Polaris Sportsman 850 Service Manual
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Also See for Sportsman 850:
- Service manual (510 pages) ,
- Owner's manual (167 pages) ,
- Owner's manual for maintenance and safety (153 pages)
Table of Contents
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VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL: 2011 SPORTSMAN XP 850 / EPS / INT'L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
DETAILED: 2011 SPORTSMAN XP 850 / EPS / INT'L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2011 SPORTSMAN X2 850 / TOURING 850 / INT'L . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2011 SPORTSMAN X2 850 / TOURING 850 / INT'L . . . . . . . . . . . . . . . . . . 1.7
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
9923067 - 2011 Sportsman 850 Service Manual
© Copyright 2010 Polaris Sales Inc.
GENERAL INFORMATION
CHAPTER 1
1
1.1
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Summary of Contents for Polaris Sportsman 850
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Page 1: Table Of Contents
GLOSSARY OF TERMS..........1.11 9923067 - 2011 Sportsman 850 Service Manual... -
Page 2: Vehicle Identification
Check Digit Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). -
Page 3: Vehicle Information
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. -
Page 4: Specifications
1500 lbs. / 680 kg Unbraked Trailer 1914 lbs. / 868 kg Towing Capacity (EU)* Hitch Tongue Weight 150 lbs. / 68 kg * Data based on EU Directive 76/432/EEC 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc. -
Page 5: General: 2011 Sportsman Xp 850 / Eps / Int'l
Circuit Breaker Fan Motor: 10A Lights: 20 Amp Drive: 20 Amp Fuses Accessory: 20 Amp EFI: 20 Amp (Located in Relay/Fuse Box) Unswitched: 10 Amp EPS: 30 Amp 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc. - Page 6 1500 lbs. / 680 kg Unbraked Trailer 1995 lbs. / 905 kg Towing Capacity (EU)* Hitch Tongue Weight 150 lbs. / 68 kg * Data based on EU Directive 76/432/EEC 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc.
- Page 7 Circuit Breaker Fan Motor: 10A Lights: 20 Amp Drive: 20 Amp Fuses Accessory: 20 Amp EFI: 20 Amp (Located in Relay/Fuse Box) Unswitched: 10 Amp EPS: 30 Amp 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc.
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Page 8: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc. -
Page 9: Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc. -
Page 10: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.10 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc. -
Page 11: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. - Page 12 GENERAL INFORMATION NOTES 1.12 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc.