two red cable posts. If the solenoid does not pass either test, replace the solenoid. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.88 © Copyright Polaris Inc.

  • Page 713: Capacitors

    Reference the meter’s owner’s manual for details. 4. The reading should match the capacitance specification for the capacitor. If it does not, replace the capacitor. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.89 © Copyright Polaris Inc.

  • Page 714: Electric Start / Battery Bracket

    7 ft-lbs (10 Nm) Starter Motor Electric Start Lower Tube Bracket Gear Clamp Electric Start Upper Tube Bracket Do not over-tighten / strip teeth Starter Flex Shaft 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.90 © Copyright Polaris Inc.

  • Page 715: Starter Motor / Flex Drive Service

    • Drive belt • Drive clutch • Y-pipe 5. Remove the fasteners attaching the pinion assembly to the engine. 8. Remove the starter motor gear clamp 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.91 © Copyright Polaris Inc.
  • Page 716 The red (+) starter motor power cable connects to . Attach the black (-) battery ground cable to the post and install washer lock nut 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.92 © Copyright Polaris Inc.

  • Page 717: Battery Bracket Assembly

    22 ft-lbs (30 Nm) 36 in-lbs (4 Nm) Battery Box Battery Heat Shield D-ring Strap Seal-Bulb Battery Box Bracket Fasteners Battery 22 in-lbs (2.5 Nm) 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.93 © Copyright Polaris Inc.

  • Page 718: Electric Start Harness Routing

    4. The electric start harness / battery bullet connector wire should be routed along the battery box bracket and secured in the edge clip / panduit in the location shown . The edge clip / panduit should retaining the battery tender fuse. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.94 © Copyright Polaris Inc.

  • Page 719: Battery Harness Routing

    4. Secure the positive and negative battery cables together with the edge clip / panduit in location shown NOTICE The white tape signifies a retention point. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.95 © Copyright Polaris Inc.
  • Page 720 5. Route the positive and negative battery cables under the battery tray and secure together with the edge clip / panduit in location shown NOTICE The white tape signifies a retention point. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.96 © Copyright Polaris Inc.
  • Page 721 7. Connect the negative battery cable to the negative starter terminal 8. Secure the positive and negative battery cables together with the panduit in location shown NOTICE The white tape signifies a retention point. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.97 © Copyright Polaris Inc.
  • Page 722 / panduit in the location shown 3. Complete routing by connecting the electric start harness battery bullet connector to the female bullet connector as shown 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.98 © Copyright Polaris Inc.

  • Page 723: Circuit Diagrams

    Diagrams. These additional colored circuit diagrams are intended for online service manual use only and will not be available in the paper manual. The main wiring diagram(s) will still be found in the back of the paper manual. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.99 © Copyright Polaris Inc.

  • Page 724: Next-Gen Service Power Harness Circuit Diagram

    ECU power Next-Gen Service Power Harness Circuit: Click circuits when connected to a 12V stand-alone automotive type Here. battery with the Chassis Power-Up Harness. 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.100 © Copyright Polaris Inc.

  • Page 725: Hand / Thumb Warmers

    • If any of either the hand or thumb warmer switches are not working, replace the left-hand control and re-test. THUMB WARMER DIAGNOSTICS The thumb warmer on all Polaris snowmobiles is a thermistor-type warming element pad. This means its resistance will change based on temperature.

  • Page 726: Hand Warmer Diagnostics

    BATTERY / ELECTRICAL HAND WARMER DIAGNOSTICS FULL LENGTH HAND WARMERS A common misconception with Polaris hand warmer Full length hand warmers differ from standard length elements is the higher resistance circuit is the high warmers in that they are cut to match the bend of the temperature element.

  • Page 727: Accessory Power Connectors

    12V RECEPTACLE / JUMPER HARNESS PART NUMBER / REF. PLUGS INTO: DESCRIPTION 4010638 / 12V Jumper Harness Receptacle 2411352 / Receptacle Hood Harness Two Pin Plug Jumper Harness 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.103 © Copyright Polaris Inc.
  • Page 728 BATTERY / ELECTRICAL NOTES 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual 10.104 © Copyright Polaris Inc.
  • Page 729 Cleanfire Fuel Injection Brake Fluid Type ............2.39 Fuel Hose Quick Disconnect Fittings ......5.7 Brake Line Ignition Coil Packs ..........4.10 Brake Line Routing Overview ............... 4.6 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.1 © Copyright Polaris Inc.
  • Page 730 Vehicle Historical Information ........1.93 SKS ............... 3.134 Vehicle Identification Information ......1.116 Digital Wrench® Cooling Hose - Hot Side Routing / Retention ..........3.130 Polaris Mobile Digital Wrench® (PMDW) ....1.119 Cooling System Drive Belt Installation ............ 2.25, 7.11 Assembly Removal............2.24, 7.10 PRO-RMK ............
  • Page 731 Chassis Ground .............2.58 Removal............. 3.151 Circuit Breaker............. 10.86 Exhaust Gas Temperature (EGT) Connector Probing Guidelines......... 1.124 Sensor ..............4.7 Continuity / Resistance .......... 1.125 Exhaust Manifold 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.3 © Copyright Polaris Inc.
  • Page 732 Fuel Pump Specifications.........5.25 Fuel Tank Assembly View – RMK.......5.20 Fuel Tank Installation – RMK........5.23 Fuel Tank Removal – RMK ........5.21 Keys Fuel Type Selection 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.4 © Copyright Polaris Inc.
  • Page 733 Oil Level Sender ............. 10.84 Pre-Ride Inspection ..........2.7 Oil Pump Jumper Harness Pre-Season............2.8 Harness Routing ..........10.25 QuickDrive System ..........2.37 Oil Supply Hose 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.5 © Copyright Polaris Inc.
  • Page 734 Rear Bumper / Closeoff Locking the System ..........10.64 Assembly View ............9.18 Pass Code Reset ..........10.59 Rear Suspension ............2.47 Unlocking the System..........10.65 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.6 © Copyright Polaris Inc.
  • Page 735 Testing ............... 10.79 Two Piece Throttle Control Stator / Flywheel Installation ............8.42 Assembly View ............3.58 Steering Steering Post Installation ......... 8.11 Steering Post Removal ..........8.9 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.7 © Copyright Polaris Inc.
  • Page 736 Vehicle Identification Numbers Locations............... 1.5 Vehicle Information Tunnel Decal ............1.4 VIN Designation - 2017 + ..........1.4 Water Pump Assembly View ............3.60 Installation ............3.92 Removal...............3.89 9850060 R02 - 2020-2021 850 AXYS™ Long Track Snowmobile Service Manual IX.8 © Copyright Polaris Inc.
  • Page 737 HARNESS-MAIN,850 PREM PBR (ECU,CAN,GND) REVERSE SW OIL LEVEL SWITCH FURUKAWA FSW-C-6F-B (Black) (P/N 4012624) SUMITOMO CONSOLE JUMPER FILE NAME: 2414479-HARNESS MAIN 850 PREM RE.RSD 6180-2321 PBR (DC PWR) LEVEL SENDER OUTPUT WIRE COLOR LEGEND BEIGE (TAN) FUEL GAUGE *FUEL HEIGHT ('H') RESISTANCE E = ENGINE GROUND FURUKAWA QLW-A-B3F-B...
  • Page 740 HARNESS-ESTART SCHEMATIC CABLE/WIRE TERMINATION TABLE CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION WIRE COLOR LEGEND MAIN HARNESS GND SPLICE CHASSIS GND BEIGE (TAN) MAIN HARNESS GND SPLICE CHASSIS GND E = ENGINE GROUND BATTERY TENDER BLACK BATTERY TENDER FUSE, 10A...
  • Page 741 850 Long Track Jumper - Console Switches (2413927)
  • Page 742 PBR (ECU,CAN,GND) FURUKAWA FSW-C-6F-B (Black) CONSOLE JUMPER PBR (DC PWR) FURUKAWA QLW-A-B3F-B P4 P5 P6 A B C D E F G H J K P4 P5 P6 A B C D E F A B C D E F A B C D E F GC25 BN GC23 BN...
  • Page 743 SCHEMATIC CABLE/WIRE TERMINATION TABLE INDEX CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION Chassis Power - 850 Long Track VT/WH CHASSIS/HOOD FUEL PUMP FUEL LEVEL WH/BK CHASSIS/HOOD CONSOLE JUMPER SET SWITCH WH/RD CHASSIS/HOOD CONSOLE JUMPER MODE SW CHASSIS/HOOD ELECTRIC START...
  • Page 744 Critical Power - 850 Long Track PBR (ECU,CAN,GND) PROVIDES FUEL FURUKAWA FSW-C-6F-B (Black) CONSOLE JUMPER PUMP GROUND PBR (DC PWR) LEVEL SENDER OUTPUT FUEL GAUGE *FUEL HEIGHT ('H') RESISTANCE FURUKAWA QLW-A-B3F-B READING (REF) (BOTTOM OF FLOAT) (OHMS) PIN FUNCTION P4 P5 P6 WIRE COLOR LEGEND OIL PUMP (P/N 1204446) PWM OUT...
  • Page 745 Critical Power - 850 Long Track SCHEMATIC CABLE/WIRE TERMINATION TABLE INDEX CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION VT/WH CHASSIS/HOOD FUEL PUMP FUEL LEVEL WH/BK CHASSIS/HOOD CONSOLE JUMPER SET SWITCH WH/RD CHASSIS/HOOD CONSOLE JUMPER MODE SW CHASSIS/HOOD ELECTRIC START...
  • Page 746 ECU POWER CIRCUIT PBR (ECU,CAN,GND) FURUKAWA FSW-C-6F-B (Black) PBR (DC PWR) WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND FURUKAWA QLW-A-B3F-B BLACK LIGHT BLUE P4 P5 P6 DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN P4 P5 P6 A B C D E F NC = SWITCH NORMALLY CLOSED DARK GREEN...
  • Page 747 Next-Gen Service Power Harness SCHEMATIC CABLE/WIRE TERMINATION TABLE WIRE COLOR LEGEND CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION BEIGE (TAN) DIAGNOSTIC POWER ECU PWR ECU PWR E = ENGINE GROUND BLACK DIAGNOSTIC POWER CRITICAL PWR CRITICAL PWR LIGHT BLUE...

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