Polaris 850 MATRYX INDY XC 129 2021 Manual
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Polaris 850 MATRYX INDY XC 129 2021 Manual

Trail performance crossover snowmobile
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2021 650 / 850 Matryx Trail Performance /
Crossover 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 9850064 R03)
© 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 MATRYX INDY XC 129 2021

  • Page 1 Publication Printed October 2020 (PN 9850064 R03) © 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 Revised PBR Update / Replacement procedure 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 2021 650 / 850 Matryx Trail Performance / Crossover 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 :...

  • Page 7: Table Of Contents

    ..........1.40 DIGITAL WRENCH – SYSTEM CONFIGURATIONS 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 8 ............1.72 POLARIS MOBILE DIGITAL WRENCH® (PMDW) .

  • Page 9: Vehicle Identification

    The VIN (2) number is permanently stamped into the tunnel. The model number is embossed on the decal. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 10: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 11: Engine Serial Number Location

    ENGINE SERIAL NUMBER LOCATION The engine serial number is located on the identification label on the engine case next to the recoil cover. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 12: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual...

  • Page 13: 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 14: Model Specifications (Model Year 2021)

    650 INDY XC Launch Edition 137 S21TDP6RS / S21TDP6RE 850 INDY XC Launch Edition 137 S21TDP8RS / S21TDP8RE *850 INDY XC 137 SHOWN 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 15 *850 INDY VR1 137 SHOWN 650 SWITCHBACK ASSAULT 146 S21TLC6RS / S21TLC6RE 850 SWITCHBACK ASSAULT 146 S21TLC8RS / S21TLC8RE *850 SWITCHBACK ASSAULT 146 SHOWN 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 16 57 to 62.5 psi (393 to 431 kPa) Fuel Pressure <91 Octane Fuel Octane (R+M/2) (Non-Oxygenated) 10% Ethanol Mode 87/89/91+ (Up to 10% Oxygenated) Premium Mode (Non-Oxygenated) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.10 © Copyright Polaris Inc.
  • Page 17 Stud protection kits are designed to work with studded tracks that have no-greater than 0.375 in Stud Protection (0.953 cm) of stud penetration (that is, distance of the stud above the lug-tip). Polaris does not recommend studding anything above a 1.352 in (3.43 cm) Cobra track, although the stud protection will work on a 1.6 in (4.06 cm) Cobra track on 146 models.
  • Page 18 Temp.) Spark Plug NGK BPR9ES Spark Plug Gap .27 in (.70 mm) For clutch settings; See later in this chapter. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.12 © Copyright Polaris Inc.

  • Page 19: Clutch Settings (Model Year 2021)

    * Shaded cells indicate factory settings. Use 2 gram lighter shift weights when operating in temperatures above 40° F (5° C). Drive Clutch Bolt Torque: 80 ft-lbs (108 Nm) Re-torque after running engine. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.13 © Copyright Polaris Inc.

  • Page 20: 650 Switchback Assault 146 Clutch Settings

    * Shaded cells indicate factory settings. Use 2 gram lighter shift weights when operating in temperatures above 40° F (5° C). Drive Clutch Bolt Torque: 80 ft-lbs (108 Nm) Re-torque after running engine. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.14 © Copyright Polaris Inc.

  • Page 21: Misc Specifications And Charts

    EV Actuator Push / Pull (M8 x 1.25 x 80) 13 ft-lbs (18 N·m) threads prior to Cable Jam Nut installation. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.15 © Copyright Polaris Inc.
  • Page 22 Second Pass: 15 ft- lbs (20 N·m) Front Seat Mount 36 in-lbs (4 N·m) Fastener 28 ft-lbs (38 N·m) PFA Nut 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.16 © Copyright Polaris Inc.
  • Page 23 33 ft-lbs (45 N·m) Fastener 11 ft-lbs (15 N·m) Tie Rod Jam Nut Rear Bumper Fastener 4 ft-lbs (6 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.17 © Copyright Polaris Inc.
  • Page 24 Head / Bearing Cap Front Torque Arm Bumper 4 ft-lbs (6 N·m) Walker Evans Force Body Fasteners 45 ft-lbs (61 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.18 © Copyright Polaris Inc.
  • Page 25 Mounting Fasteners Fasteners Starter Motor Positive 8 ft-lbs (11 N·m) Upper Over Structure Cable Nut 12.5 ft-lbs (17 N·m) Fasteners 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.19 © Copyright Polaris Inc.
  • Page 26 ITEM TORQUE Starter Motor Pinion 7 ft-lbs (10 N·m) Fasteners Starter Motor / Clip 8 ft-lbs (11 N·m) Bracket Nuts 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.20 © Copyright Polaris Inc.

  • Page 27: Conversion Table

    = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.21 © Copyright Polaris Inc.

  • Page 28: Sae Tap / Drill Sizes

    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 7/16–14 3–4 2 3/4 7/16–20 25/64 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.22 © Copyright Polaris Inc.

  • Page 29: Decimal Equivalents

    14 mm = 0.5512″ 35/64 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″ 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.23 © Copyright Polaris Inc.

  • Page 30: Fuel Recommendation

    NEVER use unleaded fuels with an ethanol rating of E15 or E85 as severe engine damage may occur. * = When the type of fuel in the tank is unknown, Polaris recommends setting the fuel selector feature to IMPORTANT E10 – 87 ETHANOL mode.

  • Page 31: 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 32: General Diagnostics

    This Trouble Code Sets if the Fuel Pressure Sensor Circuit is below 0.1V. Can be caused by Damaged Wiring, a faulty Fuel Pressure Sensor or ECU / Connections. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.26 © Copyright Polaris Inc.
  • Page 33 This Trouble Code Sets if Ignition Coil 2 (PTO) Driver Circuit is Open. Open Can be caused by Damaged Wiring/Connections, a Faulty PTO Ignition Coil or ECU. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.27 © Copyright Polaris Inc.
  • Page 34 This Trouble Code Sets if the Regulator has detected Excessive High Voltage in the Chassis Circuit. Can be caused by damaged wiring, Regulator connections or Regulator. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.28 © Copyright Polaris Inc.
  • Page 35 45.0% when trying to achieve Mid position. This can be caused by a faulty Exhaust Valve Actuator, Broken Cable or Broken Exhaust Valve Assembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.29 © Copyright Polaris Inc.
  • Page 36 This Trouble Code Sets if the engine is in "Batch Fire Mode". Can be caused by Damaged Wiring, a faulty Crankshaft Sensor or ECU / Connections. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.30 © Copyright Polaris Inc.
  • Page 37 This trouble code sets if the water temperature changes by 20C in 1 sec Transition 3 times. Can be caused by Faulty Wiring, Faulty Water Temperature Sensor, or Faulty ECU. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.31 © Copyright Polaris Inc.

  • Page 38: Diagnostic Trouble Codes (Dtcs) - Left Hand Control

    Thumb heater driver Disable thumb Replace left hand C1111 Driver Internal condition does FET shorted heater control Short not exist 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.32 © Copyright Polaris Inc.

  • Page 39: Dc-Cfi Axys Diagnostics

    The PBR is a smart regulator that is CAN capable. If the PBR / System Power charging system has an issue it will report a Diagnostic Trouble Code. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.33 © Copyright Polaris Inc.

  • Page 40: 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 41 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 42: Digital Wrench Diagnostic Software

    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 43: Digital Wrench Software Version / Update

    Wrench® start-up screen. 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. Digital Wrench Update NOTICE You must already have the current version installed before adding an update.

  • Page 44: 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 45: Digital Wrench® Feature Map

    Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.39 © Copyright Polaris Inc.

  • Page 46: 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 47: General Information

    DTC. If guided diagnostic are available for the DTC, click on the icon to launch the feature. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.41 © Copyright Polaris Inc.

  • Page 48: Digital Wrench - Data List Display

    Click the folder button to display more preset data lists or create a customized data list. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.42 © Copyright Polaris Inc.

  • Page 49: Digital Wrench - Data Trigger (Freeze Frame)

    Enable or reset trigger recording In the example shown below, TPS Volts was selected as the Data Item Trigger. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.43 © Copyright Polaris Inc.

  • Page 50: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.44 © Copyright Polaris Inc.

  • Page 51: Digital Wrench - Output State Control Testing

    NOTICE Test items may appear different than what is shown and are vehicle-specific. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.45 © Copyright Polaris Inc.

  • Page 52: 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 53: Digital Wrench - Ecu / Injector / Oil Pump Replacement Menu

    3. Connect the Next-Gen Service Power Harness to the diagnostic connector on the wiring harness. Next-Gen Service Power Harness: PS-52573 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.47 © Copyright Polaris Inc.
  • Page 54 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.48 © Copyright Polaris Inc.
  • Page 55 2. Digital Wrench will notify the user that it is unable to or “Security Disabled”. Click on “Continue”. communicate with the ECU. Click on “Done / Continue”. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.49 © Copyright Polaris Inc.
  • Page 56 IMPORTANT Severe engine damage may occur if the wrong oil pump offset number code is entered. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.50 © Copyright Polaris Inc.

  • Page 57: Digital Wrench - Fuel Injector Replacement

    6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.51 © Copyright Polaris Inc.
  • Page 58 13. Click “Continue”. Repeat steps 7 – 11 to verify the correct fuel injector color is set in the ECU. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.52 © Copyright Polaris Inc.

  • Page 59: 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 60 14. Write the offset value on the ECU label for future reference. 11. On the following screen, select “Oil Pump Replacement”. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.54 © Copyright Polaris Inc.

  • Page 61: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.55 © Copyright Polaris Inc.
  • Page 62 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.56 © Copyright Polaris Inc.

  • Page 63: Oil Pump Enrichment Mode Timer Reset

    4. Connect one of the Chassis Power Up harness leads to the ECU PWR diagnostic test connector on the Next-Gen Service Power Harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.57 © Copyright Polaris Inc.

  • Page 64: Ev Actuator Learn Procedure

    Do not attempt to increase battery voltage by connecting batteries in series. EV actuator damage will occur if battery power supply exceeds 16 volts. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.58 © Copyright Polaris Inc.
  • Page 65 6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.59 © Copyright Polaris Inc.
  • Page 66 The actuator will also be heard moving back and forth as the ECU sets the travel limits. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.60 © Copyright Polaris Inc.

  • Page 67: Fuel Pump Prime Procedure

    6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.61 © Copyright Polaris Inc.
  • Page 68 • Non-ES models that have been run out of gas and cannot be re-started 10. Click “Done / Continue” after reading the following screen. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.62 © Copyright Polaris Inc.

  • Page 69: Gearing Change Reprogramming

    10. Select the track that is installed on the snowmobile. 7. Start Digital Wrench, and select the correct vehicle. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.63 © Copyright Polaris Inc.

  • Page 70: 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 71 7. Start Digital Wrench, and select the appropriate vehicle. 8. Select the Special Tools (Tool Box) menu and then Service Procedures. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.65 © Copyright Polaris Inc.

  • Page 72: 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 73 7. Connect the SmartLink cable to the vehicle and PC / laptop. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.67 © Copyright Polaris Inc.
  • Page 74 14. Enter or paste the Request Code into the box. ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.68 © Copyright Polaris Inc.
  • Page 75 Harness connector from the ECU PWR Test connector. 20. Wait for 10 seconds. 21. Reconnect the Chassis Power-Up Harness connector to the ECU PWR Test connector. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.69 © Copyright Polaris Inc.

  • Page 76: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.70 © Copyright Polaris Inc.
  • Page 77 Item is the software program version 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 78: 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 79: Pvt System Diagnostics

    • Inspect the spider rollers / bushings. • Inspect / adjust belt-to-sheave clearance. • Inspect the moveable / cover bushings. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.73 © Copyright Polaris Inc.

  • Page 80: Belt Wear / Burn Diagnostics

    Clutch malfunction clutch. Slow, easy belt engagement - easing on the throttle Use fast, effective throttle to engage the clutch. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.74 © Copyright Polaris Inc.

  • Page 81: Steering / Suspension Diagnostics

    (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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.75 © Copyright Polaris Inc.

  • Page 82: Electrical Diagnostics

    • All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.79 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 83: 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 84: 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 1.79 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.78 © Copyright Polaris Inc.

  • Page 85: 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”. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.79 © Copyright Polaris Inc.

  • Page 86: Testing For Intermittent Conditions

    • Moving the harness by wiggling it or flexing certain Charging system damage will occur if incompatible areas. components are installed. Always reference the Polaris • Pulling at or near the suspected connector. Electronic Parts Catalog for the proper part numbers.

  • Page 87: Testing Voltage Drop

    “open in new tab”. systematically removing one fuse at a time until the value drops, indicating the circuit that requires attention. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.81 © Copyright Polaris Inc.
  • Page 88 GENERAL INFORMATION NOTES 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 1.82 © Copyright Polaris Inc.
  • Page 89 ..............2.30 FUEL SYSTEM MAINTENANCE 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 90 ..................2.60 LED LIGHTS 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 91 ................2.65 STORING THE SNOWMOBILE 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 92: Maintenance

    NOTICE The speedometer may give wrong values at the existence of electromagnetic radiation >= 10 V/m. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 93 10. Rotate the spark plug wrench clockwise until it locks into place. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 94: Vehicle Break-In

    IMPORTANT result could be sludge formation, filter blockage, and Track break-in time is dependent on track type, riding reduced cold weather flow rates. All Polaris oils are style, and whether your snowmobile is equipped with compatible with each other. studs.

  • Page 95: Maintenance Program

    • Verify steering fasteners / linkage / handlebars for Chassis / Suspension proper torque and operation • Verify ski fasteners for proper torque • Inspect ski skags 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 96: Pre-Season Maintenance

    Fuel / Vent Hoses Oil Hoses Air Box L = Lubricate I = Inspect or Adjust R = Replace C = Clean 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 97 Hood / Seat / Chassis / Engine Compartment L = Lubricate I = Inspect or Adjust R = Replace C = Clean 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 98: 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 99 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 100 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 101 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 102 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 103: Lubricants / Service Products

    2871423 — Starter Grease 2871460 Carbon Clean — 2871326 (Will sub to 2881413 when discontinued.) — 5:1 Carbon Clean 2881413 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.15 © Copyright Polaris Inc.
  • Page 104 Never Rust Spray — 2830209 Cleaners / Polishes All Purpose Cleaner — 2830205 XP Spray Wash — 2830202 — XP Wash 2830203 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.16 © Copyright Polaris Inc.

  • Page 105: 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 106: Hood / Side Panel Service

    3. Close the panel and secure with the three 1/4 turn fasteners. 2. Open the side panel, then pull the panel outward to release the tabs at the bottom. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.18 © Copyright Polaris Inc.

  • Page 107: Hood Removal

    5. Reinstall the left and right side panels. 4. Disconnect the hood wire harness connector 5. Remove the hood assembly from the vehicle. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.19 © Copyright Polaris Inc.

  • Page 108: Engine Maintenance

    If engine RPM increases, the throttle lever freeplay is too tight and must be readjusted. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.20 © Copyright Polaris Inc.

  • Page 109: Spark Plug Maintenance

    An audible “click” should be heard TORQUE when the terminal ring is properly seated below terminal tip indentation. Spark Plug: 22 ft-lbs (30 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.21 © Copyright Polaris Inc.

  • Page 110: 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 111: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.23 © Copyright Polaris Inc.

  • Page 112: Drive Belt / Clutch Maintenance

    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 113 6. Reinstall the left side panel. 7. When installing a new belt, follow the belt break-in procedures. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.25 © Copyright Polaris Inc.

  • Page 114: Belt Deflection Inspection / Adjustment

    TORQUE Deflection Screw Jam Nut: 145 in-lbs (16 N·m) 6. Rotate the belt clockwise while removing the L- wrench 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.26 © Copyright Polaris Inc.

  • Page 115: Clutch Alignment / Offset - Ps-51607

    AXYS and MATRYX snowmobiles. Do not use Verify it fits tight against the clutch sheaves. the Clutch Alignment tool on other Polaris snowmobiles. 4. Push the driven clutch inward until it stops. 5. The optimum clutch alignment / offset is when the The drive and driven clutches are offset from each other.

  • Page 116: Clutch Offset / Float Adjustment

    Driven Clutch Bolt: 18 ft-lbs (25 N·m) 5. Apply a light film of Polaris Premium grease to the jackshaft. Install the driven clutch and push it tight toward the bulkhead. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.28...

  • Page 117: Clutch Cleaning

    IMPORTANT Do not lubricate the clutch bushings or any internal clutch components. Clutch bushings are self- lubricating. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.29 © Copyright Polaris Inc.

  • Page 118: Fuel / Air Intake / Exhaust Maintenance

    * = When the type of fuel in the tank is unknown, or damage. Always check fuel line condition after periods Polaris recommends setting the fuel selector feature to of storage. Normal deterioration from weather and fuel E10 – 87 ETHANOL mode.

  • Page 119: Fuel System Deicers

    ETHANOL MODE MODE * = When the type of fuel in the tank is unknown, Polaris recommends setting the fuel selector feature to E10 – 87 ETHANOL mode. FUEL SYSTEM DEICERS If you use non-ethanol fuel (sometimes labeled “non- oxygenated”), POLARIS recommends the regular use of isopropyl-based fuel system deicer.

  • Page 120: Exhaust System Inspection

    When re-installing the exhaust system, the EGT sensor wires must be tied back to the designated retention points or wire failure may occur. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.32 © Copyright Polaris Inc.

  • Page 121: Drive System Maintenance

    TORQUE Drive Chain Tensioner Jam Nut: 21 ft-lbs (28 N·m) 7. Reinstall the side panels. Release the parking brake. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.33 © Copyright Polaris Inc.

  • Page 122: 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.34 © Copyright Polaris Inc.
  • Page 123 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.35 © Copyright Polaris Inc.

  • Page 124: Brake System Maintenance

    Brake Pad injury or death. Have the brakes serviced at the first sign of abnormal feel or performance. Brake Disc 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.36 © Copyright Polaris Inc.

  • Page 125: Brake Reservoir Fluid Level

    Position the handlebars so the brake fluid reservoir is as close to level as possible. View the fluid level through the reservoir and verify the reservoir is almost full. If the fluid level is low, add POLARIS DOT 4 brake fluid to proper specification. MEASUREMENT Brake Reservoir Fluid Level: 0.1125±0.0625 in (2.856±1.588 mm)

  • Page 126: Brake System Bleeding

    6. Install cover and fasteners. Torque fasteners to specification. TORQUE Brake Reservoir Cover Fasteners: 6-8 in-lbs (0.68-0.90 N·m) 2. Remove the reservoir cover and gasket 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.38 © Copyright Polaris Inc.
  • Page 127 5. Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4-turn to release air. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.39 © Copyright Polaris Inc.

  • Page 128: Steering / Suspension Maintenance

    11 ft-lbs (15 N·m) Hand Guard Clamp Fasteners -18 in-lbs (2 N·m) Auxiliary Engine Stop Switch Holder Fastener 20 in-lbs (2.3 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.40 © Copyright Polaris Inc.

  • Page 129: Handlebar Component Locations

    0.078 in (2 mm) 9.25 in (235 mm) To grip end 0.078 in (2 mm) 6.30 in (160 mm) To grip end 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.41 © Copyright Polaris Inc.

  • Page 130: Handlebar Angle Adjustment

    Stretching the wires could damage the handwarmers. 3. Tighten the fasteners to specification. TORQUE Handlebar Riser Fasteners: 11 ft-lbs (15 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.42 © Copyright Polaris Inc.

  • Page 131: Left Hand Control Adjustment

    If applicable, hand guards may need to be loosened or removed to access and move the brake master cylinder. 2. Loosen the four left hand control mounting screws 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.43 © Copyright Polaris Inc.

  • Page 132: Front Suspension

    Tie Rod End Nuts 8 ft-lbs (11 N·m) 37 ft-lbs (50 N·m) Ski Loop Rear Fasteners 6 ft-lbs (8 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.44 © Copyright Polaris Inc.

  • Page 133: Control Arm Pivot Adjustment

    Front Lower Control Arm Pivot Screw / Nut: 40 ft-lbs (54 N·m) MEASUREMENT Ski Toe Setting (Overall): 1/8 - 1/4 in (3 - 6 mm) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.45 © Copyright Polaris Inc.

  • Page 134: Ski Skag Inspection / Skag Replacement

    9. Torque steering tie rod jam nuts and spindle fasteners to specification. TORQUE Tie Rod Spindle Fasteners: 37 ft-lbs (50 N·m) Rod End Jam Nuts: 11 ft-lbs (15 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.46 © Copyright Polaris Inc.
  • Page 135 3. Reverse the steps to install a skag. Tighten nuts to specification. TORQUE Ski Skag Nuts: 8 ft-lbs (11 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.47 © Copyright Polaris Inc.

  • Page 136: Rear Suspension

    56 ft-lbs (76 N·m) 17 ft-lbs (23 N·m) Bogie Wheel Fastener Limiter Strap Fasteners 10 ft-lbs (14 N·m) 12 ft-lbs (16 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.48 © Copyright Polaris Inc.

  • Page 137: Rear Suspension Inspection - Igx 146

    46 ft-lbs (63 N·m) 33 ft-lbs (45 N·m) Rear Pivot Arm Fastener Limiter Strap Fasteners 33 ft-lbs (45 N·m) 12 ft-lbs (16 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.49 © Copyright Polaris Inc.

  • Page 138: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.50 © Copyright Polaris Inc.

  • Page 139: Track Alignment

    See Track 6. Tighten the idler shaft bolts to specification. Tension Specifications. TORQUE Rear Idler Fastener: 33 ft-lbs (45 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.51 © Copyright Polaris Inc.

  • Page 140: Track Tension Adjustment

    7. Tighten the lock nuts. 8. Tighten idler shaft fasteners to specification. TORQUE Rear Idler Fastener: 33 ft-lbs (45 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.52 © Copyright Polaris Inc.

  • Page 141: Track Tension Specifications

    IMPORTANT Rear Idler 16 in (40 cm) 10 lb (4.54 Fasteners: ahead of rear If the track is studded, Polaris recommends IGX 146 33 ft-lbs (45 N·m) idler shaft maintaining 7/8 in (2.2 cm) track tension setting at all times.

  • Page 142: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.54 © Copyright Polaris Inc.

  • Page 143: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.55 © Copyright Polaris Inc.

  • Page 144: Battery Installation

    9. Reinstall the console using the plastic rivet and Battery Cable Connector: console fastener. 36 in-lbs (4 N·m) 10. Reinstall the side panel. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.56 © Copyright Polaris Inc.

  • Page 145: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.57 © Copyright Polaris Inc.
  • Page 146 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 147: Battery Tender Port

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

  • Page 148: Lights

    If an LED fails to illuminate in either the taillight, the entire assembly must be replaced. NOTICE Image for reference only. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.60 © Copyright Polaris Inc.

  • Page 149: Adjustable Headlight

    3. To LOWER the beam, turn the adjuster knob CLOCKWISE. 4. To RAISE the beam, turn the adjuster knob COUNTERCLOCKWISE. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.61 © Copyright Polaris Inc.

  • Page 150: Controls

    CAUTION Perform procedure in well-ventilated area. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.62 © Copyright Polaris Inc.

  • Page 151: 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 152: 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 153: 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 154 MAINTENANCE NOTES 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 2.66 © Copyright Polaris Inc.
  • Page 155 ..............3.57 CYLINDER ASSEMBLY VIEW 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 156 ................3.99 PISTON INSTALLATION 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 157 ............... 3.154 EXHAUST MANIFOLD REMOVAL 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 158 ................3.155 EXHAUST INSTALLATION 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 159: General Information

    To perform the Electronic Oil Pump Prime procedure, see Electronic Oil Pump Prime Procedure page 1.64. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 160: Special Tools

    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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 161 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 162: 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 163 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 164: Oil Pump Line Connections

    ENGINE / COOLING / EXHAUST OIL PUMP LINE CONNECTIONS Match the oil line and fittings as shown when installing the oil pump. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.10 © Copyright Polaris Inc.
  • Page 165 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.11 © Copyright Polaris Inc.

  • Page 166: Oil Check Valve Fitting Hose Clamp Position

    9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.12 © Copyright Polaris Inc.

  • Page 167: 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.13 © Copyright Polaris Inc.

  • Page 168: Oil Injector Check Valves

    6 psi (41.4 kPa) or 17 psi (117.2 kPa) for the external center gallery check valve to open. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.14 © Copyright Polaris Inc.

  • Page 169: Cross Shaft Oil Gallery Outlet Check Valve

    PTO Oil Check Valve Ratchet Extension Fitting Check Valve Fitting Press Tool 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.15 © Copyright Polaris Inc.

  • Page 170: Cross Shaft Oil Gallery Outlet Check Valve Testing

    NOTICE The inner crankcase fasteners are longer than the outer crankcase fasteners. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.16 © Copyright Polaris Inc.
  • Page 171 Crankcase ring land damage in the area shown is caused by improper crankcase separation. 8. Finish removing the outer crankcase fasteners. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.17 © Copyright Polaris Inc.
  • Page 172 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.18 © Copyright Polaris Inc.
  • Page 173 Do not over-apply Loctite in oil injector area. Doing so may block the oil passage. Keep Loctite out of the snap ring groove. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.19 © Copyright Polaris Inc.
  • Page 174 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.20 © Copyright Polaris Inc.
  • Page 175 • Install the cylinder. See Cylinder Installation page 3.100. • Install the cylinder head. See Cylinder Head Installation page 3.101. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.21 © Copyright Polaris Inc.

  • Page 176: Electronic Oil Pump - Resistance Check

    After performing this procedure 4–5 times, start the engine to prevent surplus oil from accumulating in the crankcase. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.22 © Copyright Polaris Inc.
  • Page 177 6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.23 © Copyright Polaris Inc.

  • Page 178: Electronic Oil Pump Manual Prime Procedure

    Hold for at least 15 seconds. Chassis Power Up Harness: PS-47296–B 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.24 © Copyright Polaris Inc.

  • Page 179: 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 180 14. Write the offset value on the ECU label for future reference. 11. On the following screen, select “Oil Pump Replacement”. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.26 © Copyright Polaris Inc.

  • Page 181: Electronic Oil Pump - Trouble Codes / Protection Mode

    9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.27 © Copyright Polaris Inc.

  • Page 182: Oil Tank

    7 ft-lbs (9 N·m) Fitting Washer Flanged Grommet Clutch Guard Clutch Guard Fasteners Oil Tank 8 ft-lbs (10 N·m) Oil Level Switch 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.28 © Copyright Polaris Inc.

  • Page 183: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.29 © Copyright Polaris Inc.

  • Page 184: Oil Tank Installation

    3. Slide the oil tank into position and align mounting 7. Install the hood and side panels. holes with the mounting brackets on the clutch guard. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.30 © Copyright Polaris Inc.

  • Page 185: Engine Service

    6. Draw the recoil slowly then tie a knot in the rope near the recoil housing to secure the rope. 7. Remove the recoil handle. 8. Remove the oil level sender connector 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.31 © Copyright Polaris Inc.
  • Page 186 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.32 © Copyright Polaris Inc.
  • Page 187 This makes air box removal much easier. 21. Remove the edge clip retaining the wiring harness to the intake plenum. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.33 © Copyright Polaris Inc.
  • Page 188 28. Tape the holes for the spark plugs shut to prevent debris form entering the cylinders. 29. Disconnect the PBR connectors and Stator connector from the PBR. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.34 © Copyright Polaris Inc.
  • Page 189 35. Remove the exhaust valve assembly. the snowmobile. a. Do not remove the actuator cable off of the actuator pin. The cable will remain installed. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.35 © Copyright Polaris Inc.
  • Page 190 NOTICE Do not attempt to disconnect the fuel injectors from the sub harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.36 © Copyright Polaris Inc.
  • Page 191 46. Remove the coolant hose from the cylinder head. 49. Disconnect the throttle cable and remove the cable from the throttle body 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.37 © Copyright Polaris Inc.
  • Page 192 Have an assistant help lift the engine. 51. Remove the left side engine mounting bolts 4& 52. Remove the right rear engine mounting bolt 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.38 © Copyright Polaris Inc.

  • Page 193: Engine Installation

    8. If the throttle body was removed, see Throttle Body Installation page 5.14. NOTICE Ensure the clamps are properly orientated. See Component Orientation Views page 3.54. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.39 © Copyright Polaris Inc.
  • Page 194 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 Installation page 10.92. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.40 © Copyright Polaris Inc.
  • Page 195 TPS harness into and along the side of the wire support securing the harness with new cable ties 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.41 © Copyright Polaris Inc.
  • Page 196 Torque in sequence page 3.50 d. Verify the actuator cable is still installed on the actuator pin and properly retained in actuator bracket. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.42 © Copyright Polaris Inc.
  • Page 197 TORQUE Air Box Coil Fasteners: 36 in-lbs (4 N·m) TORQUE PBR Fasteners: 6 ft-lbs (8 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.43 © Copyright Polaris Inc.
  • Page 198 See the following procedures for installation: • Drive Clutch Installation page 7.22 • Driven Clutch Installation page 7.28 • Drive Belt Installation page 2.24 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.44 © Copyright Polaris Inc.
  • Page 199 Torque the fastener to specification. 35. Connect the ECU to the wiring harness TORQUE Lower Intake Tube Fastener: 36 in-lbs (4 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.45 © Copyright Polaris Inc.
  • Page 200 NOTICE Place a rag under the fitting to catch any spilled oil. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.46 © Copyright Polaris Inc.
  • Page 201 See Important Engine Service Notes page 54. Install the hood and side panels. TORQUE Oil Tank Mounting Fasteners: 7 ft-lbs (9 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.47 © Copyright Polaris Inc.

  • Page 202: 650 / 850 Engine

    ALL ENGINES NOMINAL (1.630 mm) (0.139 mm) (0.65 mm) (1.34 mm) MAXIMUM 0.064 in 0.005 in 0.025 in 0.052 in 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.48 © Copyright Polaris Inc.

  • Page 203: 850 Engine

    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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.49 © Copyright Polaris Inc.

  • Page 204: 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.50 © Copyright Polaris Inc.
  • Page 205 ENGINE / COOLING / EXHAUST ELECTRONIC VARIABLE EXHAUST VALVE COVER EXHAUST MANIFOLD 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.51 © Copyright Polaris Inc.
  • Page 206 ENGINE / COOLING / EXHAUST INTAKE CRANKCASE 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.52 © Copyright Polaris Inc.
  • Page 207 ENGINE / COOLING / EXHAUST RECOIL HOUSING WATERPUMP COVER 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.53 © Copyright Polaris Inc.

  • Page 208: Component Orientation Views

    COMPONENT ORIENTATION VIEWS DET Sensor 60° ± 10° toward PTO Side Orient Throttle Body Clamps at 6 O’Clock ± 10° 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.54 © Copyright Polaris Inc.

  • Page 209: 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.55 © Copyright Polaris Inc.
  • Page 210 ZERO sealant near the inner edges of the water pump cross shaft gallery (between the two seal grooves) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.56 © Copyright Polaris Inc.

  • Page 211: Engine Assembly Views

    Apply VES oil under fastener head and to threads prior to installation. O-Ring Throttle Body Coolant Hose O-Ring Springband Clamp Cylinder 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.57 © Copyright Polaris Inc.

  • Page 212: Crankcase Assembly View

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.58 © Copyright Polaris Inc.

  • Page 213: Piston & Crankshaft Assembly View

    Bearing (PTO) Snap Ring Piston Bearing (PTO) Piston Pin Bearing is slip fit Bearing Piston Circlip Bearing (MAG) Woodruff Key 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.59 © Copyright Polaris Inc.

  • Page 214: Stator / Flywheel Assembly View

    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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.60 © Copyright Polaris Inc.

  • Page 215: Engine Mount Assembly View

    Mount Bracket to be retained while mount nut is torqued Mount Bracket to be retained while mount nut is torqued 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.61 © Copyright Polaris Inc.

  • Page 216: Water Pump Assembly View

    Water Pump Driven Shaft Water Pump Impeller Ensure cross shaft turns and indexes with crankshaft during assembly Ball Bearing D-Washer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.62 © Copyright Polaris Inc.
  • Page 217 ENGINE / COOLING / EXHAUST 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.63 © Copyright Polaris Inc.

  • Page 218: Reed Valve Assembly View

    REED VALVE ASSEMBLY VIEW Reed / Throttle Body Adapter Fasteners Throttle Body Adapter 12 ft-lbs (16 N·m) Gear Clamps Reed Assemblies 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.64 © Copyright Polaris Inc.

  • Page 219: Stator / Flywheel Service

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.65 © Copyright Polaris Inc.

  • Page 220: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.66 © Copyright Polaris Inc.

  • Page 221: Stator Installation

    1. Carefully install the magneto/stator into the crankcase. NOTICE The stator wires will be pulled through the cutout in the crankcase. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.67 © Copyright Polaris Inc.

  • Page 222: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.68 © Copyright Polaris Inc.
  • Page 223 Recoil Housing Fasteners: 9 ft-lbs (12 N·m) Torque in sequence page 3.50 6. Reinstall the exhaust silencer and pipe. See Exhaust Installation. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.69 © Copyright Polaris Inc.

  • Page 224: Reed Valve Service

    The air gap should not exceed specification. VForce3 Reeds: MEASUREMENT Reed Valve Air Gap Limit: 0.015 in (.381 mm) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.70 © Copyright Polaris Inc.

  • Page 225: Reed Petal Replacement Inspection

    Inspect each reed petal. There should be no cracks or chipping on any of the petals. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.71 © Copyright Polaris Inc.

  • Page 226: Reed Petal Removal

    2. Remove the inner cage from the outer flange 6. Thoroughly clean the inner and outer cages. Do not reuse if damage is found. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.72 © Copyright Polaris Inc.

  • Page 227: Reed Petal Installation

    8. Install the two outer reed petals onto the cage making sure the slots engage the cage tabs. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.73 © Copyright Polaris Inc.
  • Page 228 10. When installing each reed assembly back into the engine, verify the model number is at the bottom and “MOTOTASSINARI” is at the top. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.74 © Copyright Polaris Inc.

  • Page 229: Engine Disassembly / Inspection - 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.75 © Copyright Polaris Inc.

  • Page 230: Cylinder Head Inspection

    6. Inspect the cylinder head / combustion domes for any damage. Measure cylinder head flatness. Replace cylinder head if required. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.76 © Copyright Polaris Inc.

  • Page 231: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.77 © Copyright Polaris Inc.

  • Page 232: 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.78 © Copyright Polaris Inc.

  • Page 233: 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 234: Piston Removal

    IMPORTANT Do not apply heat to the piston ring. The ring may lose radial tension. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.80 © Copyright Polaris Inc.

  • Page 235: Piston Markings

    Subtract this measurement from the minimum cylinder measurement (90° to the pin). If clearance exceeds the service limit piston/cylinder overhaul may be required. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.81 © Copyright Polaris Inc.

  • Page 236: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.82 © Copyright Polaris Inc.

  • Page 237: Piston Needle Bearing

    If play or roughness is evident with a new pin and bearing, replace the connecting rod. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.83 © Copyright Polaris Inc.

  • Page 238: Engine Disassembly / Inspection - 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.84 © Copyright Polaris Inc.

  • Page 239: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.85 © Copyright Polaris Inc.

  • Page 240: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.86 © Copyright Polaris Inc.

  • Page 241: 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 242: 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.88 © Copyright Polaris Inc.

  • Page 243: Crankshaft Truing

    If point measures high, squeeze the crankshaft as shown. High at point If point measures high, spread the crankshaft as shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.89 © Copyright Polaris Inc.

  • Page 244: 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 245: Water Pump Service

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.91 © Copyright Polaris Inc.
  • Page 246 Carefully disassemble any remaining pieces of the mechanical seal until just the mechanical seal body is remaining. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.92 © Copyright Polaris Inc.
  • Page 247 Do not pry on the water pump mating surface or bore as crankcase damage may occur. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.93 © Copyright Polaris Inc.

  • Page 248: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.94 © Copyright Polaris Inc.
  • Page 249 7. Install new water pump seal on water pump cover. NOTICE Ensure the seal tab aligns with the notch in the water pump cover. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.95 © Copyright Polaris Inc.

  • Page 250: Engine Assembly - Bottom End

    Do not over-apply Loctite in oil injector area. Doing so may block the oil passage. Keep Loctite out of the snap ring groove. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.96 © Copyright Polaris Inc.
  • Page 251 VES / VES Extreme oil. ring. 4. Apply VES / VES Extreme oil into the two connecting rod bearings 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.97 © Copyright Polaris Inc.

  • Page 252: Crankcase Assembly

    Do NOT allow the bearing to slide against the crankshaft. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.98 © Copyright Polaris Inc.
  • Page 253 4. Install the piston circlips in the correct orientation. 5. Install the cylinder. See Cylinder Installation page 3.100. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.99 © Copyright Polaris Inc.

  • Page 254: 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 3.50...

  • Page 255: 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.101 © Copyright Polaris Inc.

  • Page 256: Recoil

    Recoil Spring Friction Plate Recoil Reel Washer Recoil Friction Plate Fastener Recoil Return Spring 15 ft-lbs (20 N·m) Recoil Washer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.102 © Copyright Polaris Inc.

  • Page 257: Recoil Housing Removal

    The new service part assembly is completely assembled with the rope. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.103 © Copyright Polaris Inc.

  • Page 258: 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 259 12. Verify the recoil friction spring tang fits in the notch on the ratchet. 13. Install the friction plate 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.105 © Copyright Polaris Inc.

  • Page 260: Recoil Housing Installation

    TORQUE Recoil Housing Fasteners: 9 ft-lbs (12 N·m) Torque in sequence page 3.50 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.106 © Copyright Polaris Inc.

  • Page 261: Electronic Variable Exhaust Valves (E-Ves-Ii)

    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 262 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.108 © Copyright Polaris Inc.

  • Page 263: E-Ves-Ii Assembly View

    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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.109 © Copyright Polaris Inc.

  • Page 264: E-Ves-Ii Operation Notes

    • The exhaust valve base seals must be inspected when the assembly is removed from the engine and replaced if damaged or worn. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.110 © Copyright Polaris Inc.
  • Page 265 E-VES learn procedure. Performing the Push / Pull Cable Travel Test can be done to ensure the E- VES system is functioning as designed. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.111 © Copyright Polaris Inc.
  • Page 266 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: 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.112 © Copyright Polaris Inc.
  • Page 267 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.113...

  • Page 268: E-Ves-Ii Removal

    Verify all wires are in good condition and connectors are connected to the actuator, and ECU. 1. Remove the four exhaust valve base fasteners 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.114 © Copyright Polaris Inc.

  • Page 269: E-Ves-Ii Inspection

    1. Remove the E-VES assembly from the cylinder. See E-VES-II Removal page 3.114. 2. Remove the exhaust valve tiebar fasteners 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.115 © Copyright Polaris Inc.

  • Page 270: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.116 © Copyright Polaris Inc.

  • Page 271: E-Ves-Ii Installation

    NOTICE The shorter exhaust valve base fasteners should be positioned in the outer mounting holes. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.117 © Copyright Polaris Inc.

  • Page 272: E-Ves Diagnostic Trouble Codes (Dtcs)

    • Verify smooth valve operation by operating the Range cable by hand through its full travel (Mid) • Relearn EV If no problem 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.118 © Copyright Polaris Inc.
  • Page 273 P1408 Abnormal • Command wire (Dark Blue/White) short to Rate of +12V Change • Command wire (Dark Blue/White) short to 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.119 © Copyright Polaris Inc.
  • Page 274 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.120 © Copyright Polaris Inc.

  • Page 275: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.121 © Copyright Polaris Inc.
  • Page 276 13. Install nut and torque to specification. TORQUE E-VES Actuator Cable Jam Nut: 13 ft-lbs (18 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.122 © Copyright Polaris Inc.

  • Page 277: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.123 © Copyright Polaris Inc.

  • Page 278: Ev Actuator Learn Procedure

    6. Connect the SmartLink cable to the vehicle and PC / laptop. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.124 © Copyright Polaris Inc.
  • Page 279 The actuator will also be heard moving back and forth as the ECU sets the travel limits. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.125 © Copyright Polaris Inc.
  • Page 280 Typically, the fault will be caused by a partially- charged battery or loose wire connector as noted by this error screen. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.126 © Copyright Polaris Inc.

  • Page 281: 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.127 © Copyright Polaris Inc.

  • Page 282: Ev Actuator Wire Harness Connector

    E-VES system or if the EV Learn Procedure fails due to insufficient battery voltage and the battery is supplying at least 12.5 volts. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.128 © Copyright Polaris Inc.

  • Page 283: Cooling System

    Hose, Bottle / Tunnel Mounted to upper crankcase half Hose Clamp Hose / Electrical Wires Support 5 ft-lbs (7 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.129 © Copyright Polaris Inc.

  • Page 284: Coolant Bottle Assembly View

    Coolant Bottle Vent Line Connector Placement Bracket Edge Clip Coolant Bottle Bracket Coolant Bottle Bracket Fasteners 7 ft-lbs (9 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.130 © Copyright Polaris Inc.

  • Page 285: 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.131 © Copyright Polaris Inc.
  • Page 286 Orientation of panduit strap on the stator wire support cable support should be pointing toward downward. should be pointing toward upside. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.132 © Copyright Polaris Inc.

  • Page 287: Cooling Hose - Cold Side Routing / Retention

    COOLING HOSE - COLD SIDE ROUTING / RETENTION Cooling hoses are secured in 3 locations as shown Cooling hoses are secured in 3 locations as shown 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.133 © Copyright Polaris Inc.
  • Page 288 COOLING HOSE - COLD SIDE ROUTING / RETENTION CONTINUED Cooling hoses are secured in 3 locations as shown Cooling hose is secured in 3 locations as shown 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.134 © Copyright Polaris Inc.

  • Page 289: Coolant Bottle / Thermostat Removal

    7. Remove the two plastic rivets securing the NOTICE connector placement bracket. If thermostat replacement is required, the coolant bottle must be replaced. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.135 © Copyright Polaris Inc.

  • Page 290: Coolant Bottle / Thermostat Installation

    9. Install the resonator. See Exhaust Installation page 3.155. 10. Fill coolant bottle with coolant and follow coolant bleeding procedure. 11. Install hood and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.136 © Copyright Polaris Inc.

  • Page 291: Coolant Bottle Overflow Line Routing

    1. Secure the coolant overflow line routing in the locations shown below and make sure the coolant overflow line passes through the bracket. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.137 © Copyright Polaris Inc.

  • Page 292: Thermostat Location

    Replace the thermostat if it tests outside of specification. NOTICE If thermostat replacement is required, the coolant bottle must be replaced. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.138 © Copyright Polaris Inc.

  • Page 293: Air Intake

    5 ft-lbs (7 N·m) LH Intake Vent Mount Cable Tie Drain Plug LH Intake Vent LH Intake Screen Plastic Push Rivet 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.139 © Copyright Polaris Inc.

  • Page 294: Air Intake Plenum Removal

    ECU mounting fasteners. 5. Disconnect the ECU connectors from the wiring harness or remove the ECU mounting fasteners. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.140 © Copyright Polaris Inc.

  • Page 295: Air Intake Tube Removal

    4. Remove the push rivets retaining the intake tube to the intake plenum. 5. Remove the diagnostic connector from the cap. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.141 © Copyright Polaris Inc.

  • Page 296: Air Intake Tube Installation

    3. Install the push rivets retaining the intake tube to the intake plenum. 6. Install the hood and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.142 © Copyright Polaris Inc.

  • Page 297: Air Box Removal

    9. Remove the fastener retaining the lower intake sliding the front out of the fender. tube. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.143 © Copyright Polaris Inc.
  • Page 298 15. Remove the fasteners securing the PBR and carefully move the PBR to the side. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.144 © Copyright Polaris Inc.
  • Page 299 18. Cut the cable tie of the routing clip securing the stator wiring harness and throttle cable to the air box. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.145 © Copyright Polaris Inc.

  • Page 300: Air Box Installation

    36 in-lbs (4 N·m) 2. Install new cable tie on air box routing clip secure the stator wiring harness and throttle cable. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.146 © Copyright Polaris Inc.
  • Page 301 . Torque the fasteners to specification. 9. Connect the ECU to the wiring harness TORQUE Left Support Brace Fasteners: 22 ft-lbs (30 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.147 © Copyright Polaris Inc.
  • Page 302 11. Install the fastener retaining the lower intake tube. Torque the fastener to specification. TORQUE Lower Intake Tube Fastener: 36 in-lbs (4 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.148 © Copyright Polaris Inc.
  • Page 303 • Drive Belt Installation 18. Install the console. See Console Installation page 9.25. 19. Install the hood and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.149 © Copyright Polaris Inc.

  • Page 304: Exhaust

    EGT sensor(s) from the wiring harness. DO NOT REMOVE the EGT probe from the resonator or pipe if it is not necessary. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.150 © Copyright Polaris Inc.

  • Page 305: 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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.151 © Copyright Polaris Inc.

  • Page 306: Exhaust Removal

    8. Carefully separate the resonator and tuned pipe and lift upward to remove the resonator from the chassis. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.152 © Copyright Polaris Inc.
  • Page 307 13. Remove the tuned pipe. NOTICE An extended length exhaust spring tool aids in lower exhaust spring removal. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.153 © Copyright Polaris Inc.
  • Page 308 Torque in sequence page 3.50 NOTICE Image for reference only. 3. Proceed to exhaust Installation. See Exhaust Installation page 3.155. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.154 © Copyright Polaris Inc.
  • Page 309 3. Set the tuned pipe in place. NOTICE Stainless steel (gray) springs connect the tuned pipe to the exhaust manifold. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.155 © Copyright Polaris Inc.
  • Page 310 8. Install the Exhaust Seal, Socket NOTICE Inspect; replace if damaged. 9. Inspect the upper and lower resonator mounts. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.156 © Copyright Polaris Inc.
  • Page 311 18. Install the hood and side panels. 19. Verify proper operation. 15. Connect the EGT sensor to the wiring harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.157 © Copyright Polaris Inc.
  • Page 312 ENGINE / COOLING / EXHAUST NOTES 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 3.158 © Copyright Polaris Inc.
  • Page 313 POLARIS ELECTRONIC REVERSE CONTROL (PERC) ........

  • Page 314: General Information

    (OG – BRN Circuits) Not Applicable Fuel Prime Prime Not Applicable Jumper IMPORTANT Fuel pump prime can be done through Digital Wrench. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 315: Engine Protection Features

    Vehicle use load/high engine RPM and low ground speed) Verify track is not missing lugs. Set correct track tension Track condition/tension 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 316: Detonation (Det) Protection Modes

    Check engine LED flashing / “DET” or engine RPM / power. Re-start engine “DETONATION” displayed to reset. Standard Gauge 7S Display 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 317: Detonation (Det) Troubleshooting

    If equipped with electric start, the 7S display (if equipped) will remain on when the key is in the ON position. After 60 seconds, the display backlight will dim and then fully shut down after 10 minutes of inactivity. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 318: 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 319: Exhaust Gas Temperature (Egt) Sensor

    EXHAUST TEMPERATURE SENSOR 349.5Ω @ 392 °F (200 °C) Resistance 767.3Ω @ 1562 °F (850 °C) Values 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 320: Air Temperature / Pressure Sensor (T-Map)

    2400 - 8200Ω Pins 3 to 4 (Pressure) 3400 - 8200Ω WHT – WHT/RED Two-Tooth 280 Ω +/- 15% GRN – WHT/GRN Five-Tooth 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 321: Crankshaft Position Sensor Air Gaps

    CPS must be adjusted. 3. To adjust a CPS, use an 8 inch pry bar to carefully deflect the sensor. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 322: Ignition Coil Packs

    ECT / Jumper Harness Cylinder Head Assembly TORQUE ECT Sensor: 18 ft-lbs (24 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.10 © Copyright Polaris Inc.

  • Page 323: Knock (Det) Sensor

    NOTICE If fuel sensor replacement is required, the return fuel line must be replaced as an assembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.11 © Copyright Polaris Inc.

  • Page 324: Electronic Control Unit (Ecu)

    GY/YE Load Center ECU 5V Power Splice OG/WH ECU 5V Sensor PWR Splice, Chassis Sensor Ground #2 BK/DB Sensor GND 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.12 © Copyright Polaris Inc.

  • Page 325: Ecu (Cnb) 34 Pin Connector Pinout

    Handlebar Connection Logger Switch Logger Switch GY/WH Digital Wrench CAN2 Hi Digital Wrench CAN2 Lo Splice, CAN Hi CAN Hi 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.13 © Copyright Polaris Inc.

  • Page 326: Ecu Label Information

    A second, smaller label is located at the bottom right of the ECU. This label will have the base ECU part number on it. Use the appropriate Polaris parts manual / online catalog to determine the correct ECU part number for the vehicle.
  • Page 327 7 ft-lbs (9 N·m) 5. Reconnect Digital Wrench to the vehicle and finish the ECU replacement procedure. 6. Reinstall hood and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.15 © Copyright Polaris Inc.

  • Page 328: Throttle Position Sensor (Tps)

    TPS voltage readings. • Use a fully charged 12VDC battery to power the engine management system. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.16 © Copyright Polaris Inc.
  • Page 329 If the signal return is erratic and no wiring issues are found and the TPS is securely mounted to the throttle body, replace the TPS. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.17 © Copyright Polaris Inc.

  • Page 330: Throttle Position Sensor (Tps) Wire Routing

    1. From the throttle position sensor (TPS), route the TPS wire lead back along the sensor and secure the wire lead to the sensor with a panduit strap 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.18 © Copyright Polaris Inc.
  • Page 331 Secure the TPS connector to the connector placement bracket using the Christmas tree clip on the connector. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 4.19 © Copyright Polaris Inc.

  • Page 332: 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 333 ................5.38 FUEL LINE ROUTING 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 334: General Information

    All fuel injectors must share the same color code (Yellow, Blue, or Red). Always verify the fuel injector part number prior to installation. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 335: Fuel Recommendation

    NEVER use unleaded fuels with an ethanol rating of E15 or E85 as severe engine damage may occur. * = When the type of fuel in the tank is unknown, Polaris recommends setting the fuel selector feature to IMPORTANT E10 – 87 ETHANOL mode.

  • Page 336: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 337 • Test fuel system pressure • Non-ES models that have been run out of gas and cannot be re-started 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 338: Fuel Pump Prime Procedure Without Service Tool

    2. Fill the fuel tank with minimum 2 gal (7.6 L) of fuel. 3. Reinstall the fuel cap, verify the Engine Stop Switch is reset, and turn the ignition key to START. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 339: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 340: Fuel Injectors / Fuel Rail / Throttle Body

    Return Quick Connect Fittings (BLUE) rings and bushing are serviceable. O-Ring Foam Block Replace with new when removed. Rubber Bushing Replace with new when removed. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 341: Fuel Hose Quick Disconnect Fittings

    Verify proper operation of the fitting and clip by lightly pulling on fitting to ensure it is secure before completing repair. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 342 8. Remove the diagnostic connector from the cap. to the intake plenum. 9. Remove the fastener retaining the lower intake tube. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.10 © Copyright Polaris Inc.
  • Page 343 15. Remove the fasteners securing the PBR and carefully move the PBR to the side. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.11 © Copyright Polaris Inc.
  • Page 344 Hose Pincher: PU-45149 NOTICE Note the cable tie positions and TPS harness routing prior to disconnecting the TPS. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.12 © Copyright Polaris Inc.
  • Page 345 / manifold assembly. 27. Pull the throttle body out of the reed valve / manifold assembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.13 © Copyright Polaris Inc.

  • Page 346: Throttle Body Installation

    (clockwise) prior to cable installation. NOTICE TORQUE For additional routing information, see TPS Wire Throttle Cable Lock Nut: Routing page 44 in-lbs (5 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.14 © Copyright Polaris Inc.
  • Page 347 If the ignition coils were removed, reinstall the ignition coils and torque fasteners to specification. TORQUE Air Box Coil Fasteners: 36 in-lbs (4 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.15 © Copyright Polaris Inc.
  • Page 348 TORQUE Left Support Brace Fasteners: 22 ft-lbs (30 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.16 © Copyright Polaris Inc.
  • Page 349 Torque the fastener to specification. 17. Connect the ECU to the wiring harness TORQUE Lower Intake Tube Air Box Fastener: 36 in-lbs (4 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.17 © Copyright Polaris Inc.
  • Page 350 • Drive Belt Installation 26. Install the console. See Console Installation page 9.25. 27. Install the hood and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.18 © Copyright Polaris Inc.

  • Page 351: Fuel Rail / Fuel Injector Removal

    Wipe away any spilled fuel using a clean shop towel. IMPORTANT Do not apply excessive pressure to fuel fittings or clips. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.19 © Copyright Polaris Inc.
  • Page 352 NOTICE Do not attempt to disconnect the fuel injectors from the sub harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.20 © Copyright Polaris Inc.

  • Page 353: Fuel Rail / Fuel Injector Installation

    Note the rubber bushings are installed cone-side into First Pass: 5 ft-lbs (6.5 N·m) bore. Second Pass: 15 ft-lbs (20 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.21 © Copyright Polaris Inc.
  • Page 354 9. Secure the fuel injector wire leads to the throttle body with new cable ties 10. Reinstall the air box assembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.22 © Copyright Polaris Inc.

  • Page 355: Fuel Injector Service

    Digital Wrench. — 5436287 RESIST- WIRE PINS INJECTOR ANCE COLOR VALUE YE/WH 12 Ω RD/DB DB/WH 12 Ω RD/DB 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.23 © Copyright Polaris Inc.
  • Page 356 3. When fuel injector is ready for installation, ensure the rubber bushing is properly oriented with the cup side of the bushing facing the injector as shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.24 © Copyright Polaris Inc.

  • Page 357: Fuel Tank Service

    Studs O-ring 18 in-lbs (2 N·m) Apply loctite to stud prior to assembly Rubber Pad RH Tank Mount Foam Rivet 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.25 © Copyright Polaris Inc.

  • Page 358: Fuel Tank Removal

    5. Turn the 1/4 turn latch at the rear of the seat and lift up to remove the seat. 2. Rotate the 1/4 turn fasteners at the rear corners of the hood. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.26 © Copyright Polaris Inc.
  • Page 359 11. Carefully remove console and set aside with the starter rope still attached to the console. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.27 © Copyright Polaris Inc.
  • Page 360 14. Remove the nuts and washers securing the fuel tank to the fuel tank support. 16. Disconnect the fuel pump wire harness connector 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.28 © Copyright Polaris Inc.

  • Page 361: Fuel Tank Installation

    5. Perform a push/pull test on the fuel line connections with at least 5 lbs. of force. IMPORTANT Connections should NOT disengage during push/pull test. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.29 © Copyright Polaris Inc.
  • Page 362 NOTICE When installing the console, make sure the o-ring on the fuel tank neck is in place and not damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.30 © Copyright Polaris Inc.
  • Page 363 14. Install the hood by inserting the front of the hood into the nosepan. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.31 © Copyright Polaris Inc.
  • Page 364 17. Align the tabs at the bottom of the side panel with the slots in the fender and carefully insert. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.32 © Copyright Polaris Inc.

  • Page 365: Fuel Pump Service

    2.0 ± 1.0 39.9 Empty 102.25 ± 2.0 PICKUP FILTER MEDIA • Primary Screen = 200 Microns • Filter = 10 Microns 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.33 © Copyright Polaris Inc.

  • Page 366: Fuel Pump Installation

    Allow adequate drying time for the alcohol. 2. Dampen a clean rag with alcohol and thoroughly remove any contaminants from the supplied gasket. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.34 © Copyright Polaris Inc.
  • Page 367 7. Verify the foam pads on the tunnel are installed and 11. Make sure the gas cap is firmly installed. not damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.35 © Copyright Polaris Inc.
  • Page 368 19. Complete the installation process by following the Fuel Tank Installation procedure. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.36 © Copyright Polaris Inc.

  • Page 369: Fuel Pump Wire Harness Routing

    2. Connect the fuel pump wire harness connector to the fuel pump connector of the main harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.37 © Copyright Polaris Inc.

  • Page 370: Fuel Line Service

    2. 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.38 © Copyright Polaris Inc.
  • Page 371 2. 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.39 © Copyright Polaris Inc.
  • Page 372 1. With both fuel supply and return line properly routed, secure both fuel lines together with a panduit at the location shown below. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 5.40 © Copyright Polaris Inc.
  • Page 373 ............6.45 BRAKE DISC INSPECTION / REPLACEMENT 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 374 ..................6.48 STUD PROTECTION 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 375: General Information

    43T, 3/4W, 15 SPL, HYVO, PM 3221188 44T, 3/4W, 15 SPL, HYVO, PM 3222239 3222146 45T, 3/4W, 15 SPL, HYVO, PM 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 376: Chaincase Sprocket Ratio Speed Chart

    1.50 1.52 1.56 1.57 1.58 1.61 1.62 1.62 1.67 1.68 1.68 1.73 1.74 1.79 1.80 1.81 1.86 1.89 1.91 1.95 2.00 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 377 THEORETICAL VEHICLE SPEED (MPH) AT 1:1 SHIFT UPPER LOWER RATIO @ RPM CHAIN LENGTH RATIO SPROCKET SPROCKET 8050 8250 8450 2.00 2.05 2.10 2.11 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 378: Chaincase Gearing Stock Settings - 2021

    Digital Wrench must be used to re- calibrate the speedometer offset. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 379: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 380 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 381: Chaincase Service

    21 ft-lbs (28 N·m) Adjuster Bolt (M10 x 1.5 x 70) Bearings Cover Finger tight, then back-off 1/2 turn. 2& Spacer Dowel Tensioner 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 382: Drive Chain Tension Adjustment

    TORQUE Drive Chain Tensioner Jam Nut: 21 ft-lbs (28 N·m) 7. Reinstall the side panels. Release the parking brake. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.10 © Copyright Polaris Inc.

  • Page 383: 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.11 © Copyright Polaris Inc.

  • Page 384: 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) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.12 © Copyright Polaris Inc.

  • Page 385: Chaincase Cover Torque Pattern

    • Draining chaincase oil using the Cover Method • Removing chaincase cover • Removing chaincase assembly 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.13 © Copyright Polaris Inc.
  • Page 386 13. Remove the cover from the chaincase. Use a flat- blade screwdriver at the pry points to aid removal. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.14 © Copyright Polaris Inc.
  • Page 387 Replace as required. 17. Loosen the chain adjuster jam nut and bolt 21. Clean the inside of the chaincase housing. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.15 © Copyright Polaris Inc.

  • Page 388: Chaincase Cover Service

    Note that the oil seal spring lip faces in. Press seal into bore until flush with the outer edge of the chaincase. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.16 © Copyright Polaris Inc.
  • Page 389 21 ft-lbs (28 N·m) 9. Inspect the cover gasket. Replace if damaged. Verify the gasket is installed in the cover groove as shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.17 © Copyright Polaris Inc.
  • Page 390 12. Install the two fender-to-chaincase housing screws. Torque screws hand-tight. 16. Loosely install the brake disc bolt and spring washers. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.18 © Copyright Polaris Inc.

  • Page 391: Chaincase Housing Removal

    FINAL DRIVE / BRAKE SYSTEMS 17. Reinstall the brake caliper and install new mounting 19. Fill-to-spill the chaincase with Polaris Synthetic fasteners . Torque caliper mounting fasteners to Chaincase Lubricant (SCL). Tighten fill plug to specification. specification. TORQUE Chaincase Fill Plug: 4 ft-lbs (6 N·m)
  • Page 392 9. While applying heat, carefully and slowly pull the chaincase housing away from the chassis. Use care as to not distort the tunnel. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.20 © Copyright Polaris Inc.

  • Page 393: Chaincase Housing Installation

    Do not press on the inner race. 13. Remove the snap rings . Note that the sharp edge of the snap rings faces outward. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.21 © Copyright Polaris Inc.
  • Page 394 The Bonded Component Service section in Chapter 9 outlines the adhesive, applicator tools, and the adhesive application procedure required to properly install bonded components. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.22 © Copyright Polaris Inc.
  • Page 395 14. Reinstall the chaincase components. Follow the procedure for chaincase assembly. 15. Reinstall the right fender assembly. 16. Reinstall the rear suspension, jackshaft, and driveshaft. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.23 © Copyright Polaris Inc.

  • Page 396: Chaincase Vent Line Routing

    2. Route the chaincase vent line behind the coolant bottle and toward the rear of the vehicle. The chaincase vent line should terminate in the coolant bottle bracket as shown below. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.24 © Copyright Polaris Inc.

  • Page 397: Driveshaft Service

    Bearing Flangette / Clinch Nuts 18 ft-lbs (25 N·m) Driveshaft Assembly Bearing Cover Not Serviceable Bearing Press on inner race until fully seated. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.25 © Copyright Polaris Inc.

  • Page 398: Driveshaft Removal

    6. Remove the bearing cover 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.26 © Copyright Polaris Inc.

  • Page 399: Driveshaft Installation

    18 ft-lbs (25 N·m) 8. Reinstall the driven clutch assembly. 9. Reinstall the rear suspension. 10. Follow the procedure for chaincase reassembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.27 © Copyright Polaris Inc.

  • Page 400: Jackshaft Service

    JACKSHAFT SERVICE JACKSHAFT ASSEMBLY VIEW Jackshaft Bearing Flange Fasteners Bearing 18 ft-lbs (25 N·m) Bearing Flange Bearing Deflector O-ring Jackshaft Asm. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.28 © Copyright Polaris Inc.

  • Page 401: Jackshaft Removal

    1. Carefully insert the jackshaft through the bulkhead and into the chaincase. 6. Extract the jackshaft out of the tunnel. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.29 © Copyright Polaris Inc.
  • Page 402 4. Reinstall the clutch guard and oil tank assembly. 5. Reinstall the driven clutch assembly. 6. Follow the procedure for chaincase reassembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.30 © Copyright Polaris Inc.

  • Page 403: Brake System

    In addition, the fluid stored in a pressure bleeder may be contaminated. Always use fresh DOT 4 brake fluid from a sealed container. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.31 © Copyright Polaris Inc.

  • Page 404: Brake System Assembly View

    40 ft-lbs (54 N·m) 100-135 in-lbs (11-15 N·m) Discard and replace with new fasteners when removed Caliper Assembly Washers Brake Pad Retaining Pin 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.32 © Copyright Polaris Inc.

  • Page 405: Master Cylinder Assembly View

    Inner Reservoir Fastener: 6-8 in-lbs (0.68-0.90 N·m) Master Cylinder Clamp Fastener Park Lever Assembly 60-80 in-lbs (6.8-9 N·m) Piston Assembly Brake Lever 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.33 © Copyright Polaris Inc.

  • Page 406: Brake System Inspection

    Brake Pad injury or death. Have the brakes serviced at the first sign of abnormal feel or performance. Brake Disc 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.34 © Copyright Polaris Inc.

  • Page 407: Brake Reservoir Fluid Level

    Position the handlebars so the brake fluid reservoir is as close to level as possible. View the fluid level through the reservoir and verify the reservoir is almost full. If the fluid level is low, add POLARIS DOT 4 brake fluid to proper specification. MEASUREMENT Brake Reservoir Fluid Level: 0.1125±0.0625 in (2.856±1.588 mm)

  • Page 408: Brake System Bleeding

    6. Install cover and fasteners. Torque fasteners to specification. TORQUE Brake Reservoir Cover Fasteners: 6-8 in-lbs (0.68-0.90 N·m) 2. Remove the reservoir cover and gasket 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.36 © Copyright Polaris Inc.
  • Page 409 5. Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4-turn to release air. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.37 © Copyright Polaris Inc.

  • Page 410: Phantom Brake Pad Inspection / Replacement

    6. Install the brake pads back into the caliper. 7. Reinstall the retaining pin. 8. Test brake system prior to returning vehicle to service. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.38 © Copyright Polaris Inc.
  • Page 411 7. Remove the cover fasteners , cover , and damper . Drain any residual brake fluid out of the reservoir into a suitable container. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.39 © Copyright Polaris Inc.
  • Page 412 Do not attempt to service the piston valve or valve body. Replace with new service part if damaged or corrosion is found. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.40 © Copyright Polaris Inc.
  • Page 413 Do not pinch the brake switch wire in the handlebar clamp. TORQUE Master Cylinder Handlebar Clamp Fasteners: 60-80 in-lbs (6.8-9 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.41 © Copyright Polaris Inc.
  • Page 414 11. Install new crush washers on the banjo bolt and install into master cylinder. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.42 © Copyright Polaris Inc.

  • Page 415: Phantom Brake Caliper Piston / Seal Replacement

    Allow the piece of steel or wood to hang off the bench by 4″ to 5″. 2. Remove and discard the brake caliper mounting fasteners 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.43 © Copyright Polaris Inc.
  • Page 416 Repeat step 7. 17. Follow the Brake Fluid Replacement and Bleeding Procedure. 18. Test brake system prior to returning vehicle to service. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.44 © Copyright Polaris Inc.

  • Page 417: Brake Disc Inspection / Replacement

    40 ft-lbs (54 N·m) 13. Apply the parking brake. Torque brake disc fastener to specification. TORQUE Brake Disc Fastener: 40 ft-lbs (54 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.45 © Copyright Polaris Inc.
  • Page 418 2. Continue to route the brake line upward along the over-structure tube. Secure the brake line with a routing clip the fuel tank bracket. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.46 © Copyright Polaris Inc.
  • Page 419 3. Complete the process by routing the brake line up to the brake master cylinder and secure with banjo bolt 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.47 © Copyright Polaris Inc.
  • Page 420 Studs placed on the outer rows are more susceptible to being ripped out of the track. • Polaris does not recommend studs on the outside band of the Storm 150 track. Damage will occur. • Adding studs may require the use of longer, more aggressive ski wear bars/carbides.
  • Page 421 Overall Installed Height Recommended (3.4 cm) Cobra for Matryx Track Track models Signature Series 1.325 .375 1.58 Signature Series 1.45 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.49 © Copyright Polaris Inc.
  • Page 422 FINAL DRIVE / BRAKE SYSTEMS NOTES 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 6.50 © Copyright Polaris Inc.
  • Page 423 DRIVEN CLUTCH ..................7.25 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 424 ..................7.32 CLUTCH CLEANING 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 425: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 426: 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 427 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 428: Spring Free Length

    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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 429: Perc Team Lwt Driven Helixes

    IMPORTANT Do not install a non-ER helix on a PERC-equipped snowmobile where the engine changes directions. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 430 Tag each spring with the part number when not in use. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 431: Drive Belt

    In order to achieve maximum efficiency from the converter, drive belt tension (deflection), clutch offset, and alignment must be adjusted properly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 432: Drive Belt Removal

    7. Turn the wrench clockwise until the sheaves open far enough to remove the belt. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.10 © Copyright Polaris Inc.

  • Page 433: Drive Belt Installation

    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 434: Drive Clutch

    , clutch spider , and the stationary sheave should line up when the clutch is assembled. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.12 © Copyright Polaris Inc.

  • Page 435: Drive Clutch Assembly View

    Starter Ring Gear Fasteners (Applicable to electric start models) Washers 165 in-lbs (19 N·m) Apply Loctite® 271™ to Threads in hole of Stationary Sheave Roller and Bushing 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.13 © Copyright Polaris Inc.

  • Page 436: 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 437 Place the pin inside the weight to check the flyweight bushing and pin surface for wear by rocking the weight back and forth. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.15 © Copyright Polaris Inc.

  • Page 438: Roller Removal

    When required, button shims are installed on the trailing (right) side of the spider leg as viewed from the front of the spider. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.16 © Copyright Polaris Inc.

  • Page 439: Roller Installation

    MEASUREMENT Button-To-Tower Clearance: .001 - .002 in (0.025 - 0.05 mm) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.17 © Copyright Polaris Inc.

  • Page 440: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.18 © Copyright Polaris Inc.

  • Page 441: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.19 © Copyright Polaris Inc.

  • Page 442: Drive Clutch Assembly

    5. Place the moveable sheave onto the stationary 2870341 sheave. TORQUE Spider Torque: 280-300 ft-lbs (380-406 N·m) Apply Loctite® 243™ to Threads 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.20 © Copyright Polaris Inc.
  • Page 443 Do not allow the side loading or misalignment of the cover or the bushing may become damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.21 © Copyright Polaris Inc.

  • Page 444: Drive Clutch Installation

    4. Slide clutch onto crankshaft taper. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.22 © Copyright Polaris Inc.

  • Page 445: Belt-To-Sheave Clearance Adjustment

    (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”. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.23 © Copyright Polaris Inc.
  • Page 446 When assembling a new clutch with all of the same components, it is not uncommon for the marks not to line up. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.24 © Copyright Polaris Inc.

  • Page 447: Driven Clutch

    Washer Deflection Spacer Retaining E-Ring Snap Ring Moveable Sheave Spring Cup Helix Helix Fasteners Spring 110 in-lbs (12 N·m) Spider 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.25 © Copyright Polaris Inc.

  • Page 448: Driven Clutch Removal

    / bushing located behind the driven clutch. 5. Inspect the jackshaft and driven clutch splines for damage. Replace components as required. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.26 © Copyright Polaris Inc.

  • Page 449: Driven Clutch Assembly

    Apply Loctite 243 to 3235592 helix fasteners. 4. Install and torque helix fasteners to specification. TORQUE Helix Fasteners: 110 in-lbs (12 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.27 © Copyright Polaris Inc.

  • Page 450: 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 451: Pvt System Adjustments

    TORQUE Deflection Screw Jam Nut: 145 in-lbs (16 N·m) 6. Rotate the belt clockwise while removing the L- wrench 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.29 © Copyright Polaris Inc.

  • Page 452: Clutch Alignment / Offset - Ps-51607

    AXYS and MATRYX snowmobiles. Do not use Verify it fits tight against the clutch sheaves. the Clutch Alignment tool on other Polaris snowmobiles. 4. Push the driven clutch inward until it stops. 5. The optimum clutch alignment / offset is when the The drive and driven clutches are offset from each other.

  • Page 453: Clutch Offset / Float Adjustment

    Driven Clutch Bolt: 18 ft-lbs (25 N·m) 5. Apply a light film of Polaris Premium grease to the jackshaft. Install the driven clutch and push it tight toward the bulkhead. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.31...

  • Page 454: Clutch Cleaning

    IMPORTANT Do not lubricate the clutch bushings or any internal clutch components. Clutch bushings are self- lubricating. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 7.32 © Copyright Polaris Inc.
  • Page 455 ..............8.33 IGX 146 RAIL ASSEMBLY VIEW 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 456 ..............8.67 IFS FACTORY CLICKER SETTINGS 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 457 ....... 8.106 WALKER EVANS VELOCITY PIGGYBACK SHOCK ASSEMBLY 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 458: General Information

    / or bump steer. 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 459: Maximum Width / Toe / Camber Specifications

    MAXIMUM SETUP WIDTH (IN / MM) OVERALL) Matryx Not Adjustable Not Adjustable 1/8 - 1/4 in (3.0 - 6.0 mm) (Wide Fixed Camber) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 460: Steering / Front Suspension Assembly Views

    Apply Premium Grease Upper Handlebar Clamp Spacers Front Handlebar Wire Clamp Steering Strap Back Handlebar Wire Clamp Upper Steering Post Mount Fasteners Riser 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 461: Hand Guard Assembly View

    Hand Guards Hand Guard Clamp Fasteners Hand Guard Mounting Arms 18 in-lbs (2 N·m) Hand Guard Arm Fasteners Tighten Until Fully Seated 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 462: Lower Steering Assembly View

    Idler Arm 37 ft-lbs (50 N·m) Rack Link to Pitman / Idler Arm 2& Pitman Arm 20 ft-lbs (27 N·m) Fasteners 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 463: Front Suspension Assembly View - Wide Fixed Camber

    Push forward to remove all clearance prior to torquing nuts Retaining Ring Ski Pivot Bushing Retaining ring must be fully seated Upper Spherical Bearing 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 464: Front Shock Mounting Assembly View

    STEERING / SUSPENSIONS FRONT SHOCK MOUNTING ASSEMBLY VIEW - XC Upper Mounting Fastener 37 ft-lbs (50 N·m) Bushing Lower Mounting Fastener 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.10 © Copyright Polaris Inc.

  • Page 465: Front Shock Mounting Assembly View - Vr1

    STEERING / SUSPENSIONS FRONT SHOCK MOUNTING ASSEMBLY VIEW - VR1 Upper Mounting Fastener Spacer Bushing Lower Mounting Fastener 37 ft-lbs (50 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.11 © Copyright Polaris Inc.

  • Page 466: Front Shock Mounting Assembly View - Switchback Assault 146

    FRONT SHOCK MOUNTING ASSEMBLY VIEW - SWITCHBACK ASSAULT 146 Upper Mounting Fastener O-ring Bushing Lower Mounting Fastener 37 ft-lbs (50 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.12 © Copyright Polaris Inc.

  • Page 467: Ski Assembly View

    Ski Toe Fastener Ski Toe Carbide 37 ft-lbs (50 N·m) Rubber Ski Stop Washer Bushing 8 ft-lbs (11 N·m) Ski Toe Fastener 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.13 © Copyright Polaris Inc.

  • Page 468: Front Sway Bar Assembly View

    20 ft-lbs (27 N·m) Sway Bar Replace with new when removed 7 ft-lbs (10 N·m) Replace with new when removed 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.14 © Copyright Polaris Inc.

  • Page 469: Steering / Front Suspension Service

    . Discard the flange nut. 8. Remove the steering post from the vehicle. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.15 © Copyright Polaris Inc.

  • Page 470: Steering Post Installation

    NOTICE Install the bushings with the split seal recess facing upward. Bushings Split Seal Spacers 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.16 © Copyright Polaris Inc.
  • Page 471 STEERING / SUSPENSIONS 3. Apply a light film of Polaris Premium Grease to the 5. Install fasteners that secure the lower steering post split seal and bushings . Assemble the spacers clamp to the steering post mount. Torque fasteners to specification.
  • Page 472 9. Install the air intake plenum. See Air Intake Plenum Installation page 3.140. 10. Reinstall the hood assembly and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.18 © Copyright Polaris Inc.

  • Page 473: Ski Service

    4. Remove the pivot bushing from the spindle. Clean the pivot bushing to remove any corrosion / foreign material. 5. Inspect the ski bumper. Replace if damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.19 © Copyright Polaris Inc.

  • Page 474: Spindle Service

    Note the position of the washers. 3. Remove the ski and ski bumper NOTICE Note the orientation of the ski bumper. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.20 © Copyright Polaris Inc.

  • Page 475: Spindle Installation

    3. Torque lower control arm and upper control arm spindle nuts to specification. TORQUE Upper / Lower Control Arm Spindle Nuts: 40 ft-lbs (54 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.21 © Copyright Polaris Inc.
  • Page 476 37 ft-lbs (50 N·m) 5. Install the rubber ski stop into the ski and reinstall the ski to the spindle. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.22 © Copyright Polaris Inc.

  • Page 477: Control Arm Service

    . Discard the flange nuts. Remove the lower control arm assembly TORQUE Shock Mounting Fasteners: 37 ft-lbs (50 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.23 © Copyright Polaris Inc.

  • Page 478: Upper Control Arm Removal

    UPPER CONTROL ARM REMOVAL 1. Remove the spindle and ski as an assembly. 2. Remove the sway bar link fastener and nut 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.24 © Copyright Polaris Inc.

  • Page 479: Upper Control Arm Installation

    Torque nut to specification. TORQUE Shock Mounting Fasteners: 37 ft-lbs (50 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.25 © Copyright Polaris Inc.

  • Page 480: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.26 © Copyright Polaris Inc.

  • Page 481: Rear Susupension Assembly Views - Pro

    Rear Cross Shaft Fastener 33 ft-lbs (45 N·m) 56 ft-lbs (76 N·m) Apply Loctite 263 to fastener prior to assembly 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.27 © Copyright Polaris Inc.

  • Page 482: Pro-Cc Rail Assembly View

    Wheel block goes in rear hole on the RH rail asm. Torque until screw protrudes 5mm out of 9 ft-lbs (12 N·m) Idler Adjustment Spacer Hitch Pin 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.28 © Copyright Polaris Inc.

  • Page 483: Pro-Cc Bogie Wheel Assembly View

    STEERING / SUSPENSIONS PRO-CC BOGIE WHEEL ASSEMBLY VIEW Bogie Wheel Asm. 10 ft-lbs (14 N·m) Bogie Wheel Fastener Offset Washer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.29 © Copyright Polaris Inc.

  • Page 484: Pro-Cc Front Torque Arm Assembly View

    56 ft-lbs (76 N·m) Apply Loctite 263 to fastener prior to assembly FTA Mount Tapped 12 ft-lbs (16 N·m) Washer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.30 © Copyright Polaris Inc.

  • Page 485: Pro-Cc Rear Torque Arm Assembly View

    17 ft-lbs (23 N·m) Pull Rod Bushing 24 ft-lbs (33 N·m) Rear Mounting Arm Shock Rod Rear Torque Arm Mount Shaft 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.31 © Copyright Polaris Inc.

  • Page 486: Rear Susupension Assembly Views - Igx 146

    FTS Mounting Shaft Rear Pivot Arm Fastener RTA Scissor Stop Guide Fastener Shock Spacer Idler Fastener Washer 33 ft-lbs (45 N·m) Washer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.32 © Copyright Polaris Inc.

  • Page 487: Igx 146 Rail Assembly View

    17 ft-lbs (23 N·m) 2& Spring Square Guide Front Jounce Bumper Spring Roller Shaft Torque until screw protrudes 5mm out of nut 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.33 © Copyright Polaris Inc.

  • Page 488: Igx 146 Bogie Wheel Assembly View

    STEERING / SUSPENSIONS IGX 146 BOGIE WHEEL ASSEMBLY VIEW Bogie Wheel Asm. 10 ft-lbs (14 N·m) Bogie Wheel Fastener Offset Washer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.34 © Copyright Polaris Inc.

  • Page 489: Igx 146 Front Torque Arm Assembly View

    24 ft-lbs (33 N·m) shaft, rubber to the outside Limiter Strap Fastener Front Torque Arm to Rail Fastener Front Torque Arm 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.35 © Copyright Polaris Inc.

  • Page 490: Igx 146 Rear Torque Arm Assembly View

    Rear Torque Arm to Tunnel Fastener RTS Bushing 46 ft-lbs (63 N·m) Washer Shock Rod Washer 33 ft-lbs (45 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.36 © Copyright Polaris Inc.

  • Page 491: Rear Suspension Service

    2. Press the bearing out of the bogie wheel. 3. Install a new bearing into the bogie wheel by pressing on the bearing’s outer race. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.37 © Copyright Polaris Inc.

  • Page 492: Shocks - Pro-Cc Models

    Limiter Strap Lock Nuts: 12 ft-lbs (16 N·m) 5. Reset the FTS spring preload to the measurement noted prior to disassembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.38 © Copyright Polaris Inc.

  • Page 493: Rear Track Shock (Rts) Service

    3. Reinstall the bogie wheel, fastener, washer, and nut. Torque nut to specification. TORQUE Bogie Wheel Lock Nuts: 10 ft-lbs (14 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.39 © Copyright Polaris Inc.

  • Page 494: Shocks - Igx 146 Models

    6. Remove the two screws securing the FTS cross shaft to the left and right rail beams. Note there is a washer on each screw. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.40 © Copyright Polaris Inc.
  • Page 495 1. .813″ x .406″ x .105″ Washers 2. Shock Centering Spacers 3. .719″ x 1.25″ x .065″ Washers 4. Cross Shaft 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.41 © Copyright Polaris Inc.

  • Page 496: Rear Track Shock (Rts) Service

    Use new lock nuts when installing the shock. Torque fasteners to specifications. TORQUE Rear Track Shock Fasteners: 33 ft-lbs (45 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.42 © Copyright Polaris Inc.

  • Page 497: Rear Suspension - Pro-Cc Models

    Push the rear idler shaft / idler wheel assembly forward. 3. Remove the two upper carrier fasteners and nuts NOTICE Right side shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.43 © Copyright Polaris Inc.

  • Page 498: Rear Suspension Installation - Pro

    Upper Carrier Fasteners: 33 ft-lbs (45 N·m) NOTICE Right side shown. 6. Perform the Track Alignment and Track Tension Adjustment procedures. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.44 © Copyright Polaris Inc.

  • Page 499: Pro-Cc Rear Suspension Side To Side Play

    9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.45 © Copyright Polaris Inc.

  • Page 500: Rear Suspension - Igx 146 Models

    Push the rear idler shaft / idler wheel assembly forward. 3. Remove the two upper carrier fasteners , spring washers , and washers NOTICE Right side shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.46 © Copyright Polaris Inc.

  • Page 501: Rear Suspension Installation - Igx 146

    Upper Carrier Fasteners: 46 ft-lbs (63 N·m) NOTICE Right side shown. 6. Perform the Track Alignment and Track Tension Adjustment procedures. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.47 © Copyright Polaris Inc.

  • Page 502: General Setup / Adjustments - All Models

    11 ft-lbs (15 N·m) Hand Guard Clamp Fasteners -18 in-lbs (2 N·m) Auxiliary Engine Stop Switch Holder Fastener 20 in-lbs (2.3 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.48 © Copyright Polaris Inc.

  • Page 503: Handlebar Component Locations

    0.078 in (2 mm) 9.25 in (235 mm) To grip end 0.078 in (2 mm) 6.30 in (160 mm) To grip end 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.49 © Copyright Polaris Inc.

  • Page 504: Handlebar Angle Adjustment

    Stretching the wires could damage the handwarmers. 3. Tighten the fasteners to specification. TORQUE Handlebar Riser Fasteners: 11 ft-lbs (15 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.50 © Copyright Polaris Inc.

  • Page 505: Left Hand Control Adjustment

    If applicable, hand guards may need to be loosened or removed to access and move the brake master cylinder. 2. Loosen the four left hand control mounting screws 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.51 © Copyright Polaris Inc.

  • Page 506: Two Piece Throttle Control Removal

    , and side as the wiring is part of the handlebar wiring adjustment washers . Note the number of washers. harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.52 © Copyright Polaris Inc.
  • Page 507 8. Slide the lower block out of the upper block Remove the throttle blocks from the handlebar. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.53 © Copyright Polaris Inc.

  • Page 508: Two Piece Throttle Control Installation

    Make sure the switch is properly oriented. block. Torque fastener to specification. TORQUE Auxiliary Stop Switch Mount Screw: 20 in-lbs (2.3 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.54 © Copyright Polaris Inc.
  • Page 509 , and e-clip 7. Torque the throttle block set screw to specification. TORQUE Throttle Block Set Screw: 27 in-lbs (3.1 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.55 © Copyright Polaris Inc.

  • Page 510: Front Suspension

    Front Lower Control Arm Pivot Screw / Nut: 40 ft-lbs (54 N·m) MEASUREMENT Ski Toe Setting (Overall): 1/8 - 1/4 in (3 - 6 mm) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.56 © Copyright Polaris Inc.

  • Page 511: Ski Skag Inspection / Skag Replacement

    9. Torque steering tie rod jam nuts and spindle fasteners to specification. TORQUE Tie Rod Spindle Fasteners: 37 ft-lbs (50 N·m) Rod End Jam Nuts: 11 ft-lbs (15 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.57 © Copyright Polaris Inc.
  • Page 512 3. Reverse the steps to install a skag. Tighten nuts to specification. TORQUE Ski Skag Nuts: 8 ft-lbs (11 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.58 © Copyright Polaris Inc.

  • Page 513: Rear Suspension

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.59 © Copyright Polaris Inc.

  • Page 514: Track Alignment

    See Track 6. Tighten the idler shaft bolts to specification. Tension Specifications. TORQUE Rear Idler Fastener: 33 ft-lbs (45 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.60 © Copyright Polaris Inc.

  • Page 515: Track Tension Adjustment

    7. Tighten the lock nuts. 8. Tighten idler shaft fasteners to specification. TORQUE Rear Idler Fastener: 33 ft-lbs (45 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.61 © Copyright Polaris Inc.

  • Page 516: Track Tension Specifications

    IMPORTANT Rear Idler 16 in (40 cm) 10 lb (4.54 Fasteners: ahead of rear If the track is studded, Polaris recommends IGX 146 33 ft-lbs (45 N·m) idler shaft maintaining 7/8 in (2.2 cm) track tension setting at all times.

  • Page 517: 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 518: General Setup / Adjustments - Pro-Cc Models

    Adding traction components, such as traction studs or additional ski skag carbides, or changing the factory equipped track, could change handling characteristics. Additional setup may be required. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.64 © Copyright Polaris Inc.

  • Page 519: Shock Locations

    For a more plush ride at the front or rear suspension, rotate the clicker(s) counter-clockwise two clicks, then test ride. Repeat the adjustment until the desired ride quality is achieved. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.65 © Copyright Polaris Inc.

  • Page 520: Torsion Spring Adjustments

    2884973 Spring, Torsion Heavy Duty 220-350 lb (100-159 kg) 2884974 Spring, Torsion Extra Heavy Duty 310-425 lb (141-193 kg) 2884975 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.66 © Copyright Polaris Inc.
  • Page 521 INSTALLED SPRING LENGTH LENGTH 10.75 in (27.3 9.75 in (24.8 INDY XC 10.75 in (27.3 9.75 in (24.8 INDY VR1 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.67 © Copyright Polaris Inc.
  • Page 522 Spring preload is measured between edge of shock INDY XC body cap and spring edge - not shock locking collar / INDY VR1 retainers. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.68 © Copyright Polaris Inc.
  • Page 523 Adding traction components, such as traction studs or additional ski skag carbides, or changing the factory equipped track, could change handling characteristics. Additional setup may be required. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.69 © Copyright Polaris Inc.
  • Page 524 For a more plush ride at the front or rear suspension, rotate the clicker(s) counter-clockwise two clicks, then test ride. Repeat the adjustment until the desired ride quality is achieved. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.70 © Copyright Polaris Inc.
  • Page 525 WEIGHT RANGE Spring, Torsion Light Duty 0-180 lb (0-82 kg) 2884976 Heavy Duty Spring, Torsion 220-350 lb (100-159 kg) 2884977 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.71 © Copyright Polaris Inc.

  • Page 526: Front Suspension

    - not shock locking collar / retainers. CLICKER SETTING MODEL (FROM FULL HARD) Switchback Assault 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.72 © Copyright Polaris Inc.

  • Page 527: Front Track Shock Factory Clicker Settings

    MODEL (FROM FULL HARD) Switchback Assault REAR TRACK SHOCK FACTORY CLICKER SETTINGS CLICKER SETTING MODEL (FROM FULL HARD) Switchback Assault 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.73 © Copyright Polaris Inc.

  • Page 528: Shocks

    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 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.74 © Copyright Polaris Inc.
  • Page 529 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/ 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.75 © Copyright Polaris Inc.

  • Page 530: 2021 Shock Specifications

    Bottom of reservoir to bottom (inches) of floating piston of floating piston of floating piston Oil Volume Full Full Full 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.76 © Copyright Polaris Inc.
  • Page 531 6 ID x .25 x 9 6 ID x .25 x 11 6 ID x .25 x 11 6 ID x .25 x 9 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.77 © Copyright Polaris Inc.
  • Page 532 Top of reservoir to top of Top of reservoir to top of (inches) floating piston floating piston floating piston Oil Volume Full Full Full 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.78 © Copyright Polaris Inc.
  • Page 533 6 ID x .30 x 11 6 ID x .30 x 11 6 ID x .30 x 11 6 ID x .30 x 11 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.79 © Copyright Polaris Inc.
  • Page 534 Top of reservoir to top of Top of reservoir to top of (inches) floating piston floating piston floating piston Oil Volume Full Full Full 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.80 © Copyright Polaris Inc.
  • Page 535 Adjuster .800 x .008 1.00 x .010 1.10 x .004 1.00 x .012 Ring .700 x .006 1.10 x .008 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.81 © Copyright Polaris Inc.

  • Page 536: Walker Evans Shocks

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.82 © Copyright Polaris Inc.

  • Page 537: Walker Evans Shock Valve Part Numbers - 3/8" I

    1800068 .900 1800069 1.000 .015 1800070 1.100 1800380 1.200 1800071 1.250 1800072 1.300 1800090 1.000 1800091 1.100 .025 1800092 1.200 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.83 © Copyright Polaris Inc.

  • Page 538: Walker Evans Shock Valve Part Numbers - 7/16" I

    1.200 1800248 1.300 1800249 1.450 1800250 1.500 1800251 1.550 1801114 .700 1801118 .800 1800252 .900 .012 1800253 1.000 1800254 1.100 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.84 © Copyright Polaris Inc.
  • Page 539 1.200 1800264 1.300 1800265 1.450 1800266 1.500 1800267 1.550 1800268 1.000 .090 (WASHERS) 1800269 1.100 1800270 1.250 1800271 1.300 .025 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.85 © Copyright Polaris Inc.

  • Page 540: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.86 © Copyright Polaris Inc.

  • Page 541: Walker Evans Piggyback Shock Ifp Depth

    Caliper. Reference the shock specification tables in this chapter for measurement (A). NOTICE The flat side of the IFP faces the clicker assembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.87 © Copyright Polaris Inc.

  • Page 542: Walker Evans Force Piggyback

    STEERING / SUSPENSIONS WALKER EVANS FORCE PIGGYBACK WALKER EVANS PIGGYBACK SHOCK ASSEMBLY VIEW 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.88 © Copyright Polaris Inc.
  • Page 543 Replace service port assembly after fifth charging. Snap Ring Sleeve Bushing Piston Assembly O-Ring Replace with new when removed. Jam Nut — Spring Not shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.89 © Copyright Polaris Inc.

  • Page 544: Walker Evans Piggyback Shock Disassembly

    3. Remove the shock bushings and spacers. 6. Depressurize the shock by installing the gas fill tool into the bleed port. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.90 © Copyright Polaris Inc.
  • Page 545 9. Remove the shock from the vise and pour shock oil into an approved container. Place shock back into vise. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.91 © Copyright Polaris Inc.
  • Page 546 The bearing cap shaft bushing is serviceable, but it is recommended to replace bearing cap assembly if bushing is worn or damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.92 © Copyright Polaris Inc.
  • Page 547 Discard the O- ring. NOTICE Servicing the clicker assembly is difficult without the proper tools. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.93 © Copyright Polaris Inc.

  • Page 548: Walker Evans Piggyback Shock Assembly

    Torque the body cap / tube to specification. TORQUE Shock Body Cap / Tube: 45 ft-lbs (61 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.94 © Copyright Polaris Inc.
  • Page 549 8. Assemble the bearing cap. Coat a new bearing cap 6. Reinstall the clicker knob and screw. O-ring with new shock oil. Install into bearing cap. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.95 © Copyright Polaris Inc.
  • Page 550 11. When assembled, the O-ring , U-cup seal , wiper seal should be orientated as shown. Bushing shown for reference. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.96 © Copyright Polaris Inc.
  • Page 551 IFP. Verify the bleed screw and O-ring are removed from the IFP. Coat the IFP with shock oil. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.97 © Copyright Polaris Inc.
  • Page 552 28. Remove the bleed screw and O-ring from the IFP. 29. Set the IFP depth to specification. Reinstall the O-ring and bleed screw. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.98 © Copyright Polaris Inc.
  • Page 553 STEERING / SUSPENSIONS 33. Install the service port button screw and O-ring. 34. Reinstall the shock bushings and spacers. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.99 © Copyright Polaris Inc.

  • Page 554: Walker Evans Velocity Piggyback

    STEERING / SUSPENSIONS WALKER EVANS VELOCITY PIGGYBACK WALKER EVANS PIGGYBACK SHOCK ASSEMBLY VIEW 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.100 © Copyright Polaris Inc.
  • Page 555 Lock Nut Jam Nut O-Ring Replace with new when removed. Retaining Ring Wear Band. Spring Guide — Spring Not shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.101 © Copyright Polaris Inc.

  • Page 556: Walker Evans Velocity Piggyback Shock Disassembly

    3. Remove the shock bushings and spacer. 6. Depressurize the shock by installing the gas fill tool into the bleed port. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.102 © Copyright Polaris Inc.
  • Page 557 9. Remove the shock from the vise and pour shock oil into an approved container. Place shock back into vise. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.103 © Copyright Polaris Inc.
  • Page 558 The bearing cap shaft bushing is serviceable, but it is recommended to replace bearing cap assembly if bushing is worn or damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.104 © Copyright Polaris Inc.
  • Page 559 21. Optional service: Remove the clicker assembly from the shock bridge. NOTICE Servicing the clicker assembly is difficult without the proper tools. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.105 © Copyright Polaris Inc.

  • Page 560: Walker Evans Velocity Piggyback Shock Assembly

    Tighten nut to specification. 4. Reinstall the clicker knob and screw. TORQUE Clicker Assembly Nut: 45 in-lbs (5 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.106 © Copyright Polaris Inc.
  • Page 561 9. When assembled, the O-ring , U-cup seal , wiper seal should be orientated as shown. Bushing shown for reference. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.107 © Copyright Polaris Inc.
  • Page 562 IFP. Verify the bleed screw and O-ring are removed from the IFP. Coat the IFP with shock oil. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.108 © Copyright Polaris Inc.
  • Page 563 26. Remove the bleed screw and O-ring from the IFP. 27. Set the IFP depth to specification. Reinstall the O-ring and bleed screw. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.109 © Copyright Polaris Inc.
  • Page 564 30. Charge the shock with nitrogen to the specified pressure. The shock rod should extend during charging. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 8.110 © Copyright Polaris Inc.
  • Page 565 ..........9.37 FRONT TUNNEL BULKHEAD COOLER INSTALLATION 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.
  • Page 566 ..............9.42 LEFT SUPPORT BRACE INSTALLATION 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 567: General Information

    • Do not place the vehicle into service until the adhesive has completely cured (24 hours). 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 568: Chassis Assembly Views

    Chaincase Housing 22 ft-lbs (30 N·m) Chaincase / Side Support Fasteners 26 ft-lbs (35 N·m) Idler Bracket Replace with new when removed 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 569: Left Bulkhead / Side Support Assembly View

    Left Support Brace Crossover Tube Lower Steering Mount Lower Steering Mount Fasteners Jackshaft Bearing Mount to Bulkhead Fasteners 22 ft-lbs (30 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 570: Over Structure Assembly View

    22 ft-lbs (30 N·m) Tube Spacers Left Tube Brace Tube Shims Upper Over Structure Fasteners Foam Pads 12.5 ft-lbs (17 N·m) PBR Mount 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 571: Clutch Guard / Footrests Assembly View

    Console Support Clutch Guard Support U-Nut Left Footrest / Closeoff Rivets Clutch Guard Right Footrest / Closeoff 8 ft-lbs (10 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 572: Tunnel Assembly View

    9 ft-lbs (12 N·m) Footrest Support Fasteners Left Running Board 7 ft-lbs (9 N·m) Right Running Board Left Footrest Support Running Board Mount Fastener 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 573: Body Assembly Views

    1/4 Turn Retainer Middle Hood Screen 1/4 Turn Stud Retainer Hood Trim Fasteners Lower Hood Screen 11 in-lbs (1.25 N·m) RH Hood Plug 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual © Copyright Polaris Inc.

  • Page 574: Hood Foam Assembly View

    LH Rear Hood Foam RH Middle Hood Foam RH Rear Hood Foam Front Hood Foam Kit (All Pieces Included) LH Middle Hood Foam 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.10 © Copyright Polaris Inc.

  • Page 575: Hood Cap Assembly View

    Friction hinge to be pressed in flush with edge of the Grommet hood cap Display Fasteners Top Latch 53 in-lbs (6 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.11 © Copyright Polaris Inc.

  • Page 576: Nosepan Assembly View

    CHASSIS NOSEPAN ASSEMBLY VIEW Nosepan Fiber Pad RH Nosepan Foam LH Nosepan Foam Rivet 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.12 © Copyright Polaris Inc.

  • Page 577: Right Fender Assembly View

    Snow Exhaust Deflector Fender Fasteners Plastic Rivet 36 in-lbs (4 N·m) RH IFS Hole Plug Washer Rivet Exhaust Outlet Boot 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.13 © Copyright Polaris Inc.

  • Page 578: Left Fender Assembly View

    CHASSIS LEFT FENDER ASSEMBLY VIEW Left Fender Rivet LH Upper Fender Foam Plastic Rivet LH IFS Hole Plug 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.14 © Copyright Polaris Inc.

  • Page 579: Right Side Panel Assembly View

    1/4 Turn Latch 10 in-lbs (1.1 N·m) RH Upper Side Panel Foam Washer Latch Grommet RH Lower Side Panel Foam 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.15 © Copyright Polaris Inc.

  • Page 580: Left Side Panel Assembly View

    LH Side Panel 1/4 Turn Latch LH Rear Lower Side Panel Foam LH Rear Upper Side Panel Foam Washer Latch Grommet 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.16 © Copyright Polaris Inc.

  • Page 581: Console Assembly View

    71 in-lbs (8 N·m) Roller Bushing Filler Neck Nut 1/4 Turn Clip Recoil Roller Plastic Rivets Recoil Roller Fastener Console Switch Panel 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.17 © Copyright Polaris Inc.

  • Page 582: Seat Assembly View

    SEAT ASSEMBLY VIEW Seat Assembly Washer Rear Tank Trim 1/4 Turn Latch Rear Tank Trim Nuts Latch Grommet 44 in-lbs (5 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.18 © Copyright Polaris Inc.

  • Page 583: Bumper Assemby Views

    LH 1/4 Turn Mount Front Lower Bumper Rivet Bumper / Nosepan Fasteners: Bumper Mounting Fasteners 7 ft-lbs (10 N·m) Pipe / Chassis Bracket 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.19 © Copyright Polaris Inc.

  • Page 584: Rear Bumper / Closeoff Assembly View

    Only applicable if stud protection accessory kit is installed 7 ft-lbs (9 N·m) Tube Plug Only applicable if stud protection accessory kit is installed 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.20 © Copyright Polaris Inc.

  • Page 585: Body Service

    3. Close the panel and secure with the three 1/4 turn fasteners. 2. Open the side panel, then pull the panel outward to release the tabs at the bottom. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.21 © Copyright Polaris Inc.

  • Page 586: Hood Removal

    5. Reinstall the left and right side panels. 4. Disconnect the hood wire harness connector 5. Remove the hood assembly from the vehicle. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.22 © Copyright Polaris Inc.

  • Page 587: Console Removal

    3. Disconnect the hood harness connector from the main harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.23 © Copyright Polaris Inc.
  • Page 588 9. Remove fuel cap and plastic fuel filler neck nut 12. Reinstall the fuel cap. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.24 © Copyright Polaris Inc.

  • Page 589: Console Installation

    NOTICE When installing the console, make sure the o-ring on the fuel tank neck is in place and not damaged. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.25 © Copyright Polaris Inc.
  • Page 590 10. Align the tabs at the bottom of the side panel with into the nosepan. the slots in the fender and carefully insert. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.26 © Copyright Polaris Inc.
  • Page 591 1/4 turn latches . Repeat this step to install the side panel onto opposite side of the snowmobile. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.27 © Copyright Polaris Inc.

  • Page 592: Bonded Component Service

    The recommended source of heat is the use of propane gas, and can be obtained at most commercial hardware stores. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.28 © Copyright Polaris Inc.

  • Page 593: Bonded Component Surface Preparation

    BONDED COMPONENT SURFACE ADHESIVE APPLICATOR KITS Polaris offers a repair kit, individual adhesive cartridges, PREPARATION and replacement needle packs. It is recommended to leave the product unopened until needed. When WARNING...

  • Page 594: Adhesive Application

    Obtaining Adhesive / Mixing Tools Commercially material, slowly compress the caulk gun trigger to fill the mixer needle. The needle will automatically mix • The only Polaris-authorized adhesive is Lord 406/19 and dispense the correct volumetric ratio of adhesive Acrylic Adhesive (Lord 50 ml PN:3003680).

  • Page 595: Adhesive Application Patterns

    ADHESIVE APPLICATION PATTERNS IMPORTANT Reference the following illustrations showing the exact patterns for each bonded component when applying the adhesive. BULKHEAD FLOOR 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.31 © Copyright Polaris Inc.
  • Page 596 CHASSIS CHAINCASE REAR TABS RIGHT BULKHEAD CLIP / CHAINCASE SUPPORT SPAR MATING SURFACE 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.32 © Copyright Polaris Inc.
  • Page 597 CHASSIS RIGHT BULKHEAD CLIP FRONT CORNER LEFT SUPPORT MATING SURFACE 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.33 © Copyright Polaris Inc.
  • Page 598 CHASSIS LEFT BULKHEAD CLIP / SUPPORT SPAR MATING SURFACE LEFT BULKHEAD CLIP FRONT CORNER 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.34 © Copyright Polaris Inc.

  • Page 599: Bulkhead Floor Plate Removal

    7. Thoroughly clean the chassis mating surfaces where the plate attaches to the chassis. Reference the Bonded Component Surface Preparation section. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.35 © Copyright Polaris Inc.

  • Page 600: Front Tunnel Bulkhead Cooler Removal

    • Bulkhead floor plate (See Bulkhead Floor Plate Removal page 9.35) 2. Drill out the rivets securing the cooler to the top of the tunnel. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.36 © Copyright Polaris Inc.

  • Page 601: Front Tunnel Bulkhead Cooler Installation

    Torque fasteners to specification. TORQUE Chaincase / Side Support Fasteners: 26 ft-lbs (35 N·m) Tube Brace Fastener: 22 ft-lbs (30 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.37 © Copyright Polaris Inc.

  • Page 602: Left Bulkhead Clip Removal

    Doing so will require removing the part, removing adhesive, and then re-applying new adhesive. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.38 © Copyright Polaris Inc.

  • Page 603: Left Bulkhead Clip Installation

    Lower Steering Idler Bracket Mount Fasteners Fastener Clip Mounting Side Support Fasteners Fasteners Front Lower Over Crossover Tube Structure Fasteners Fastener 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.39 © Copyright Polaris Inc.

  • Page 604: Right Bulkhead Clip Removal

    Doing so will require removing the part, removing adhesive, and then re-applying new adhesive. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.40 © Copyright Polaris Inc.

  • Page 605: Right Bulkhead Clip Installation

    Side Support Lower Steering Fasteners Mount Fasteners Crossover Tube Idler Bracket Fastener Fastener Clip Mounting Front Lower Over Fasteners Structure Fasteners 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.41 © Copyright Polaris Inc.

  • Page 606: Left Support Brace Removal

    Allow the adhesive to cure for 24 hours at 68 °F (20 °C) before placing the snowmobile back into service. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 9.42 © Copyright Polaris Inc.
  • Page 607 ................10.42 BATTERY REMOVAL 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.1 © Copyright Polaris Inc.
  • Page 608 STATOR..................... 10.72 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.2 © Copyright Polaris Inc.
  • Page 609 ..............10.100 ACCESSORY POWER CONNECTORS 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.3 © Copyright Polaris Inc.
  • Page 610 ..............10.100 12V ACCESSORY RCA ADAPTER 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.4 © Copyright Polaris Inc.

  • Page 611: General Information

    When disconnecting the battery, remove the negative (-) black cable first, and then remove the positive (+) red cable. Reverse steps when connecting battery. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.5 © Copyright Polaris Inc.

  • Page 612: Diagnostic Power Connector

    (OG – BRN Circuits) Not Applicable Fuel Prime Prime Not Applicable Jumper IMPORTANT Fuel pump prime can be done through Digital Wrench. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.6 © Copyright Polaris Inc.
  • Page 613 ECU Connector B Detonation Sensor 2& Coolant Temp Sensor Oil Pump ECU Connector A PBR (ECU, CAN, GND) EV Actuator TPS Sensor 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.7 © Copyright Polaris Inc.

  • Page 614: Chassis Harness Retention Locations

    BATTERY / ELECTRICAL CHASSIS HARNESS RETENTION LOCATIONS The white tape on the harness signifies a retention point. Cable Tie Retention Locations 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.8 © Copyright Polaris Inc.

  • Page 615: Chassis Harness Routing

    BATTERY / ELECTRICAL CHASSIS HARNESS ROUTING NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.9 © Copyright Polaris Inc.

  • Page 616: Rear Harness Component Locations

    BATTERY / ELECTRICAL REAR HARNESS COMPONENT LOCATIONS Main Harness Passenger Power Driver Seat Heater Tail Light 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.10 © Copyright Polaris Inc.

  • Page 617: Rear Harness Routing / Retention

    REAR HARNESS ROUTING / RETENTION ROUTING NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.11 © Copyright Polaris Inc.
  • Page 618 BATTERY / ELECTRICAL RETENTION The white tape on the harness signifies a retention point. Cable Tie Retention Location P-clamp Retention Location 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.12 © Copyright Polaris Inc.

  • Page 619: Hood Harness Component Locations (Standard Instrument Cluster)

    BATTERY / ELECTRICAL HOOD HARNESS COMPONENT LOCATIONS (STANDARD INSTRUMENT CLUSTER) Display Connector 12V Accessory Power Connector Main Harness Connector Headlight Connector 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.13 © Copyright Polaris Inc.

  • Page 620: Hood Harness Routing / Retention (Standard Instrument Cluster)

    HOOD HARNESS ROUTING / RETENTION (STANDARD INSTRUMENT CLUSTER) The white tape on the harness signifies a retention point. Edge Clip Retention Locations 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.14 © Copyright Polaris Inc.

  • Page 621: Hood Harness Component Locations (7S Display)

    HOOD HARNESS COMPONENT LOCATIONS (7S DISPLAY) Display Connector 12V Accessory Power Connector USB Port Headlight Connector Main Harness Connector Display USB Connector 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.15 © Copyright Polaris Inc.

  • Page 622: Hood Harness Routing / Retention (7S Display)

    The cable tie retains the V2V and GPS antenna wiring together The white tape on the harness signifies a retention point. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.16 © Copyright Polaris Inc.

  • Page 623: Handlebar Harness

    BATTERY / ELECTRICAL HANDLEBAR HARNESS HANDLEBAR HARNESS COMPONENT LOCATIONS Handlebar Connections Connector Left Hand Control Connector 12 pin connector 16 pin connector 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.17 © Copyright Polaris Inc.

  • Page 624: Handlebar Harness Routing / Retention

    Secures harness to the handlebar Handlebar Wire Clamp The wire clamp has a clip that hooks onto the handlebar riser block 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.18 © Copyright Polaris Inc.

  • Page 625: Handlebar Connections Pinout

    The white terminal lock will come up 0.15 in (3.8 mm) and stop due to retaining tabs on the sides. There may be an audible click noted. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.19 © Copyright Polaris Inc.

  • Page 626: Handlebar Harness Connector Terminal De-Pinning

    8. Connect the handlebar connections connector and/or the LH controls connector. 9. Install the resonator. 10. Install the hood and side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.20 © Copyright Polaris Inc.
  • Page 627 3. Rewrap the harness covering to cover the wires. 4. Carefully route the connectors through the console switch panel opening. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.21 © Copyright Polaris Inc.
  • Page 628 If more than one heater is replaced, the CALIBRATE connector to the key switch ALL option in Digital Wrench will be necessary. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.22 © Copyright Polaris Inc.

  • Page 629: Left Hand Control Overview

    Digital wrench must be used troubleshooting issues with CAN High the left hand control. CAN Low Ignition Switch Power Start Solenoid Start Ground — — — 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.23 © Copyright Polaris Inc.

  • Page 630: Diagnostic Trouble Codes (Dtcs) - Left Hand Control

    Thumb heater driver Disable thumb Replace left hand C1111 Driver Internal condition does FET shorted heater control Short not exist 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.24 © Copyright Polaris Inc.

  • Page 631: Left Hand Control Service

    7. Unravel the harness covering to expose the wires. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.25 © Copyright Polaris Inc.
  • Page 632 4. Rewrap the harness covering to cover the wires. 5. Carefully route the connectors through the console switch panel opening. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.26 © Copyright Polaris Inc.
  • Page 633 7. Place console switch panel near its installed position and connect the main harness key switch connector to the key switch 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.27 © Copyright Polaris Inc.

  • Page 634: Additional Routings

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.28 © Copyright Polaris Inc.
  • Page 635 3. 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 point outward like shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.29 © Copyright Polaris Inc.

  • Page 636: Speed Sensor Harness Routing

    Secure the speed sensor connector to the connector placement bracket using the Christmas tree clip. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.30 © Copyright Polaris Inc.

  • Page 637: Knock (Det) Sensor Harness Routing

    4. Secure the knock (DET) sensor connector and harness slack to the main harness with a panduit as shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.31 © Copyright Polaris Inc.

  • Page 638: Engine Coolant Temperature (Ect) Sensor Harness Routing

    IMPORTANT ECT IS GLUED TO JUMPER HARNESS CONNECTOR! DO NOT ATTEMPT TO SEPARATE THE ECT FROM THE JUMPER HARNESS. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.32 © Copyright Polaris Inc.

  • Page 639: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.33 © Copyright Polaris Inc.
  • Page 640 Connect the PTO coil connector (blue connector) from the main harness to the coil pack. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.34 © Copyright Polaris Inc.

  • Page 641: Fuel Injector Harness Routing

    3. Route the fuel injector upward toward the coolant bottle and secure on the outside of the hose/electrical support with a panduit 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.35 © Copyright Polaris Inc.
  • Page 642 Secure the fuel injector harness connector to the connector placement bracket using the Christmas tree clip on the connector. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.36 © Copyright Polaris Inc.

  • Page 643: Oil Pump Jumper Harness Routing

    Secure the oil pump jumper harness connector to the connector placement bracket using the Christmas tree clip on the connector. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.37 © Copyright Polaris Inc.

  • Page 644: Load Center

    Power Out Power In 10A Fuse Headlight Power Out — OPEN — Power In 2A Fuse Brake Light Power Out 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.38 © Copyright Polaris Inc.

  • Page 645: Relay / Fuse Details

    RD / BK Load Center Load Center 10A Fuse Headlight Splice, Light Fused Light Power RD / BK Load Center Power 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.39 © Copyright Polaris Inc.
  • Page 646 Gauge Test Power RD / BK Load Center Power EV Actuator Relay Control GY / YE ECU CNA Load Center 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.40 © Copyright Polaris Inc.

  • Page 647: Load Center Location

    NOTICE To access the fuse box, remove the side panels and hood. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.41 © Copyright Polaris Inc.

  • Page 648: Battery

    6. Pull the fender away from the battery compartment to gain better access. 7. Remove the battery hold down strap 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.42 © Copyright Polaris Inc.

  • Page 649: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.43 © Copyright Polaris Inc.
  • Page 650 8. Secure the right fender using the plastic rivet. 9. Reinstall the console using the plastic rivet and console fastener. 10. Reinstall the side panel. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.44 © Copyright Polaris Inc.

  • Page 651: Battery Identification

    • Removable cap plugs / strip on top of battery • Distilled water added as required (Lead Acid only) • Vent tube on side of battery (Lead Acid only) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.45 © Copyright Polaris Inc.

  • Page 652: Dry-Shipped Agm Battery

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.46 © Copyright Polaris Inc.
  • Page 653 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 654: Dry Shipped Agm Battery Charging And Testing

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

  • Page 655: Agm Low Maintenance Battery

    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 656: 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 657: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.51 © Copyright Polaris Inc.

  • Page 658: 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 659: Standard Instrument Cluster

    2. Install the instrument cluster into the display door. 2. As the instrument cluster is removed, disconnect the instrument cluster connector 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.53 © Copyright Polaris Inc.

  • Page 660: Standard Instrument Cluster Pinout

    YE/RD — — — — VT/WH FUEL LEVEL — — — — — — — — WH/RD ACCENT LED CONTROL 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.54 © Copyright Polaris Inc.

  • Page 661: 7S Display With Integrated Ride Command

    6. Disconnect the USB connector , display connector , V2V/antenna connector , and GPS antenna connector from the display. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.55 © Copyright Polaris Inc.

  • Page 662: 7S Display Installation

    Make sure the USB cable in not pinched between the display wire cover and the back of the display door. TORQUE Display Fasteners: 53 in-lbs (6 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.56 © Copyright Polaris Inc.
  • Page 663 7. Reinstall the hood and side panels. TORQUE Display Fasteners: 53 in-lbs (6 N·m) 5. Close the display door and flip the hood over. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.57 © Copyright Polaris Inc.

  • Page 664: 7S Display Pinout

    YE/RD — — — — VT/WH FUEL LEVEL — — — — — — — — WH/RD ACCENT LED CONTROL 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.58 © Copyright Polaris Inc.

  • Page 665: Led Headlight / Tail Light

    LED HEADLIGHT / TAIL LIGHT HEADLIGHT ASSEMBLY VIEW Headlight Fasteners Headlight 22 in-lbs (2.5 N·m) Headlight Adjuster Hardware Includes adjuster knob and retainer 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.59 © Copyright Polaris Inc.

  • Page 666: Led Headlight Overview

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.60 © Copyright Polaris Inc.

  • Page 667: Led Headlight Installation

    22 in-lbs (2.5 N·m) 2. Connect the headlight connector to the headlight. 3. Install the hood. 4. Install the side panels. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.61 © Copyright Polaris Inc.

  • Page 668: Taillight Assembly View

    BATTERY / ELECTRICAL TAILLIGHT ASSEMBLY VIEW Taillight Fasteners Taillight 16 in-lbs (1.8 N·m) Taillight Cover 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.62 © Copyright Polaris Inc.

  • Page 669: Led Tail Light Overview / Service

    LED TAILLIGHT REMOVAL 1. Remove the two fasteners securing the taillight assembly. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.63 © Copyright Polaris Inc.
  • Page 670 2. Install the two fasteners securing the taillight assembly. Torque fasteners to specification. TORQUE Taillight Fasteners: 16 in-lbs (1.8 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.64 © Copyright Polaris Inc.

  • Page 671: Power Boosting Regulator (Pbr)

    3-phase power to ground. connectors by pulling the wires or damage may occur. TORQUE PBR Mounting Fasteners: 6 ft-lbs (8 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.65 © Copyright Polaris Inc.

  • Page 672: Pbr Details

    Red / White Chassis Power Injector Power Splice Injector Power Sense Red / Dark Blue Critical Power #2 Splice Critical Power 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.66 © Copyright Polaris Inc.

  • Page 673: Pbr Circuit

    BATTERY / ELECTRICAL PBR CIRCUIT 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.67 © Copyright Polaris Inc.

  • Page 674: Pbr Testing

    Temp alarm P1605 520365 None allow the temperature idle with a regulator to warning snow-covered cool appears on hood gauge 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.68 © Copyright Polaris Inc.
  • Page 675 Polaris tester Check Chassis Chassis Condition no engagement P1610 520369 voltage above None overvoltage longer exists of PBR connectors 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.69 © Copyright Polaris Inc.

  • Page 676: Pbr Update / Replacement

    Place the battery on the floor next to the engine compartment. 12. Click Continue. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.70 © Copyright Polaris Inc.
  • Page 677 14. Request an Authorization Key from the Dealer Web Site, and click Continue. 15. Digital Wrench will reprogram the PBR software. Once complete, click Finish. 16. Click Return. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.71 © Copyright Polaris Inc.

  • Page 678: Stator

    STATOR STATOR CIRCUIT / ARCHITECTURE 3-Phase AC Coils Crankshaft Position Sensor - 2 Crankshaft Position Sensor - 5 Tooth Tooth 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.72 © Copyright Polaris Inc.
  • Page 679 (Y1 to Y2, Y1 to Y3, Y2 to Y3). 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.73 © Copyright Polaris Inc.

  • Page 680: Stator Harness Routing

    Connect the 3 pin connector to the PBR and the 6 pin connector to the main harness. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.74 © Copyright Polaris Inc.

  • Page 681: Ferrite Suppressor

    This suppressor reduces high frequency noise on ECU CPS input circuit. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.75 © Copyright Polaris Inc.

  • Page 682: Controllers / Converters

    E-VES system or if the EV Learn Procedure fails due to insufficient battery voltage and the battery is supplying at least 12.5 volts. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.76 © Copyright Polaris Inc.

  • Page 683: Ev Actuator Wire Harness Lead Routing

    2. Continue routing the EV actuator wire harness down to the EV actuator and secure to the routing clip 3. Connect the EV actuator connector to the EV actuator. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.77 © Copyright Polaris Inc.

  • Page 684: Switches

    If both of the original keys are lost, the ignition switch assembly must be replaced. PIN CONTINUITY SWITCH CONTINUITY FUNCTION POSITION BETWEEN Down Pins 9 and 10 Shutdown 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.78 © Copyright Polaris Inc.

  • Page 685: Throttle Release Switch

    Circuit closed when tether pulled. The tether switch connects to the main wire harness tether switch connector on the left rear overstructure tube. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.79 © Copyright Polaris Inc.

  • Page 686: Fuses / Diodes / Resistors

    Applies only to models equipped with a battery / electric start wire harness. The battery / electric start wire harness features a 10 amp battery tender fuse. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.80 © Copyright Polaris Inc.

  • Page 687: Relays

    Battery Charge Relay Control NOTICE If relay is removed for service, re-install with a drop of NyoGel on each connector blade. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.81 © Copyright Polaris Inc.

  • Page 688: Capacitors

    4. The reading should match the capacitance specification for the capacitor. If it does not, replace the capacitor. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.82 © Copyright Polaris Inc.

  • Page 689: Electric Start / Battery Bracket

    22 ft-lbs (30 N·m) Terminal Hardware Routing Clip 36 in-lbs (4 N·m) D-ring Rubber Strap Battery Heat Shield 7 ft-lbs (10 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.83 © Copyright Polaris Inc.

  • Page 690: Electric Start Harness Routing

    The panduit head should point away from the fuel tank. 3. Secure the battery tender port to the console support with two fasteners. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.84 © Copyright Polaris Inc.
  • Page 691 6. Finish routing by securing the battery tender fuse to the right footrest with an edge clip as shown. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.85 © Copyright Polaris Inc.

  • Page 692: 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.86 © Copyright Polaris Inc.
  • Page 693 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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.87 © Copyright Polaris Inc.
  • Page 694 8. Secure the positive and negative battery cables together with the panduit in location shown NOTICE The white tape signifies a retention point. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.88 © Copyright Polaris Inc.
  • Page 695 3. Make sure the electric start harness is routed along the right footrest and secured in the edge clip / panduit in the location shown 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.89 © Copyright Polaris Inc.

  • Page 696: Starter Motor / Flex Drive Assembly View

    Electric Start Lower Tube Bracket Gear Clamp Electric Start Upper Tube Bracket Do not over-tighten / strip teeth Starter Flex Shaft 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.90 © Copyright Polaris Inc.

  • Page 697: Starter Motor / Flex Drive Removal

    • Y-pipe 5. Remove the fasteners attaching the pinion assembly to the engine. 8. Remove the starter motor gear clamp 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.91 © Copyright Polaris Inc.

  • Page 698: Starter Motor / Flex Drive Installation

    10. Install the exhaust pipe and silencer. 11. Install the hood and side panels. TORQUE Pinion / Bracket Fasteners: 7 ft-lbs (10 N·m) 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.92 © Copyright Polaris Inc.

  • Page 699: Starter Solenoid Bench Test

    77 °F (25 °C), verify there is continuity between the two red cable posts If the solenoid does not pass either test, replace the solenoid. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.93 © Copyright Polaris Inc.

  • Page 700: Circuit Diagrams

    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. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.94 © Copyright Polaris Inc.

  • Page 701: Hand / Thumb Warmers

    SMARTWARMERS DIAGNOSTIC OVERVIEW WHAT IS THE SMARTWARMERS SYSTEM? SmartWarmers is a programmable hand and thumb warmer system exclusively available on Polaris Matryx snowmobiles. The heating elements build heat quickly and maintain a customized temperature regardless of external factors like ambient temperature and cross winds. To achieve a customized level of comfort, riders can independently set the thumb heating element and grip heating elements to his/her preferred setting ranging from 68 - 158 °F (20 - 70...
  • Page 702 When troubleshooting the SmartWarmers system, it is best practice to perform the SmartWarmers calibration procedure as a first attempt to resolve any issues. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.96 © Copyright Polaris Inc.

  • Page 703: Thumb Warmer Diagnostics

    BATTERY / ELECTRICAL THUMB WARMER DIAGNOSTICS FULL LENGTH HAND WARMERS The thumb warmer on all Polaris snowmobiles is a Full length hand warmers differ from standard length thermistor-type warming element pad. This means its warmers in that they are cut to match the bend of the resistance will change based on temperature.

  • Page 704: Heated Grip Calibration Procedure

    Next-Gen Service Power Harness. The Tri Power- Up Adapter can be used to power all three connections Tri Power-Up Adapter: PS-50805-B 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.98 © Copyright Polaris Inc.
  • Page 705 “No Response” cycle key switch and try again. 13. Select all the components that have been replaced and then click “Continue” to proceed. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.99 © Copyright Polaris Inc.

  • Page 706: Accessory Power Connectors

    12V hood receptacle (if equipped). The adapter converts the receptacle outlet into a RCA outlet that some rider accessories require for use. 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual 10.100 © Copyright Polaris Inc.
  • Page 707 Belt Deflection PERC Overview .............4.20 Adjustment ........... 2.26, 7.29 PERC Troubleshooting Notes ........4.20 Inspection............. 2.26, 7.29 T-MAP Sensor ............4.8 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual IX.1 © Copyright Polaris Inc.
  • Page 708 Cooling Hose - Cold Side Vehicle Identification Information .......1.70 Routing / Retention ..........3.133 Digital Wrench® Cooling Hose - Hot Side Polaris Mobile Digital Wrench® (PMDW) .....1.72 Routing / Retention ..........3.131 Drive Belt Cooling System Installation ............ 2.24, 7.11 Assembly View ............
  • Page 709 Assembly View - Switchback Assault 146 ....8.12 Ignition Timing ............10.5 Assembly View - VR1 ..........8.11 Electrical Systems Assembly View - XC..........8.10 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual IX.3 © Copyright Polaris Inc.
  • Page 710 Rear Torque Arm Assembly View.......8.36 General Cautions and Notes ......... 9.3 Jackshaft Assembly View ............6.28 Installation ............6.29 Hand Guard Removal...............6.29 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual IX.4 © Copyright Polaris Inc.
  • Page 711 Coolant Level Check ..........2.22 Installation ............3.30 Cooling System Bleeding .........2.23 Removal...............3.29 Cooling System Overview ........2.22 Orientation Views Drive Belt..............1.73 Component ............3.54 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual IX.5 © Copyright Polaris Inc.
  • Page 712 Walker Evans Piggyback Assembly View....8.88, 8.100 Factory Clicker Settings ........8.68, 8.73 Walker Evans Velocity Piggyback Rear Track Shock (RTS) Shock Assembly ..........8.106 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual IX.6 © Copyright Polaris Inc.
  • Page 713 Tether Switch ............10.79 Water Pump Assembly View ............3.62 Installation ............3.94 Removal...............3.91 Taillight Assembly View ............ 10.62 Team Driven Springs........... 7.8 Thermostat 9850064 R03 - 2021 650 / 850 Matryx Trail Performance / Crossover Snowmobile Service Manual IX.7 © Copyright Polaris Inc.
  • Page 714 HANDLEBAR CONNECTOR LEFT HAND CONTROLS HOOD/CHASSIS HARNESS-MAIN,STD 650/850 OIL LEVEL SWITCH (P/N 4012624) PBR (ECU,CAN,GND) FUEL PUMP FRONT WORK LIGHT SWITCH FURUKAWA FSW-C-6F-B (Black) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 LEVEL SENDER OUTPUT 1 2 3 4 5 6 PBR (DC PWR) WIRE COLOR LEGEND...
  • Page 717 HARNESS-HOOD STD WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN SCHEMATIC CABLE/WIRE TERMINATION TABLE ORANGE NO = SWITCH NORMALLY OPEN CCT # TYPE GAUGE COLOR FROM COMPONENT...
  • Page 718 HARNESS-ESTART 6/850 TP-CO 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 719 HARNESS-REAR 129 WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN SCHEMATIC CABLE/WIRE TERMINATION TABLE GRAY CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION LIGHT GREEN NC = SWITCH NORMALLY CLOSED MAIN HARNESS...
  • Page 720 HARNESS-REAR 137 WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN SCHEMATIC CABLE/WIRE TERMINATION TABLE GRAY CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION LIGHT GREEN NC = SWITCH NORMALLY CLOSED MAIN HARNESS...
  • Page 721 HARNESS-REAR 146 WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN SCHEMATIC CABLE/WIRE TERMINATION TABLE GRAY CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION LIGHT GREEN NC = SWITCH NORMALLY CLOSED MAIN HARNESS...
  • Page 722 HANDLEBAR CONNECTOR LEFT HAND CONTROLS HOOD/CHASSIS CHASSIS POWER CIRCUIT OIL LEVEL SWITCH (P/N 4012624) PBR (ECU,CAN,GND) FUEL PUMP FRONT WORK LIGHT SWITCH FURUKAWA FSW-C-6F-B (Black) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 LEVEL SENDER OUTPUT 1 2 3 4 5 6 PBR (DC PWR) WIRE COLOR LEGEND...
  • Page 723 CHASSIS POWER CIRCUIT WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN ORANGE NO = SWITCH NORMALLY OPEN PINK HARNESS: 2415122_650_850_CHAS-01 VIOLET (PURPLE) WHITE YELLOW...
  • Page 724 HANDLEBAR CONNECTOR LEFT HAND CONTROLS HOOD/CHASSIS CRITICAL POWER CIRCUIT OIL LEVEL SWITCH (P/N 4012624) PBR (ECU,CAN,GND) FUEL PUMP FRONT WORK LIGHT SWITCH FURUKAWA FSW-C-6F-B (Black) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 LEVEL SENDER OUTPUT 1 2 3 4 5 6 PBR (DC PWR) WIRE COLOR LEGEND...
  • Page 725 CRITICAL POWER CIRCUIT WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN ORANGE NO = SWITCH NORMALLY OPEN PINK HARNESS: 2415122_650_850_CRIT-01 VIOLET (PURPLE) WHITE YELLOW...
  • Page 726 HANDLEBAR CONNECTOR LEFT HAND CONTROLS HOOD/CHASSIS ECU POWER CIRCUIT OIL LEVEL SWITCH (P/N 4012624) PBR (ECU,CAN,GND) FUEL PUMP FRONT WORK LIGHT SWITCH FURUKAWA FSW-C-6F-B (Black) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 LEVEL SENDER OUTPUT 1 2 3 4 5 6 PBR (DC PWR) WIRE COLOR LEGEND...
  • Page 727 ECU POWER CIRCUIT WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN ORANGE NO = SWITCH NORMALLY OPEN PINK HARNESS: 2415122_650_850_ECU-01 VIOLET (PURPLE) WHITE YELLOW...

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