Polaris 2009 Sportsman XP 850 Service Manual
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Polaris 2009 Sportsman XP 850 Service Manual

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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: 2009 SPORTSMAN XP 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL: 2009 SPORTSMAN XP 850 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
DETAILED: 2009 SPORTSMAN XP 850 / XP 850 EPS. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GENERAL INFORMATION
GENERAL INFORMATION
CHAPTER 1
1
1.1

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Summary of Contents for Polaris 2009 Sportsman XP 850

  • Page 1: Table Of Contents

    GENERAL: 2009 SPORTSMAN XP 850 EPS ....... . . 1.4...

  • 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

    Hitch Tongue Weight 150 lbs. / 68 kg MODEL: 2009 SPORTSMAN XP 850 EPS MODEL NUMBER:..A09ZX85AG, AL, AQ, AR, AS, AX, FS ENGINE MODEL:..EH085OLE...

  • Page 5: General: 2009 Sportsman Xp 850 Eps

    GENERAL INFORMATION 2009 SPORTSMAN XP 850 / XP 850 EPS Drivetrain Automatic PVT XP MODELS: A09ZN85AL,AQ,AS,AT,AX,FL Transmission Type In-Line H-L-N-R-P XP EPS MODELS: A09ZX85AG,AL,AQ,AR,AS,AX,FS Synthetic Sportsman XP ENGINE MODEL: EH085OLE Transmission Transmission Fluid / Fluid Type / Fluid Capacity Engine 32 oz.

  • Page 6: Misc. Specifications And Charts

    GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C...

  • Page 7: Standard Torque Specifications

    GENERAL INFORMATION 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.

  • Page 8: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes...

  • Page 9: 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 10 GENERAL INFORMATION NOTES 1.10...
  • Page 11 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART ......... 2.2 BREAK-IN PERIOD / MAINTENANCE CHART KEY .

  • Page 12: Periodic Maintenance Chart

    Polaris dealer. = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death.

  • Page 13: Maintenance Intervals

    25 H Monthly 250 (400) Inspect level Transmission Fluid 25 H Monthly 250 (400) Inspect level Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
  • Page 14 10000 (16000) Inspect; adjust Toe Adjustment Inspect periodically; adjust as needed Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 15: Grease Lubrication Points

    Method Frequency Front Propshaft Yoke Grease before long periods Grease fittings of storage, and after Front & Rear A-Arms Polaris Premium U-Joint Grease (3 pumps maximum) pressure washing or every 500 miles (800 km). Rear Bearing Carrier submerging the ATV.

  • Page 16: Maintenance Quick Reference

    Lube Rec. Method Frequency* Change after 1st month or first 20 hours of operation, 100 Engine Oil Polaris PS-4 PLUS 2W-50 Add oil to proper level on hours thereafter; Change more Performance Synthetic dipstick often (25 hours) in severe duty...

  • Page 17: Maintenance Quick Reference, Continued

    Maintain fluid level in both Check level during pre-ride Brake Fluid Polaris DOT 4 Brake Fluid master cylinder reservoirs to inspection; change fluid every indicated levels two years * More often under severe use, such as operated in water or under severe loads.

  • Page 18: Lubricants / Service Products

    MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Additives / Sealants / Thread Locking Agents / Misc. 2870585 Loctite™ Primer N, Aerosol, 25 g Polaris Lubricants,Maintenance and Service Products Loctite™ Thread Sealant 565 2871956 (50 ml.) (6 Count) Part No. Description Loctite™ Threadlock 242 2871949 (50 ml.) (10 Count)

  • Page 19: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION FUEL SYSTEM AND AIR INTAKE AND MAINTENANCE Fuel System Pre-ride / Daily Inspection WARNING Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Gasoline is extremely flammable and explosive • Tires - check condition and tire pressure under certain conditions.

  • Page 20: Fuel Filters / Vent Line

    MAINTENANCE Fuel Filters Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment There are two fuel filters located within the fuel pump assembly. NOTE: Sportsman XP requires a new adjustment procedure. The fuel pump is non-serviceable. If the internal fuel pump Slide the boot back far enough to expose the inline cable filters require service, the fuel pump and fuel tank must be adjuster sleeve and loosen the adjuster locknut.

  • Page 21: Air Filter / Pre-Filter Service

    MAINTENANCE Air Filter / Pre-Filter Service Cleaning: Slip the pre-filter screen off of main element. Clean the pre- It is advisable to replace the filter when it is dirty. However, in filter with hot soapy water. an emergency, it is permissible to clean the main filter if you observe the following practices.

  • Page 22: Engine

    Always use PS-4 PLUS engine oil. Oil may need to be changed more frequently if Polaris engine oil is not used. Position the ATV on a level surface. Place the transmission in park.

  • Page 23: Engine Breather Hose / Breather Assembly

    MAINTENANCE NOTE: The sealing surfaces on the drain plug and 16. Stop the engine and check for leaks. crankcase should be clean and free of burrs, nicks 17. Re-check the oil level on the dipstick and add oil as or scratches. necessary to bring the level to the upper mark on the Reinstall drain plug and torque to 12 ft.

  • Page 24: Valve Clearance Adjustment

    MAINTENANCE Valve Clearance Adjustment MAG & PTO ADJUSTMENT PROCEDURE Remove the seat and both upper side panels. Disconnect the shift linkage from the shift lever. Remove the (2) screws retaining the lower portion of the air box. Remove the hose from the breaker valve located on top of the valve cover.

  • Page 25: Compression And Leakdown Tests

    MAINTENANCE 16. Loosen the jam nut and turn the lash adjuster until the valve 21. Repeat steps 16-18. lash is correct. 22. Clean sealing surfaces of the cylinder head and valve cover. 17. Set the intake and exhaust valve lash to specification. 23.

  • Page 26: Exhaust Silencer Cleaning

    MAINTENANCE Exhaust Silencer Cleaning If particles are still suspected to be in the silencer, back the machine onto an incline so the rear of the machine is 1 ft. (30.5 cm) higher than the front. Place the transmission in WARNING park and block the wheels.

  • Page 27: Transmission And Gearcases

    MAINTENANCE TRANSMISSION AND GEARCASES Transmission Fluid Change Access the drain plug through the rear right-hand wheel well. Transmission Lubrication The plastic skid plate can be removed for better access to the drain plug. NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Remove the fill plug (refer to “Transmission Fluid Level Maintenance Chart.

  • Page 28: Front Gearcase Lubrication

    MAINTENANCE Front Gearcase Lubrication Front Gearcase Fluid Change: The drain plug is located on the bottom side of the front NOTE: It is important to follow the front gearcase gearcase. Access the drain plug through the access hole in the maintenance intervals described in the Periodic front skid plate.

  • Page 29: Front Gearcase Adc Fluid

    MAINTENANCE Front Gearcase ADC Fluid Begin the bleeding process by filling reservoir to the “MAX” level with clean ADC Front Drive Fluid. NOTE: It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well.

  • Page 30: Rear Gearcase Lubrication

    MAINTENANCE Rear Gearcase Lubrication Rear Gearcase Fluid Change: NOTE: It is important to follow the rear gearcase The drain plug is located on the bottom right-hand side of the maintenance intervals described in the Periodic rear gearcase. Access the drain plug from the rear right-hand Maintenance Chart.

  • Page 31: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti- freeze/coolant or a 50/50 mixture of high quality aluminum NOTE: If overheating is evident, allow system to compatible anti-freeze/coolant and distilled water.

  • Page 32: Cooling System Hoses / Coolant Strength / Coolant Type

    • Straight water or antifreeze may cause the system to freeze, corrode, or overheat. Recommended Anti-Freeze/Coolant: Polaris 60/40 Anti-Freeze/Coolant (PN 2871534) (Quart) NOTE: For further information on the engine cooling system, refer to Chapter 4.

  • Page 33: Pvt / Final Drive / Wheel And Tire

    MAINTENANCE PVT / FINAL DRIVE / WHEEL AND TIRE Drive Belt Removal Refer to Chapter 7 “Clutching (PVT)” for more detail. PVT Drying Elevate vehicle and remove the left rear wheel. NOTE: If operating the ATV through water, be sure to check the PVT system components for water Remove the lower left-hand frame support.

  • Page 34: Wheel And Hub Torque Table

    MAINTENANCE Wheel and Hub Torque Table Wheel Installation Verify the transmission is still in PARK and the parking Item Nut Type Specification brake is locked. Tapered Nut Install the wheel hub, washers, and hub nut, if previously Aluminum Wheels 75 ft. lbs. (102 Nm) (Long) removed.

  • Page 35: Tire Pressure / Tire Inspection

    MAINTENANCE Tire Pressure ELECTRICAL AND IGNITION SYSTEM Battery Maintenance Tire Pressure Inspection (PSI - Cold) Keep battery terminals and connections free of corrosion. If Front Rear cleaning is necessary, remove the corrosion with a stiff wire 7 psi (48 kPa) 5 psi (34.5 kPa) brush.

  • Page 36: Battery Removal / Installation

    MAINTENANCE Battery Removal Place the spacers on top of the battery terminals. Be sure they are placed between the battery terminal and cable(s). Remove the seat to access the battery. Positive Negative Cables Cable Spacer Spacer Retaining Screw Connect and tighten the positive (+) (red) battery cable first, followed by the negative (-) (black) battery cable.

  • Page 37: Engine / Chassis Ground

    MAINTENANCE Engine / Chassis Ground Spark Plug Inspection / Installation Inspect electrodes for wear and carbon buildup. Look for Periodically inspect the electrical ground cable attachments. a sharp outer edge with no rounding or erosion of the Cables and connections should be tight and corrosion-free. electrodes.

  • Page 38: Steering

    Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts.

  • Page 39: Toe Alignment

    MAINTENANCE Tie Rod End / Steering Inspection Tie a length of string between two stands as shown in the following illustration. Position the stands so the string is To check for play in the tie rod end, grasp the steering tie rod, flush or parallel with the side of the rear tire.

  • Page 40: Toe Alignment Adjustment

    MAINTENANCE Toe Alignment Adjustment SUSPENSION If toe alignment is incorrect, measure the distance between Suspension Inspection vehicle center and each wheel. This will tell you which tie rod needs adjusting. Compress and release the suspension. Damping should be smooth throughout the range of travel. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.

  • Page 41: Brake System

    • Keep fluid level in the hand master cylinder reservoir to the indicated level inside reservoir. Figure 2-31 • Use Polaris DOT 4 Brake Fluid (PN 2872189). CAUTION Fluid Level “Eye” DO NOT OVERFILL! Excess brake fluid may cause brake drag.

  • Page 42: Auxiliary Brake Pedal

    MAINTENANCE Auxiliary Brake Pedal The hydraulic auxiliary brake system requires no adjustment. Frequently check the brake fluid level for the auxiliary brake system by viewing the level in the master cylinder reservoir located underneath the front rack assembly (see Figure 2-31). Foot Brake •...

  • Page 43: Maintenance Log

    MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 20 Hours / 1 Month (Break-In) 100 / 6 Months 2.33...
  • Page 44 MAINTENANCE NOTES 2.34...
  • Page 45 ELECTRONIC FUEL INJECTION CHAPTER 3 ELECTRONIC FUEL INJECTION SPECIAL TOOLS ............3.2 FUEL TANK .

  • Page 46: Special Tools

    This tester allows the use of a digital multi-meter to test TPS Leave room for expansion of fuel. function and perform the “TPS Adjustment” procedure. Polaris * Never start the engine or let it run in an enclosed Dealers can order special tools from SPX Corporation.
  • Page 47 ECU and the Digital Wrench™ diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU- 47470. This kit is available to Polaris dealers through our tool supplier, SPX (1-800-328-6657). PU-47469 PU-47468 PU-47470 Digital Wrench™...

  • Page 48: Fuel Tank

    ELECTRONIC FUEL INJECTION FUEL TANK Exploded View PFA Nut Electrical Connector Pressure Regulator Fuel Pump* Float Arm Tank Vent Rollover Valve PFA Gasket Fuel Tank Assembly *NOTE: Fuel Pump is NOT Serviceable Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters...

  • Page 49: Fuel Line

    Lift white retainer reconnecting the ECU does not resolve the issue, then at before removing that point a known-good ECU (from another Polaris 850) may be used to test for problem resolution. • Never attempt to service any fuel system component Pull out on the fuel line and remove it from the pump outlet.

  • Page 50: Efi System Layout

    ELECTRONIC FUEL INJECTION EFI SYSTEM LAYOUT Exploded View 1. Electronic Control Unit (ECU) 2. Temperature / Manifold Absolute Pressure Sensor (T-MAP) 3. Idle Air Control (IAC) 4. Crankshaft Position Sensor (CPS) 5. Fuel Injectors 6. Fuel Rail 7. Fuel Line (quick connect) 8.

  • Page 51: Efi Components

    ELECTRONIC FUEL INJECTION EFI COMPONENTS Crankshaft Position Sensor (CPS) - Located in the top portion of the magneto cover on the Identification / Location front of the engine. Electronic Control Unit (ECU) - Attached to the air box, located behind the LH side panel. Fuel Injectors - Located in the Integrated Air Fuel Manifold (IAFM).
  • Page 52 ELECTRONIC FUEL INJECTION Fuel Pump / Regulator / Fuel Gauge Sender Assembly 10. Throttle Position Sensor (TPS) - Located behind the right-hand side panel. - Located on the MAG end (front) of the throttle body. Fuel Pump - Located in the fuel tank as an assembly. 11.
  • Page 53 ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for General Information intake air temperature, manifold absolute pressure (load), engine temperature, speed (RPM), and throttle position. These The Electronic Fuel Injection (EFI) system is a complete engine primary signals are compared to the programming in the ECU fuel and ignition management design.

  • Page 54: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU from Depending on the significance or severity of the fault, normal another Polaris Sportsman XP 850 of the same model may be operation may continue, or "Fail-Safe" operation (slowed speed, used without system or engine component damage.

  • Page 55: Ecu Removal / Replacement

    ELECTRONIC FUEL INJECTION ECU Removal / Replacement FUEL PUMP Remove the seat and upper left-hand side panel (see Operation Chapter 9 “Seat and Side Panels”). NOTE: All EFI units utilize quick connect fuel lines. With the ignition turned off, disconnect the wire harness from the ECU by pulling the black slider out away from the An electric fuel pump assembly is used to transfer fuel to the EFI ECU while pulling down on the connector.

  • Page 56: Fuel Sender Test

    ELECTRONIC FUEL INJECTION Fuel Sender Test Locate the fuel pressure valve attached to the fuel rail. If the fuel gauge reading on the instrument cluster is not working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender. Disconnect the fuel pump / sending unit connection and measure Pressure Valve the resistance between the Purple and Brown wires.

  • Page 57: Fuel Pump / Fuel Tank Removal

    ELECTRONIC FUEL INJECTION Fuel Pump / Fuel Tank Removal Remove the vent line from the fitting on top of the fuel tank. IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the ATV. Vent Fitting WARNING Always wear safety goggles when working with...

  • Page 58: Fuel Pump / Fuel Tank Installation

    ELECTRONIC FUEL INJECTION Fuel Pump / Fuel Tank Installation FUEL INJECTORS Reinstall the fuel tank assembly through the right side. Operation Overview Connect the fuel line to the fuel pump outlet and connect The fuel injectors mount into the Integrated Air Fuel Manifold the fuel pump electrical harness.

  • Page 59: Fuel Injector Test / Replacement

    ELECTRONIC FUEL INJECTION Injector leakage is very unlikely, but in rare instances it can be Carefully disconnect the ECU by pulling the tab out while internal (past the tip of the valve needle), or external (weeping pulling down on the connector. around the injector body).

  • Page 60: Crankshaft Position Sensor (Cps)

    ELECTRONIC FUEL INJECTION CRANKSHAFT POSITION SENSOR Connect an ohmmeter between the pin terminals as shown. A resistance value of 860 Ω ± 10% at room temperature (CPS) ° ° C, 68 F) should be obtained. Operation Overview CPS Connector The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft.

  • Page 61: Temp / Manifold Absolute Pressure Sensor (T-Map)

    ELECTRONIC FUEL INJECTION TEMP / MANIFOLD ABSOLUTE IDLE AIR CONTROL VALVE (IAC) PRESSURE SENSOR (T-MAP) Operation Overview Operation Overview The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations. Mounted on the (IAFM), the temperature and manifold absolute pressure sensor (T-MAP) performs two functions in one unit.

  • Page 62: Iac Replacement

    ELECTRONIC FUEL INJECTION IAC Replacement Remove the (3) Phillips-head mounting screws and remove the IAC from the housing. Remove the seat and upper right-hand side panel (see Chapter 9 “Seat and Side Panels”). Disconnect the shift linkage from the shift lever. Remove the spark plug wires.

  • Page 63: Throttle Position Sensor (Tps)

    ELECTRONIC FUEL INJECTION THROTTLE POSITION SENSOR (TPS) TPS Resistance Tests The throttle position sensor (TPS) is a non-serviceable item. If Operation Overview it is faulty, it must be replaced. It can be tested using the following method: The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU.

  • Page 64: Checking Tps Reading

    ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage Checking TPS Reading A 5 volt reference voltage signal from the TPS Tester harness is Remove the seat and upper left-hand side panel (see required for the TPS test to be accurate. Refer to the instructions Chapter 9 “Seat and Side Panels”).

  • Page 65: Tps Adjustment

    ELECTRONIC FUEL INJECTION If voltage varies with throttle movement, continue on to the Retighten TPS mounting screws and torque next step. If the sensor did not function correctly, replace it. specification. Allow the throttle lever to rest in the idle position. The voltmeter should read .700 ±...

  • Page 66: Tps Replacement

    IMPORTANT: If replacing the TPS or throttle body, you must perform the “TPS Adjustment” procedure. Refer to Chapter 4 for additional ECT information. Polaris dealers can test the sensor by using the Digital Wrench™ Refer to “TPS Adjustment” for setting the TPS voltage.

  • Page 67: Ect Sensor Replacement

    ELECTRONIC FUEL INJECTION ECT Sensor Replacement IGNITION COIL Drain coolant to level below sensor. Operation Overview Disconnect the ECT sensor from engine harness. Remove The ignition coil is used to provide high voltage to fire the spark the T-MAP sensor to allow access to the ECT sensor. plugs.

  • Page 68: Ignition Coil And Ht Lead Replacement

    ELECTRONIC FUEL INJECTION Primary Test Ignition Coil and HT Lead Replacement NOTE: The plug caps or coil ends are not removable. The high tension lead (coil wire) must be replaced as an assembly. Remove the seat and upper right-hand side panel to access the ignition coil (see Chapter 9 “Seat and Side Panels”).

  • Page 69: Efi Diagnostics

    ELECTRONIC FUEL INJECTION EFI DIAGNOSTICS Instrument Cluster Trouble Code Display Use the “Diagnostic Trouble Code Table” as a reference. Press and hold the “MODE” button to cycle through all Use the following procedure to display diagnostic trouble codes currently active trouble codes. logged in the ECU if the Check Engine (MIL) icon is illuminated on the instrument cluster.
  • Page 70 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Component Condition Suspect Parameter Number Failure Mode Indentifier Driver Circuit Open / Grounded Injector 1 (MAG) Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open / Grounded Injector 2 (PTO) Driver Circuit Short to B+ Driver Circuit Grounded Ignition Coil Primary Driver 1 (MAG) Driver Open / Grounded...
  • Page 71 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Component Condition Suspect Parameter Number Failure Mode Indentifier Speed Too High 520211 Idle Speed Speed Too Low 520211 Calibration Checksum/CRC Error Steering Over Current Shut Down Current Above Normal or Grounded 520221 Steering Excessive Current Error Current Above Normal or Grounded 520222 Steering Torque or Speed Sensor...

  • Page 72: Fuel System Troubleshooting

    ELECTRONIC FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING Poor Idle Symptom: Idle Too High (If greater than 1400 RPM when engine is warm) The correct position of the throttle body • Throttle stop screw tampering stop screw is established and set at the factory.

  • Page 73: Efi System Break-Out Diagrams

    ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK-OUT DIAGRAMS 3.29...

  • Page 74: Fuel Injector Circuits

    ELECTRONIC FUEL INJECTION Fuel Injector Circuit (PTO) Fuel Injector Circuit (MAG) 3.30...

  • Page 75: Idle Air Control (Iac) Circuit

    ELECTRONIC FUEL INJECTION Idle Air Control (IAC) Circuit Crankshaft Position Sensor (CPS) Circuit 3.31...

  • Page 76: Fuel Pump / Fuel Level Sensor Circuit

    ELECTRONIC FUEL INJECTION Fuel Pump / Fuel Level Sensor Circuit Wire Color Functions Wire Color Function BROWN Ground VT / WHT Fuel Level Sender Signal RED / BLUE EFI Relay Output Battery Voltage 3.32...

  • Page 77: Fuel Pump Circuit

    ELECTRONIC FUEL INJECTION Fuel Pump Circuit Fuel Gauge Circuit 3.33...

  • Page 78: Engine Coolant Temperature Sensor (Ect) Circuit

    ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Circuit Throttle Position Sensor (TPS) Circuit 3.34...

  • Page 79: Diagnostic Connector Circuit

    ELECTRONIC FUEL INJECTION Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit Diagnostic Connector Circuit 3.35...

  • Page 80: Diagnostic Connector Circuit (Eps Models)

    ELECTRONIC FUEL INJECTION Diagnostic Connector Circuit (EPS Models) 3.36...
  • Page 81 COOLING SYSTEM CHAPTER 4 COOLING SYSTEM SPECIAL TOOLS ............4.2 TORQUE SPECIFICATIONS.

  • Page 82: Special Tools

    IMPORTANT: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Thermostat Water Pump Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.

  • Page 83: Cooling System Specifications

    COOLING SYSTEM 850cc ENGINE COOLANT FLOW Cooling System Specifications Resistance Reading @ Idle The engine coolant temperature sensor is located in the engine cylinder head below the thermostat housing (see Chapter 3 for Approx. Reading Condition Temperature further information). (Ohms) 70 Ω...

  • Page 84: Cooling System Bleeding Procedure

    Squeeze the coolant lines to help purge the system of air. Washing the vehicle with a high-pressure With the engine still idling, top off the radiator with Polaris washer could damage the radiator fins and Premium Antifreeze. If no air bubbles are seen at the impair the radiators effectiveness.
  • Page 85 COOLING SYSTEM Drain the coolant from the radiator by removing the coolant Carefully pull rearward on the lower portion of the recovery hose from the lower right-hand portion of the radiator. bottle to disengage the lower tab. Then lift up on the bottle and remove it from the radiator fan shroud.

  • Page 86: Water Pump Service

    COOLING SYSTEM WATER PUMP SERVICE Remove the coolant by-pass hose from the water pump cover fitting. Water Pump Impeller Removal NOTE: The water pump impeller, mechanical seal, drive coupler, pump shaft, and pump shaft bearing can be serviced without removing the engine. Remove the fuel tank (see Chapter 3).

  • Page 87: Water Pump Mechanical Seal Replacement

    COOLING SYSTEM Water Pump Mechanical Seal Replacement Support the stator cover by the stator mounting boss, using an aluminum or PVC pipe section or other suitable support Perform the “Water Pump Impeller Removal” procedure. block (C) positioned inside the stator housing as shown. Do not attempt to press water pump shaft out of stator Disconnect the stator and CPS wire harnesses.

  • Page 88: Water Pump Shaft & Bearing Replacement

    COOLING SYSTEM Water Pump Mechanical Seal Replacement (Cont.) 11. Turn cover over and drive new mechanical seal squarely into housing using seal installer. Protect water pump cover gasket surface and turn cover over. Drive mechanical seal out from stator side of cover. PA-44995-A 12.

  • Page 89: Stator Cover Installation

    COOLING SYSTEM Rotate impeller and check for smooth rotation. CAUTION Refer to the following pages for water pump assembly and torque information. Be sure bearing is fully seated in cover after Stator Cover Installation Step 2, or severe crankshaft damage will result. Install new coupler hub (A) from kit onto shaft.

  • Page 90: Water Pump Assembly / Torque Specifications

    COOLING SYSTEM Water Pump Assembly / Torque Specifications 89 in. lbs. (10 Nm) 89 in. lbs. (10 Nm) Stator wire routing 10 ft. lbs. See procedure (13.5 Nm) 89 in. lbs. (10 Nm) See procedure TORQUE SEQUENCE 4.10...

  • Page 91: Stator Cover Assembly Torque Specifications

    COOLING SYSTEM Stator Cover Assembly Torque Specifications 89 in. lbs. (10 Nm) Crankshaft Position Sensor (CPS) Lubricate New O-Rings 1/8 NPTF Coolant Coolant Fitting Pipe 89 in. lbs. (10 Nm) TORQUE SEQUENCE Use weather strip or contact cement to hold damper rubber (A) on water pump coupler nut (B) during stator cover installation.

  • Page 92: Thermostat

    COOLING SYSTEM THERMOSTAT TROUBLESHOOTING Removal (Engine Installed) Cooling System Drain coolant so the coolant level is below the thermostat Overheating housing (see “Coolant Drain / Radiator Removal”). • Low coolant level Remove the (2) screws from the rear portion of the air box. Locate the thermostat housing on the left side of the valve •...
  • Page 93 ENGINE CHAPTER 5 ENGINE GENERAL INFORMATION - ENGINE........5.3 SPECIAL TOOLS .
  • Page 94 ENGINE CRANKSHAFT / CAM CHAIN REMOVAL ........5.46 CAM CHAIN / SPROCKET INSPECTION .

  • Page 95: General Information - Engine

    Capacity - Approximately 2 U.S. Quarts (1.9 l) Oil Type - Polaris PS4 Plus 2W-50 Synthetic Filter Wrench - PV-43527 or equivalent Oil Pressure Specification - 10-25 PSI @ Idle RPM (using Polaris PS4 Plus 2W-50 Synthetic), Engine at operating temperature. Oil Pressure Test Remove center Main Oil Gallery plug (A) from right side Insert a 1/4”...

  • Page 96: Oil Flow Diagram

    ENGINE Oil Flow Diagram Holes in rocker arm shafts Carrier bolt passages feed rocker arms and rollers feed Center and PTO camshaft main journals Mag end cylinder head bolt passage (exhaust side) Balance Shaft Balance Shaft Bearings Bearings PTO End MAG End Upper Crankcase Main Oil Gallery Cam chain tensioner...

  • Page 97: Engine Specifications - Eh085Ole-011

    ENGINE Engine Specifications - EH085OLE-011 CYLINDER HEAD (IN. / MM) Cam Lobe Height - Intake (Standard) 0.897" (22.795 mm) Cam Lobe Height - Exhaust (Standard) 0.908" (23.067 mm) .8632" ± 0.0004" (21.925 ± 0.01 mm) Camshaft Journal Outer Diameter - (All) Camshaft .8661"...
  • Page 98 ENGINE CYLINDER / PISTON (IN. / MM) Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) 3.4252" ± .0005 (87 mm ± .01mm) Cylinder Bore - Standard Cylinder Cylinder Out of Round Limit 0.0003" (0.0075 mm) .0021" ± .0013" (.053 ± .03mm) Cylinder to Piston Clearance Piston - Standard O.D.

  • Page 99: Engine Assembly Views And Torque Values

    ENGINE ENGINE ASSEMBLY VIEWS AND TORQUE VALUES Torque & Torque Sequence - Main Engine Components 89 lb-in. (10 Nm) 89 lb-in. (10 Nm) 13 lb-ft. (18 Nm) ° VALVE COVER 26 lb-ft. (35 Nm) + 90 (see procedure) CYLINDER HEAD 13 lb-ft.

  • Page 100: Valve Cover / Breather Valve

    ENGINE Valve Cover / Breather Valve = Apply All Purpose Grease 89 lb-in (10 Nm) Torque Pattern 89 lb-in (10 Nm) 44 lb-in (5 Nm)

  • Page 101: Camshaft Carrier / Camshaft / Rocker Arm

    ENGINE Camshaft Carrier / Camshaft / Rocker Arm Torque Pattern Slots must be vertical and face OUT 1. Crankshaft at TDC MAG cylinder 2. Camshaft pin at 10:00 position 3. Snug all bolts 4. Torque to 13 lb-ft. (18 Nm) 26 mm +/- 1 mm following torque pattern 89.0 lb-in (10 Nm)

  • Page 102: Cylinder Head / Valve / Iafm

    ENGINE Cylinder Head / Valve / IAFM 89 lb-in. (10 Nm) Thermostat Step 3 - 18 lb-in. (2 Nm) Step 4 - 18 lb-in. (2 Nm) Step 6 - 89 lb-in. (10 Nm) Step 7 - 89 lb-in. (10 Nm) ±...

  • Page 103: Valve & Spring Height Detail

    ENGINE Valve & Spring Height Detail Bottom 1.861 in. (47.26 mm) Free Length Combustion chamber top Combustion chamber top 5.11...

  • Page 104: Piston / Connecting Rod

    ENGINE Piston / Connecting Rod NOTE: Pistons can be installed in either orientation as they are symmetric. Place circlip gap at top or bottom Paint tolerance mark (see text) Match stamp on rod and cap. Rod stamp can face front or rear of engine (Rod has no offset) 120 mm...

  • Page 105: Crankshaft

    ENGINE Crankshaft Main Journal O.D. ± 54.98 mm ± (2.1646" .0004) Runout Limit .001" (.025 mm) Connecting Rod Journal O.D. ± ± 45.015 mm .01 (1.7722" .0004) Refer to bearing selection procedure and chart on page 5.48. 5.13...

  • Page 106: Crankcase

    ENGINE Crankcase M6 x 20 89 lb-in. (10 Nm) M6 x 35 89 lb-in. (10 Nm) ** Apply light film of engine oil to flange and threads of all M9 crankcase bolts M9 x 160** M9 x 115** 26 lb-ft. 26 lb-ft.

  • Page 107: Crankcase - Upper

    ENGINE Crankcase - Upper 89 lb-in. (10 Nm) Detail - balance shaft end cap and bearing Use tool PA-49320 See procedure See removal procedure. Piston must be removed / installed through top of cylinder as an assembly, with connecting rod attached. 5.15...

  • Page 108: Balance Shaft / Balance Shaft Timing

    ENGINE Balance Shaft / Balance Shaft Timing Washer (Install before pin) Split Gear Springs Drive Gear Bearing - Press on inner race only Bearing (retaining ring OUT) Replace if removed Press on inner race only Replace if removed Balance Shaft Timing at TDC on MAG Cylinder 5.16...

  • Page 109: Crankcase (Lower) With Oil Pump

    ENGINE Crankcase (Lower) With Oil Pump See “Crankcase (Lower) / Oil Pump Disassembly” on page 5.41 89 lb-in. (10 Nm) 89 lb-in. (10 Nm) M6x20 106 lb-in. (12 Nm) M3 end cap screws 6-8 lb-in. (.69-.89 Nm) M6x16 (all outer screws) 21 lb-ft.

  • Page 110: Water Pump Coupler

    ENGINE Water Pump Coupler M6 x 16 89 lb-in. (10 Nm) Crankshaft Position Sensor (CPS) 74 lb-ft. (100 Nm) 1/8 NPTF Coolant Coolant Fitting Pipe O-Ring 89 lb-in. M6 x 20 (10 Nm) 89 lb-in. (10 Nm) 35 lb-in. (4 Nm) Sealant bead should face the cover.

  • Page 111: Water Pump / Water Pump Coupler / Stator / Flywheel

    ENGINE Water Pump / Water Pump Coupler / Stator / Flywheel 89 lb-in. (10 Nm) 89 lb-in. (10 Nm) Stator wire routing See procedure 10 lb-ft. (13.5 Nm) 89 lb-in. (10 Nm) See procedure Torque Sequence 5.19...

  • Page 112: Drive Coupler (Rear) / Starter Gear

    ENGINE Drive Coupler (Rear) / Starter Gear 14 lb-ft. (19 Nm) Torque Sequence 5.20...

  • Page 113: Engine Service

    It is important to note that two types of engine crankcases were produced for the 2009 Sportsman XP 850. Some of the engines produced have NiCaSil plated cylinder walls, while others have iron lined cylinder walls.
  • Page 114 ENGINE Remove the high tension leads from the engine and remove 12. Disconnect the ECU from the main harness. Pull down on the (2) nuts from each exhaust flange at the engine. the connector while pulling the connector tab out. 13.
  • Page 115 ENGINE 16. Remove the (4) screws retaining the engine skid plate and 21. Use the Roll Pin Removal Tool (PN 2872608), to drive out remove the plate from the vehicle. the roll pin from the front propshaft. Pull the shaft back towards the transmission to remove it from the front 17.
  • Page 116 ENGINE 24. Remove the (2) through-bolt fasteners retaining the LH 27. Remove the (2) screws retaining the IAC mount plate to the engine isolator mount to the engine and remove the lower frame at the front of the engine. nut from the mount. Pry up between the frame and isolator 28.

  • Page 117: Engine Installation Notes

    The engine break-in period is defined as the first 20 hours of engine operation or 2 full tanks of fuel. Use only Polaris PS-4 Plus 2W-50 Synthetic engine oil. Never substitute or mix oil brands. Serious engine damage can result.

  • Page 118: Engine Disassembly And Inspection

    ENGINE ENGINE DISASSEMBLY AND Rocker Carrier / Camshaft Removal INSPECTION Rotate engine in direction of rotation until pin (A) is facing UP. Rotate cam another 60° to the 10:00 position to relieve Valve Cover / Breather Valve valve spring pressure from camshaft lobes. Remove (2) breather housing bolts (A).

  • Page 119: Rocker Arm / Rocker Arm Shaft Inspection

    ENGINE Rocker Arm / Rocker Arm Shaft Inspection Measure I.D. of rocker arms and O.D. of rocker arm shafts. Measure shaft bore in cam carrier. Compare to Mark or tag rocker arms and shafts to keep them in their specifications (See “Engine Specifications - EH085OLE- respective locations for assembly.

  • Page 120: Camshaft / Camshaft Bore Inspection

    ENGINE Camshaft / Camshaft Bore Inspection Cylinder Head Removal After camshaft carrier is removed, lift camshaft from Loosen two outer bolts (A), then loosen all head bolts (B) cylinder head. Inspect all main journals and cam lobes as evenly, 1/8 turn at a time following the pattern below (6, 5, described below and compare to specifications (See etc.) until all are loose.

  • Page 121: Cylinder Head Warp Inspection

    ENGINE Cylinder Head Warp Inspection Cylinder Head Disassembly Lay a straight edge (A) across surface of cylinder head at WARNING several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the Wear eye protection when removing and installing cylinder head.

  • Page 122: Valve Inspection

    ENGINE Valve Inspection Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six Remove all carbon from valves with a soft wire wheel or measurements total). Compare to specifications. brush. Check valve face for runout, pitting, and burnt spots. To Measure valve stem in several places.

  • Page 123: Combustion Chamber

    ENGINE Combustion Chamber Drive or press new guides from camshaft side of head to proper installed height. Note difference between intake and Clean all accumulated carbon deposits from combustion exhaust guide height below. chamber and valve seat area. Intake Valve Guide Height: 8.93 - 9.43 mm NOTE: Carbon Clean Fuel Treatment (2871326) can be used to help remove carbon deposits.

  • Page 124: Valve Seat Reconditioning

    ENGINE Valve Seat Reconditioning * If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat Valve seat reconditioning should be performed by a technician surface is evident.
  • Page 125 ENGINE NOTE: When using an interference angle, the seat Clean all filings from the area with hot soapy water. Rinse contact point on the valve will be very narrow, and is and dry with compressed air. a normal condition. Look for an even and continuous Lubricate the valve guides with clean engine oil, and apply contact point all the way around the valve face (A).

  • Page 126: Cylinder Head Assembly

    ENGINE Cylinder Head Assembly Valve Sealing Test NOTE: Assemble valves one at a time to maintain Clean and dry the combustion chamber area (A). proper order. Pour a small amount of clean solvent into each intake port Apply engine oil to valve guides and seats. (B) and check for leakage around the valves.

  • Page 127: Cylinder Head Installation

    ENGINE Cylinder Head Installation Thread cam chain through a new head gasket and install gasket, locating it on the alignment pins. Prepare cylinder head gasket sealing surfaces by cleaning Set cylinder head in place on alignment pins. Apply engine thoroughly to remove all residue. The head gasket must be oil to threads and flange of the (6) main cylinder head bolts.

  • Page 128: Camshaft / Carrier Assembly

    ENGINE Camshaft / Carrier Assembly Camshaft / Camshaft Carrier Installation Lubricate all camshaft lobes and bearing journal surfaces Loosen all valve adjuster lock nuts. with Premium Starter Grease (PN 2871460). Turn adjuster screws out (counterclockwise) until they lightly seat against rocker arm. NOTE: DO NOT force screws against rocker arm.

  • Page 129: Camshaft Timing

    ENGINE Camshaft Timing Align two sprocket marks with valve cover gasket surface. Also refer to Camshaft Timing Quick Reference (page 5.39). Slide sprocket onto camshaft, aligning slot in sprocket with pin. Rotate camshaft clockwise until pin (A) is facing UP (use a wrench across the flats on the sprocket end).

  • Page 130: Cam Chain Tensioner Installation

    ENGINE Cam Chain Tensioner Installation Push tensioner plunger in and hold. Lubricate tensioner plunger and install in tensioner bore with check valve end of plunger (B) facing OUT (toward cap plate). Rotate plate and gasket into position and start the inner bolt. Slowly draw bolts evenly until snug.

  • Page 131: Camshaft Timing - Quick Reference

    ENGINE Camshaft Timing - Quick Reference View With Stator Cover Removed View Through Timing Plug Crankcase Parting Line TDC Mark Flywheel Sprocket marks aligned Pin facing UP with surface of head IMPORTANT! Valve and / or piston damage can Crankshaft / Camshaft Center line occur if engine is rotated with camshaft incorrectly timed.

  • Page 132: Crankcase Disassembly

    ENGINE Crankcase Disassembly Remove water pump drive coupler damper (D). CAUTION The rotor contains powerful magnets. Use caution when removing and installing the stator cover. DO NOT place fingers between cover and crankcase at any time during the removal / installation process or injury could result. NOTICE Do not attempt to lift the upper crankcase / cylinder from the lower crankcase for piston / ring access without first...

  • Page 133: Crankcase (Lower) / Oil Pump Disassembly

    ENGINE Crankcase (Lower) / Oil Pump Disassembly Fully install Flywheel Puller PA-49316 on threads of flywheel (left hand thread - turn flywheel puller Remove oil pump cover plate screws. Note location of two COUNTERCLOCKWISE to install on flywheel). longer (M6x20) screws for assembly. These screws secure Hold puller body (A) and tighten center bolt (B) to remove the pump.
  • Page 134 ENGINE Measure pump rotor clearance to pump cover plate with a Remove oil pressure relief from crankcase. Replace if feeler gauge through the pump outlet window and compare debris has entered, or if oil pressure was outside of specified to specification. range.

  • Page 135: Crankcase Disassembly (Upper)

    ENGINE Crankcase Disassembly (Upper) Piston / Connecting Rod Removal Remove the oil passage connecting tube (F) with O-rings. Some pistons may have an orientation marking. Note the arrow (A) should face the MAG end of crankshaft. NOTE: Replacement pistons can be installed in either orientation as they are symmetric.

  • Page 136: Counterbalance Shaft Removal / Inspection

    ENGINE Counterbalance Shaft Removal / Inspection Hold main gear (A) and rotate split gear counterclockwise (viewed from gear end) to compress springs. Split gear Note timing marks on balance shaft drive gears and should rotate and return freely and completely without crankshaft drive gear.
  • Page 137 ENGINE Visually inspect thrust washer. Remove pin and replace Lay gear assembly on press plate with split gear side UP. washer if damaged or worn to less than 1.15 mm (.045 in.). Carefully align pin of balance shaft with slot in gear. Press shaft into gear assembly until seated against washer.

  • Page 138: Crankshaft / Cam Chain Removal

    ENGINE Crankshaft / Cam Chain Removal Crankshaft Inspection Visually inspect surface of crankshaft main and Remove crankshaft with cam chain and end seals. connecting rod journals. Replace crankshaft if any journal is scratched or pitted. Measure each main journal (A) and rod journal (B) in two locations, 90 degrees apart.

  • Page 139: Connecting Rod Inspection

    ENGINE Connecting Rod Inspection Measure small end I.D. in two directions as shown. Record measurements. Difference between measurements is Secure connecting rod lightly in a soft jawed vise. concentricity. Compare to specifications. Note location of the piston circlip gap (A) at top. Connecting Rod (Small End) Diameter: 0.7886 + 0.0 / - .015"...

  • Page 140: Connecting Rod Big End Bearing Selection

    ENGINE Connecting Rod Big End Bearing Selection Piston / Piston Ring Inspection If using NEW connecting rods, install the bearing color Measure piston ring to ring land clearance with a thickness that matches the color marked on the connecting rod cap as gauge (A) inserted between bottom edge of ring (B) and shown below.

  • Page 141: Piston Ring Installed Gap

    ENGINE Piston Ring Installed Gap Cylinder Inspection Place each piston ring (A) inside the cylinder (B) (from Remove all gasket material from gasket surface. cylinder head side of crankcase). Use the piston to push the Lay a straight edge across cylinders (upper crankcase). ring squarely into cylinder, as shown below.

  • Page 142: Piston-To-Cylinder Clearance

    ENGINE Piston-to-Cylinder Clearance Measure in two directions (front to back and side to side) on three levels and record measurements. If cylinder is Measure piston outside diameter at a point 33 mm down from tapered or out of round beyond .001", the crankcase must piston crown, at a right angle to piston pin bore.

  • Page 143: Engine Assembly

    ENGINE ENGINE ASSEMBLY Install second ring with undercut facing bottom of piston. Rotate ring to place end gap generally toward (intake) side Crankcase Preparation - Upper of piston as shown below. Refer to Oil Flow Diagram (page 5.4) and trace the oil Install top ring with “0”...

  • Page 144: Piston / Connecting Rod Assembly

    ENGINE Piston / Connecting Rod Assembly Piston / Connecting Rod Installation Lubricate connecting rod small end, piston pin bore, and Apply clean engine oil to piston assembly and cylinder piston pin with engine oil. walls of upper crankcase. Be sure ring end gaps are positioned at least 120 degrees CAUTION apart.

  • Page 145: Crankshaft Installation

    ENGINE Crankshaft Installation 11. Install new bolts and tighten evenly until snug. 12. Torque bolts using the following procedure: Refer to illustration Crankcase Assembly (Upper) page 5.54. Install New Clean the bearing bore surfaces of upper crankcase (main bearings), connecting rods, and connecting rod caps. Match marks Align tab of a new main bearing with the slot in main bearing bore of crankcase.

  • Page 146: Crankcase Assembly - Upper

    ENGINE Crankcase Assembly - Upper 89 lb-in. (10 Nm) Detail - balance shaft end cap and bearing Use tool PA-49320 See procedure 5.54...

  • Page 147: Balance Shaft Installation

    ENGINE Balance Shaft Installation Rotate crankshaft until SINGLE dot on crankshaft gear is visible. See “Balance Shaft Timing” on page 5.56. Align single dot of drive gear between two dots of balance Balance shafts are identical but should be installed in the gear.

  • Page 148: Balance Shaft Timing

    ENGINE Balance Shaft Timing 5.56...

  • Page 149: Crankcase Preparation (Lower)

    ENGINE Crankcase Preparation (Lower) Clean lower crankcase gasket sealing surfaces. Refer to Oil Flow Diagram (page 5.4) and trace the oil path from the through the lower crankcase. Flush all passages with solvent and then warm soapy water. Rinse with clear warm water and dry with compressed air. Be sure passages are clean and dry before assembling the lower crankcase.

  • Page 150: Crankcase Sealant And Torque Values

    ENGINE Crankcase Sealant and Torque Values M6 x 20 89 lb-in. (10 Nm) M6 x 35 89 lb-in. (10 Nm) M9 x 160** M9 x 115** ** Apply a light film of engine oil to flange 26 lb-ft. and threads of M9 crankcase bolts. 26 lb-ft.

  • Page 151: Crankcase Assembly

    ENGINE Crankcase Assembly WATER PUMP Prepare upper and lower crankcase and install all Water Pump Impeller Removal components as described on page 5.51 through page 5.57. IMPORTANT: Water pump impeller removal is not Inspect crankshaft seals to be sure they are aligned flush required to remove the stator cover.

  • Page 152: Troubleshooting

    ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate • Spark plug fouled / weak spark Engine • Broken throttle cable Spark Plug Fouling • Air intake obstructed • Restricted air filter (main or pre-cleaner) or breather • Air box removed (reinstall all intake components) system •...
  • Page 153 ENGINE Low Compression • No valve clearance • Valve not seating properly (bent valve or carbon / debris accumulated on sealing surface) • Cylinder head gasket leak • Cylinder or piston worn • Piston rings worn, leaking, broken, or sticking •...
  • Page 154 ENGINE NOTES 5.62...
  • Page 155 TRANSMISSION CHAPTER 6 TRANSMISSION TRANSMISSION SPECIFICATIONS......... 6.2 TORQUE SPECIFICATIONS .

  • Page 156: Transmission Specifications

    TRANSMISSION TRANSMISSION SPECIFICATIONS SHIFT LINKAGE / GEAR SELECTOR Torque Specifications Shift Linkage Inspection Remove the seat and upper RH side panel (see Chapter 9). ITEM TORQUE VALUE Inspect the linkage rod pivot end attached to the 10-14 ft. lbs. transmission bellcrank and the snap linkage attached to the Transmission Fill Plug (14-19 Nm) gear selector.

  • Page 157: Transmission Service

    TRANSMISSION TRANSMISSION SERVICE 13. Remove the high tension leads from the engine and remove the (2) nuts from each exhaust flange at the engine. Transmission Removal Position the vehicle on a level surface. Remove the seat and side panels (see Chapter 9). Disconnect the negative (-) battery cable (see Chapter 2).

  • Page 158: Transmission Disassembly

    TRANSMISSION 18. Remove the (4) bolts securing the right-hand frame support 22. Once you have cleared the coupler, carefully lift the and remove the support from the vehicle. transmission assembly out the right side the of vehicle. 19. Remove the (2) through-bolt fasteners that mount the Transmission Disassembly transmission to the isolator mount on the lower LH side.
  • Page 159 TRANSMISSION Thread the (2) bolts into the transmission case pin holes to Carefully lift up on the cover. Use a soft-faced hammer to hold the coupler. tap on the input shaft and rear output shaft to ease cover removal. Coupler Output Shaft Thread bolts in pin holes.
  • Page 160 TRANSMISSION 11. Lift up on the rear output shaft assembly enough to remove 14. Lift up on each end of the shift fork and rotate the fork out the compensator assembly. of the shift shaft cam. Compensator Assembly Rear Output Shaft 12.
  • Page 161 TRANSMISSION 18. Inspect all bearings, gear teeth, engagement dogs and silent chain. 19. Remove the detent plug, snap ring, washer and gear selector switch. Washer Snap Ring Detent Plug 20. Remove the retaining ring and washer from the cam shift shaft.

  • Page 162: Transmission Shaft Service

    TRANSMISSION Transmission Shaft Service Rear Output Shaft Use the exploded views within this section when servicing the transmission shafts. Shaft bearings can be serviced using an arbor press. Input Shaft Reverse Shaft Primary Shaft...
  • Page 163 TRANSMISSION Compensator Shaft Cam Shift Shaft Bellcrank Shift Shaft NOTE: Stack the belleville washers and place them into the belleville cup upon assembly as shown. The “UP” stamping on each washer should face out when assembling the washer stack. “UP” Marking Belleville Washers...

  • Page 164: Transmission Assembly

    TRANSMISSION Transmission Assembly Thoroughly clean the transmission case halves and shafts. If the bellcrank shift shaft was disassembled, install the gear sector with the step facing the O-ring. Inspect all seals and O-rings for damage. If transmission was disassembled, seal and O-ring replacement is Replace recommended (see exploded view above).
  • Page 165 TRANSMISSION Align the timing marks on the cam shift shaft and bellcrank Install the retaining nut and torque to specification. shift shaft. Align Marks Bellcrank Retaining Nut: 15 ft. lbs. (20 Nm) 10. Install the washer and a new retaining ring onto the cam shift shaft.
  • Page 166 TRANSMISSION 15. Lift up on the lower shift fork and rotate the end into the 18. Install the oil deflector plate and install new retaining cam. screws. Torque screws to specification. Deflector Plate Retaining Screws: 7-10 ft. lbs. (9-14 Nm) 19.
  • Page 167 TRANSMISSION 26. Install the transmission coupler and cone washer (dome 33. Apply RTV silicone sealant to the outside edge of the inner facing up). PVT cover to ensure a water tight fit between the cover and the transmission. 27. Apply Loctite™ 2760 to the shaft threads and install the coupler retaining nut.

  • Page 168: Transmission Installation

    TRANSMISSION Transmission Installation Line up the engine and transmission couplers as shown. Remove the rubber coupler and inspect it for signs of Engine Transmission excessive wear or damage. Replace as needed. Coupler Coupler Install the rubber coupler into the engine coupler. Be sure rubber coupler is properly mounted.
  • Page 169 TRANSMISSION 10. Install the (2) through-bolt fasteners on the lower LH side 13. Install the rear propshaft and torque the retaining bolts to and torque to specification. specification. Rear Propshaft Bolts: 18 ft. lbs. (24 Nm) 14. Reverse the transmission removal procedure to complete the installation.

  • Page 170: Transmission Exploded View

    TRANSMISSION Transmission Exploded View 115-125 ft. lbs. (156-170 Nm) FOR REASSEMBLY 50-60 ft. lbs. Apply Polaris (68-81 Nm) Crankcase Sealant. Apply Loctite 2760 to the bolt threads. 15 ft. lbs. 10-14 ft. lbs. (20 Nm) (14-19 Nm) 17-23 ft. lbs.
  • Page 171 TRANSMISSION Exploded View, Continued. Ref. Qty. Description Ref. Qty. Description Plug, M18 Gearcase, Main Plug w/Magnet, M18 Bell Housing Screw, M8 Park Pawl Screw, M6 Gear, Sector 38T Screw, M10 Detent Bullet Screw, M6 Cup, Belleville Nut, Nylon Lock, 5/16-24 Trust Spacer, Compensator Nut, M18 Output Shaft...

  • Page 172: Troubleshooting

    TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered. • Engine idle speed is above specification • Transmission fluid type/quality • Loose or worn snap linkage bushings • Worn linkage rod pivot end at the transmission bellcrank •...
  • Page 173 CLUTCHING (PVT) CHAPTER 7 CLUTCHING (PVT) SPECIAL TOOLS AND SUPPLIES ......... . 7.2 TORQUE SPECIFICATIONS.

  • Page 174: Special Tools And Supplies

    The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift TORQUE SPECIFICATIONS and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to PVT System Fastener Torques average riding conditions and the vehicle’s intended usage.

  • Page 175: Shift Weights

    CLUTCHING (PVT) Shift Weights Maintenance / Inspection Shift weights have many factors designed into them for Under normal use the PVT system will provide years of trouble controlling engagement RPM and shifting patterns. Shift free operation. Periodic inspection and maintenance is required weights should not be changed or altered without first having a to keep the system operating at peak performance.

  • Page 176: Overheating / Diagnosis

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift Clutch malfunction. transmission to Low during loading of the vehicle to prevent belt burning.

  • Page 177: Pvt System Service

    CLUTCHING (PVT) PVT SYSTEM SERVICE PVT Sealing and Ducting Components Cover Screws Drain Plug Outer Clutch Cover Clamps Outer Seal Air Inlet Duct O-Ring Boot Screws Inner Clutch Cover Boot Outlet Duct Boot Clamps...

  • Page 178: Disassembly

    CLUTCHING (PVT) Disassembly Mark the drive belt direction of rotation and remove drive belt (see “DRIVE BELT - Belt Removal”, steps 8-10). Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fastener placement. Loosen the clamps and remove the PVT outlet duct from the inner PVT cover.

  • Page 179: Assembly

    CLUTCHING (PVT) 10. Install the Drive Clutch Holder (PN 9314177) onto the 13. Remove the (10) screws that retain the inner PVT cover to drive clutch. the transmission case and remove the cover. Drive Clutch Holder (9314177) 11. Remove the drive clutch retaining bolt by turning the bolt in a clockwise direction.
  • Page 180 CLUTCHING (PVT) Install the cover and torque the inner PVT cover screws to 13. Replace the outer PVT cover seal. specification. 14. Reinstall outer PVT cover and secure with screws. Torque screws to specification. Inner PVT Cover Screws: 6-8 ft. lbs. (8-11 Nm) Outer PVT Cover Screws: 45-50 in.

  • Page 181: Drive Belt

    CLUTCHING (PVT) DRIVE BELT Insert the belt removal tool PN 2877408 into the driven clutch as shown (tool included with vehicle’s tool kit). Belt Removal 2877408 Position the vehicle on a level surface and place the transmission in Park. Elevate and safely support the rear of the vehicle. Remove the left rear wheel from the vehicle.

  • Page 182: Belt Inspection

    NOTE: Be sure to install the drive belt as shown, so longer life and better performance. Break in the clutches and the “Polaris” label can be read . drive belt by operating at slower speeds during the 10 hour break-in period as recommended (see Chapter 5 “Engine Break-In Period”...

  • Page 183: Drive Clutch Service

    CLUTCHING (PVT) DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: To control clutch engagement RPM. The springs, which have a higher rate when the clutch is in neutral, will increase clutch engagement RPM. Red/White To control the rate at which the drive belt moves 7043349 Red/Black 7043500...

  • Page 184: Exploded View

    CLUTCHING (PVT) Exploded View Lock Bushing Washer Spring Buttons Washers Bolt Roller Bearing Cover Flat One-Way Bolts Washer Spacer Bearing Cover Bearing Spider Limiter Bolt Shift Weight Washers Clutch Disassembly Inspect cover bushing (A). The outer cover bushing is ™ manufactured with a Teflon coating.

  • Page 185: Spider Removal

    CLUTCHING (PVT) Inspect area on shaft where bushing rides for wear, galling, NOTE: It is important that the same number and thickness of washers are reinstalled beneath the nicks, or scratches. Replace clutch assembly if worn or damaged. spider during assembly. Be sure to note the number and thickness of these washers.

  • Page 186: Roller, Pin, And Thrust Washer Inspection

    CLUTCHING (PVT) Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection Inspect all rollers, bushings and roller pins by pulling a flat Inspect for any clearance between spider button to tower. metal rod across the roller. Turn roller with your finger. If If clearance exists, replace all buttons and inspect surface you notice resistance, galling, or flat spots, replace rollers, of towers.

  • Page 187: Bearing Inspection

    CLUTCHING (PVT) Clutch Inspection Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and NOTE: Remove cover, spring, and spider following free of dents or gall marks. Inspect the weight pivot bore instructions for drive clutch removal, then proceed and pivot bolts for wear or galling.

  • Page 188: Moveable Sheave Bushing Inspection

    CLUTCHING (PVT) Moveable Sheave Bushing Inspection Inspect surface of shaft for pitting, grooves, or damage. Measure outside diameter compare Inspect the Teflon™ coating (arrow) on the moveable sheave specifications. Replace the drive clutch assembly if shaft bushing. Inspect both sheaves for signs of wear, grooving or is worn or damaged.

  • Page 189: Bushing Service

    CLUTCHING (PVT) Bushing Service CAUTION IMPORTANT: Special Tools Required EBS Clutch Bushing Tool Kit - 2201379 Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the Item Qty. Part Description Part # removal process. A, B EBS Puller Tool 5132027...
  • Page 190 CLUTCHING (PVT) NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal Install main adapter (Item 8) on puller. Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Removal Tool Nut (C) a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.

  • Page 191: Clutch Assembly

    CLUTCHING (PVT) Clutch Assembly Torque the spider (counter-clockwise) to specification using the holding fixture and spider tool. Torque with NOTE: It is important that the same number and smooth motion to avoid damage to the stationary sheave. thickness of washers are reinstalled beneath the spider during assembly.

  • Page 192: Driven Clutch Service

    CLUTCHING (PVT) DRIVEN CLUTCH SERVICE Place the clutch into the Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, press down on top of the spider assembly, compressing the Clutch Disassembly spider onto the shaft. Remove snap ring (A) and slowly Remove driven clutch from the transmission input shaft.
  • Page 193 CLUTCHING (PVT) Remove the inside spider plate (D) and spider dampener Press out the spring pins (K) in the inner sheave. (E). Inspect the spider dampener (E) for wear and replace if needed. 10. Pull out the clutch roller pins (L) and rollers (M). Remove the E-clips (F), washers (G), and the clutch rollers (H).

  • Page 194: Bushing Service

    CLUTCHING (PVT) Bushing Service 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly, replace it. To remove the IMPORTANT: Special Tools Required bearing, press the bearing off the shaft. EBS Clutch Bushing Tool Kit - 2201379 Item Qty.
  • Page 195 CLUTCHING (PVT) Clutch Bushing Removal Clutch Bushing Installation Install main puller adapter (Item 8) onto puller. Install puller adapter (Item 10) onto puller. Install adapter reducer (Item 9). Install adapter (Item 9) onto puller. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.

  • Page 196: Clutch Assembly

    CLUTCHING (PVT) Clutch Assembly Line up the “X” on the moveable sheave with the “X” on the stationary sheave or use the marks previously used. Put Install a new bearing onto the output shaft using a press. the sheaves together. Align X’s Install the shaft/bearing into the outer sheave.
  • Page 197 CLUTCHING (PVT) Install the roller pin into the sheave assembly on both sides. 10. Install the spider dampener (G) inside the outer spider and The flat side of the roller pin faces downward when the install the inside spider plate (H). shaft side is laying flat on the bench.
  • Page 198 CLUTCHING (PVT) 12. Place the clutch into Clutch Compression Tool PN 14. Install the cam (helix) assembly over the shaft. Line up the 8700220. Using Compression Extensions PN PS-45909, “X” on the cam, “X” on spider, and “X” on the stationary press down on the top of the spider assembly, pushing the sheave or use the marks previously made before spider onto the shaft.

  • Page 199: Exploded View

    CLUTCHING (PVT) Exploded View Screws E-Ring Thrust Spider Washer Dampener Roller Compression Spring (Helix) Retaining Ring Moveable Sheave Outer Roller Spider Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Ball Sheave Bearing 7.27...

  • Page 200: Troubleshooting

    CLUTCHING (PVT) TROUBLESHOOTING Situation Probable Cause Remedy -Wrong or broken drive clutch spring. -Replace with recommended spring. Engine RPM below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine range, although application. engine is properly tuned.
  • Page 201 CLUTCHING (PVT) Troubleshooting, Continued..Situation Probable Cause Remedy -Plugged air intake or outlet. -Clear obstruction -Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. PVT cover on cover. Seal PVT system ducts. overheating (melting) -High vs.
  • Page 202 CLUTCHING (PVT) NOTES 7.30...
  • Page 203 FINAL DRIVE CHAPTER 8 FINAL DRIVE GENERAL SPECIFICATIONS..........8.2 TORQUE SPECIFICATIONS / SPECIAL TOOLS .

  • Page 204: General Specifications

    FINAL DRIVE GENERAL SPECIFICATIONS CAUTION Torque Specifications Locking nuts, and bolts with pre-applied locking agent should be replaced if removed. Item Nut Type Specification The self-locking properties of the nut or bolt Tapered Nut are reduced or destroyed during removal Aluminum Wheels 75 ft.

  • Page 205: Wheel Hubs

    FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Front Steel Rim Stud Wheel Hub Dust Cover Cone Washers Wheel Nuts Bearing Carrier See Page 8.2 Retaining for Torque Value Ring Front Tire Brake Disc Cotter Pin Hub Cover Castle Nut Front 80 ft.

  • Page 206: Front Bearing Carrier

    FINAL DRIVE FRONT BEARING CARRIER Remove the front wheel hub assembly. Remove the cotter pin from the bottom of the tie rod end. Inspection / Removal Hold the top of the rod end with a 13 mm open-end wrench Elevate front of vehicle and safely support machine under and remove the nut from the bottom.

  • Page 207: Bearing Replacement

    FINAL DRIVE 13. Rotate bearing by hand and check for smooth rotation. Bearing Installation Visually inspect bearing for moisture, dirt, or corrosion. Thoroughly clean the front bearing carrier housing and the NOTE: Due to extremely close tolerances and outer race on the new bearing. Be sure that all oil residue minimal wear, the bearings must be inspected has been removed from each surface.

  • Page 208: Installation

    FINAL DRIVE Installation Install the brake caliper and torque the new mounting bolts to specification. Install the drive shaft axle through the backside of the bearing carrier. Install the upper and lower ball joint ends into the bearing carrier. Install the pinch bolts and torque to specification. Front Caliper Mounting Bolts: 37 ft.

  • Page 209: Front Drive Shaft

    FINAL DRIVE FRONT DRIVE SHAFT Torque the wheel hub castle nut to specification and install a NEW cotter pin. Tighten nut slightly if necessary to align Removal cotter pin holes. Elevate front of vehicle and safely support machine under 80 ft. lbs. the frame area.

  • Page 210: Installation

    FINAL DRIVE Installation Remove the upper ball joint pinch bolt. Install a new spring ring on the end of the drive shaft and Using a soft faced hammer, lightly tap on the upper A-arm apply an anti-seize compound to the splines. to remove it from the bearing carrier.

  • Page 211: Front Propshaft

    FINAL DRIVE FRONT PROPSHAFT PROPSHAFT U-JOINT SERVICE Removal Disassembly Locate the front propshaft roll pin through the right front Remove internal or external snap ring from bearing caps. wheel well. Position the vehicle for roll pin removal. CAUTION Use the Roll Pin Removal Tool (PN 2872608), to drive out the roll pin from the front propshaft.

  • Page 212: Assembly

    FINAL DRIVE Support U-joint in vise as shown and drive inner yoke down Using a suitable arbor, fully seat the bearing cap in one side. to remove remaining bearing caps. Continually check for free movement of bearing cross as bearing caps are assembled. Force U-joint cross to one side and lift out of inner yoke.

  • Page 213: Front Gearcase - Centralized Hilliard

    FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD Exploded View 7-11 ft. lbs. (9-15 Nm) 7-11 ft. lbs. (9-15 Nm) 15 in. lbs. (1.7 Nm) 7-11 ft. lbs. (9-15 Nm) 8-10 ft. lbs. (11-14 Nm) ESCRIPTION ESCRIPTION O-Ring Gearcase Housing O-Ring Pinion Neck Housing O-Ring Clutch Housing...

  • Page 214: Awd Operation

    FINAL DRIVE AWD Operation Ring Gear The AWD switch may be turned on or off while the vehicle is Roll Cage moving, however, AWD will not enable until the engine RPM drops below 3100. Once the AWD is enabled, it remains enabled until the switch is turned off.

  • Page 215: Adc Operation

    FINAL DRIVE ADC Operation ADC Engagement: When the AWD switch is set to “4x4/ ADC”, a 12 Vdc current is present at the input shaft coil (1). Engaging the Front Gearcase: Active Descent Control (ADC) Operation is controlled by the ECU grounding and ungrounding is controlled by the ECU and will not enable until the following the coil.

  • Page 216: Awd Diagnosis

    FINAL DRIVE AWD Diagnosis Armature Plate Symptom: AWD Will Not Engage Check the gearcase AWD coil resistance. Measure between the Grey (C) and Brown/White (B) wires. The resistance value should be within specification. Check for Wear Bands Check to make sure the AWD coil is seated in the U-shaped insert that is pressed into the gearcase cover.

  • Page 217: Gearcase Removal

    FINAL DRIVE Gearcase Removal Remove the cotter pin and nut from each tie rod end at the steering post frog. Stop engine and place gear selector in Park. CAUTION Cotter Pin Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 218: Gearcase Disassembly / Inspection

    FINAL DRIVE Gearcase Disassembly / Inspection 11. Remove the vent line and the (4) bolts securing the front gearcase to frame. Drain and properly dispose of used lubricant. Remove any metal particles from the drain plug magnet. Remove the (4) screws retaining the piston pump assembly to the gearcase and remove the pump.
  • Page 219 FINAL DRIVE Remove the cover plate assembly. Inspect the thrust Remove the armature plate. Inspect the armature plate for bearing (A) for wear. distortion or other damage (see “AWD Diagnosis”). Replace as required. NOTE: Thrust bearing (A) located between the two output assemblies is pressed into the clutch pack Remove the ring gear and roll cage from the gearcase as an and is not removable.
  • Page 220 FINAL DRIVE 10. Inspect the rollers (B) for nicks, scratches and flat spots. 13. Inspect the armature plate for a consistent wear pattern. Inspect the roll cage (C) for damage or cracks. The rollers Uneven wear of the armature plate indicates a warped plate, must slide up and down freely within the roll cage surfaces.
  • Page 221 FINAL DRIVE 16. Remove the (3) bolts retaining the input cover. 20. Remove the (4) screws that retain the pump neck assembly to the main gearcase. 17. Remove the cover (H), armature plate (J) and cam (K). 21. Remove the neck and input shaft assembly from the main gearcase.

  • Page 222: Gearcase Assembly

    FINAL DRIVE Gearcase Assembly Install the cam, armature plate and input cover assembly with a new O-ring. NOTE: Refer to the photos used in the “Gearcase Disassembly / Inspection” procedure when needed, while assembling the front gearcase. Thoroughly clean all gearcase components before beginning reassembly.
  • Page 223 FINAL DRIVE NOTE: Rotate the ring gear to align the locating pins 14. Lightly crimp the thrust pad to hold the pad on the cover and holes during installation. plate during installation. 11. Install the armature plate. Verify the armature plate tabs align with tab recesses in the roll cage.

  • Page 224: Setting Ring Gear Backlash

    FINAL DRIVE Setting Ring Gear Backlash Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn. NOTE: Ring gear backlash is set at the factory. No adjustment is required, unless the front cover is Set the gearcase upright.

  • Page 225: Gearcase Installation

    FINAL DRIVE Gearcase Installation Install the gearcase back into the vehicle through the front left wheel well, between the upper and lower A-arms. Front Gearcase Mounting Bolts: 36 ft. lbs. (49 Nm) Connect and route the AWD wire harness along the frame and install a plastic tie strap to attach it to the frame.
  • Page 226 FINAL DRIVE Install the (2) bolts securing the lower portion of the 14. Add the recommended amount of fluid through the fill hole. steering post to the gearcase and torque to specification. Maintain the fluid level even with the bottom threads of the fill plug hole.

  • Page 227: Adc System Fluid Bleeding

    FINAL DRIVE ADC System Fluid Bleeding Close the valve when clean (bubble-free) fluid begins to flow from the valve. Position the vehicle on a level surface and allow the vehicle to sit for at least 30 minutes. 10. Repeat steps 7-9 on the remaining bleeder valve. Thoroughly clean the areas around the ADC reservoir and 11.

  • Page 228: Rear Bearing Carrier

    FINAL DRIVE REAR BEARING CARRIER Remove the rear wheel hub assembly. Inspection / Removal Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 229: Bearing Replacement

    FINAL DRIVE NOTE: Due to extremely close tolerances and Bearing Installation minimal wear, the bearings must be inspected Thoroughly clean the rear bearing carrier housing and the visually, and by feel. While rotating bearings by outer race on the new bearing. Be sure that all oil residue hand, inspect for rough spots, discoloration, or has been removed from each surface.

  • Page 230: Bushing Replacement

    FINAL DRIVE Bushing Replacement Installation Check bearing carrier bushings and shafts for excessive Install drive shaft axle through the backside of the bearing wear or damage. carrier. Be sure bushings and pivot tubes are installed. If replacement is required, slide shafts out and remove the bushings with a drift punch.
  • Page 231 FINAL DRIVE Install the brake caliper and torque the new mounting bolts Install the rear wheel and (4) wheel nuts. Torque wheel nuts to specification. to specification. CAUTION Wheel Nuts: New bolts have a pre-applied locking agent Steel Wheels: 45 ft. lbs. (61 Nm) which is destroyed upon removal.

  • Page 232: Rear Drive Shaft

    FINAL DRIVE REAR DRIVE SHAFT Remove the rear wheel hub assembly. Removal Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 233: Installation

    FINAL DRIVE Installation Grasp the rear drive shaft and pull sharply outward on the shaft to disengage it from the rear gearcase. Install a new spring ring on the end of the drive shaft and apply an anti-seize compound to the splines. Inspect the axle splines and CV boots for any damage.

  • Page 234: Drive Shaft Service

    FINAL DRIVE DRIVE SHAFT SERVICE Remove the large end of the boot from the CV joint and slide the boot down the shaft. Drive Shaft / CV Joint Handling Tips Care should be exercised during drive shaft removal or when servicing CV joints.
  • Page 235 FINAL DRIVE Remove the CV boot from the shaft. 13. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball CAUTION tracks and outer face flush with grease.

  • Page 236: Inner Plunging Joint / Boot Replacement

    FINAL DRIVE Inner Plunging Joint / Boot Replacement 19. Install and tighten the large clamp using the Axle Boot Clamp Tool (PU-48951). Using a side cutters, cut away and discard the boot clamps. Axle Boot Clamp Tool Remove the large end of the boot from the plunging joint PU-48951 and slide the boot down the shaft.
  • Page 237 FINAL DRIVE IMPORTANT: Tap on inner race only! 11. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined Make sure the circlip is still on the shaft and not left in the in the shaft.

  • Page 238: Drive Shaft Exploded View

    FINAL DRIVE Drive Shaft Exploded View 17. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft. FRONT SHAFT 18. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. Spring Ring 19.

  • Page 239: Rear Propshaft

    FINAL DRIVE REAR PROPSHAFT Removal Locate the rear propshaft through the right rear wheel well. Propshaft NOTE: If needed, remove the right rear wheel to gain better access to the rear propshaft bolts. Remove the (4) bolts retaining the rear propshaft to the rear gearcase input shaft coupler.

  • Page 240: Rear Gearcase

    FINAL DRIVE REAR GEARCASE Remove the upper shock mounts from each side. 10. Remove the brake line retainer and left rear brake caliper. Gearcase Removal Position the vehicle on a level surface and remove the seat. Drain the rear gearcase lubricant (see Chapter 2). Remove the rear cab (see Chapter 9).
  • Page 241 FINAL DRIVE 12. Remove the left rear suspension and drive shaft from the 14. Remove the through-bolt fastener retaining the upper A- vehicle as an assembly. arm to the bearing carrier. Pivot the wheel hub and bearing carrier down to remove the drive shaft. IMPORTANT: Take care not to stretch the brake line while removing the drive shaft.

  • Page 242: Gearcase Disassembly And Inspection

    FINAL DRIVE Gearcase Disassembly and Inspection Inspect the ring gear teeth for chipped, worn, or broken teeth. IMPORTANT: Pinion ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears.

  • Page 243: Gearcase Bearing And Seal Replacement

    FINAL DRIVE Gearcase Bearing and Seal Replacement Remove the retaining ring and lift the pinion shaft and bearing from the main gearcase (see Figure 8-27). If the gearcase is completely assembled, perform the “Gearcase Disassembly and Inspection” procedure. Support the pinion shaft and press the bearing off the shaft (see Figure 8-27).

  • Page 244: Gearcase Assembly

    13. Install the seals into the case halves using a standard seal installer or other suitable method. Seal depth should be Grease all seals with Polaris All Season Grease (PN approximately .110 in. (2.79 mm) from the main surface. 2871322) upon assembly to prevent from damaging seals.

  • Page 245: Gearcase Installation

    Install the cone washers (dome facing retaining nut) and specification (see Page 8.2). right rear hub retaining nut. Torque to specification and 15. Add Polaris ATV Angle Drive Fluid to rear gearcase (see install a new cotter pin. Chapter 2). Torque drain and fill plugs to specification.

  • Page 246: Gearcase Exploded View

    FINAL DRIVE Gearcase Exploded View 15-20 ft. lbs. (20-27 Nm) 90-110 ft. lbs. (122-149 Nm) 10-14 ft. lbs. (14-19 Nm) 10-14 ft. lbs. (14-19 Nm) ESCRIPTION ESCRIPTION Fill Plug with O-ring Ball Bearing Drain Plug with O-ring, Magnetic Main Case, Machined Screw Cover, Machined Pinion Shaft, 10T Straight Bevel...
  • Page 247 BODY / FRAME CHAPTER 9 BODY / FRAME TORQUE SPECIFICATIONS..........9.2 DECAL REPLACEMENT .

  • Page 248: Torque Specifications

    Plastic Push Rivet Removal ITEM TORQUE VALUE ft.lbs. (Nm) Polaris ATVs use a two piece plastic push rivet to fasten most Upper RH Frame Support 30 ft. lbs. (41 Nm) body components. Using the “Multi-Function Pliers” eases removal and prevents from damaging the push rivets and body Lower LH Frame Support 30 ft.

  • Page 249: Seat And Side Panels

    BODY / FRAME SEAT AND SIDE PANELS If removing the right-hand side panel, remove the gear shift selector cap, retaining screw and knob to allow removal. Removal / Installation Grasp one side of the seat near the rear edge. Pull upward abruptly to disengage the under-seat fasteners. Reverse this procedure to reinstall components.

  • Page 250: Front Bumper

    BODY / FRAME FRONT BUMPER FOOTWELLS Removal / Installation Removal / Installation Remove the (2) push rivets from each side of the bumper. Remove the seat and upper side panel (see “SEAT AND SIDE PANELS”). Remove the push rivets and screws that retain the footwell. Remove the (4) bolts retaining the upper front bumper to the frame.

  • Page 251: Front Cab

    BODY / FRAME FRONT CAB 10. Using a clean shop rag or towel, cover the fuel fill hose inlet to prevent dirt or debris from entering the fuel tank. Removal Remove the seat and upper side panels (see “SEAT AND SIDE PANELS”).

  • Page 252: Rear Rack

    BODY / FRAME REAR RACK Remove the (4) screws retaining the rear cab to the frame (see “REAR CAB”). Removal / Installation Lift up on the rear cab and remove the bumper covers by sliding them off the rear bumper. Remove the (8) Torx-headed fasteners as shown below.

  • Page 253: Headlight Pod

    BODY / FRAME HEADLIGHT POD Assembly / Installation Reverse the “Disassembly / Removal” procedure. Disassembly / Removal NOTE: Make sure to route all vent lines, wire Remove the (5) Torx-headed screws retaining the upper harness and throttle cable correctly into the lower and lower headlight pods.

  • Page 254: Main Frame

    BODY / FRAME MAIN FRAME Frame Support Exploded View...

  • Page 255: Chassis

    BODY / FRAME CHASSIS Body Plastic Removed View...
  • Page 256 BODY / FRAME NOTES 9.10...
  • Page 257 STEERING / SUSPENSION CHAPTER 10 STEERING / SUSPENSION GENERAL SPECIFICATIONS..........10.2 TORQUE SPECIFICATIONS .

  • Page 258: General Specifications

    STEERING / SUSPENSION GENERAL SPECIFICATIONS HANDLEBAR Torque Specifications Removal / Replacement Remove the upper and lower headlight pods from the Item Specification handlebar bracket (see Chapter 9). Aluminum Wheels 75 ft. lbs. (102 Nm) IMPORTANT: Take note of all vent line, wire harness Steel Wheels 45 ft.

  • Page 259: Installation

    STEERING / SUSPENSION Installation STEERING Locate the the alignment pin on the bottom side of the Steering Post Removal upper block. The pin should line up with the alignment hole in the lower block and should face the front. Remove the front rack and front cover (see Chapter 9). Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9).

  • Page 260: Steering Post Installation

    STEERING / SUSPENSION Steering Post Installation Remove the (2) bolts retaining the lower steering post bracket to the front gearcase. Reverse the “Steering Post Removal” procedure to reinstall the steering post. Refer to the “Steering Exploded View” for torque values. Remove NOTE: Make sure to route all vent lines, wire harness and throttle cable correctly into the lower...

  • Page 261: Steering Exploded View

    STEERING / SUSPENSION Steering Exploded View 20 ft. lbs. (27 Nm) 12 ft. lbs. 22 ft. lbs. 44 ft. lbs. (16 Nm) (30 Nm) (60 Nm) 12 ft. lbs. 12 ft. lbs. 12 ft. lbs. (16 Nm) (16 Nm) (16 Nm) 44 ft.

  • Page 262: Steering (Eps Models)

    STEERING / SUSPENSION STEERING (EPS MODELS) Remove the (2) fasteners retaining the upper steering post bushing bracket. Upper Steering Post Removal Remove the front rack and front cover (see Chapter 9). Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9).

  • Page 263: Power Steering Unit Removal

    STEERING / SUSPENSION NOTE: Make sure to route all vent lines, wire Remove the bolt retaining the upper steering post to the harness and throttle cable correctly into the lower power steering unit. headlight pod. When installing the headlight into the lower pod, be sure Remove to install the O-rings prior to installing the headlight.

  • Page 264: Power Steering Unit Installation

    STEERING / SUSPENSION Loosen the hose clamp and remove the fuel inlet hose from 12. Carefully lift the power steering unit up to disengage the the fuel tank. Cover the tank inlet and remove the fuel tank lower steering coupler and remove it from the chassis. assembly out the right side (see Chapter 3).
  • Page 265 STEERING / SUSPENSION Install the (4) mounting fasteners and torque fasteners to 11. Install the fuel tank assembly, fuel line and reconnect the specification. Refer to “Steering Exploded View (EPS fuel pump harness (see Chapter 3). Models)”. 12. Reinstall the upper steering post bushing bracket and torque Reconnect the (2) electrical harnesses to the power steering the (2) fasteners to specification.

  • Page 266: Steering Exploded View (Eps Models)

    STEERING / SUSPENSION Steering Exploded View (EPS Models) 20 ft. lbs. (27 Nm) 15 ft. lbs. (20 Nm) 30 ft. lbs. (41 Nm) 22 ft. lbs. (30 Nm) 12 ft. lbs. 44 ft. lbs. 22 ft. lbs. (16 Nm) (60 Nm) (30 Nm) 44 ft.

  • Page 267: Steering Tie Rod

    STEERING / SUSPENSION STEERING TIE ROD • If replacing just the tie rod end (D), loosen the jam nut (E) and remove the rod end. Tie Rod / Tie Rod End Replacement • Install new rod end and torque jam nuts to specification. Use the following procedure to replace the tie rod assembly or Install the new tie rod assembly (C).

  • Page 268: Front A-Arms

    STEERING / SUSPENSION FRONT A-ARMS Exploded View 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 21 ft. lbs. (28 Nm) 21 ft. lbs. (28 Nm) DESCRIPTION DESCRIPTION Upper A-arm Bushing Lower A-arm Pivot Shaft Retaining Ring Bolt Ball Joint CV Shield Bolt Screw...

  • Page 269: Removal / Replacement

    STEERING / SUSPENSION Removal / Replacement WARNING The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. The locking agent on the existing bolts was destroyed during removal. DO NOT reuse old Elevate and safely support the front of the vehicle and hardware.

  • Page 270: Ball Joint Service

    STEERING / SUSPENSION BALL JOINT SERVICE Use a press and correct size driver to remove the ball joint from the A-arm. Removal Correct Driver Placement IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced.
  • Page 271 STEERING / SUSPENSION is properly seated. Press into the A-arm in this direction Place driver HERE to support A-arm Upper A-arm Shown After the new ball joint is installed into the A-arm, install a new retaining ring. Reinstall the A-arm (see “FRONT A-ARMS - Removal / Replacement”).

  • Page 272: Rear A-Arms

    STEERING / SUSPENSION REAR A-ARMS Exploded View 45 ft. lbs. (61 Nm) 40 ft. lbs. (54 Nm) 45 ft. lbs. (61 Nm) DESCRIPTION DESCRIPTION Bolt Bolt Lower A-arm Bushing Bolt Upper A-arm Pivot Shaft, Upper Grease Fitting Pivot Shaft, Lower Pivot Shaft Bushing, Lower 10.16...
  • Page 273 STEERING / SUSPENSION Removal 10. Remove the fastener retaining the stabilizer linkage to the lower A-arm. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. Elevate and safely support the rear of the vehicle and remove the rear wheel.

  • Page 274: Rear Stabilizer Bar

    STEERING / SUSPENSION REAR STABILIZER BAR Exploded View 22 ft. lbs. (30 Nm) 17 ft. lbs. (23 Nm) 37 ft. lbs. (50 Nm) DESCRIPTION DESCRIPTION Bolt Stabilizer Bar Bracket Linkage, Stabilizer Bar Bushing, Stabilizer Bar Bolt Flat Washer Stabilizer Bar Bushing, Linkage 10.18...

  • Page 275: Linkage Removal / Installation

    STEERING / SUSPENSION Linkage Removal / Installation Remove the (2) exhaust springs that retain the exhaust pipe to the silencer. Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 276: Shocks / Springs

    STEERING / SUSPENSION SHOCKS / SPRINGS Remove the upper bushing from the stabilizer linkage on each side of the vehicle. Exploded View Spring 37 ft. lbs. (50 Nm) Spring Retainer Shock Remove Adjusting Cam Remove the (4) fasteners retaining the stabilizer bar bracket to the frame.
  • Page 277 BRAKES CHAPTER 11 BRAKES SPECIFICATIONS ............11.2 GENERAL BRAKE SPECIFICATIONS.

  • Page 278: Specifications

    BRAKES SPECIFICATIONS General Brake Specifications FRONT BRAKES Item Standard Service Limit Brake Pad Thickness .040” / 1 mm Brake Disc Thickness .187” / 4.75 mm .167” / 4.24 mm Brake Disc Thickness Variance Between Measurement .002” / .051 mm Brake Disc Runout .010”...

  • Page 279: Brake System Service Notes

    BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

  • Page 280: Hydraulic Brake System Operation

    Never overfill the reservoir! Do not fill the reservoir beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.

  • Page 281: Brake Caliper Exploded View

    BRAKES Brake Caliper Exploded View Apply Polaris DOT 4 Brake Fluid 47 in. lbs. to Component (5.3 Nm) Apply Polaris All Purpose Grease A. Caliper Mount B. Brake Pads C. Piston D. Caliper Assy. E. Square O-ring (thick) F. Square O-ring (thin) G.

  • Page 282: Brake Bleeding

    BRAKES BRAKE BLEEDING Polaris DOT 4 Brake Fluid Fluid Replacement PN: 2872189 NOTE: When bleeding the brakes or replacing the fluid, always start with the caliper farthest from the master cylinder. Bleeding Procedure Front Brake System Bleeding CAUTION Remove the reservoir cover from the hand brake master cylinder and verify fluid is at specified level.
  • Page 283 BRAKES Repeat the procedure on the two remaining front calipers. Using a funnel, add brake fluid to the MAX level mark on the reservoir. 10. Add DOT 4 brake fluid to .25” - .30” (6 - 8 mm) from the top of the reservoir.

  • Page 284: Hand Brake Master Cylinder

    Disassembly Brake Master The hand master cylinder is a serviceable component. Polaris Switch Cylinder offers a number of service kits to rebuild this style of master cylinder. Refer to the Polaris Electronic Parts Catalog.

  • Page 285: Foot Brake Master Cylinder

    BRAKES FOOT BRAKE MASTER CYLINDER Remove the (2) through-bolts retaining the master cylinder to the mount bracket. Replace components as needed. Operation Overview Reverse this procedure when reinstalling and torque mounting fasteners to specification. When the brake pedal is applied it contacts the piston of the foot brake master cylinder.

  • Page 286: Brake Pads

    Brake Pad Material Thickness Service Limit: .040” (1 mm) Pad Installation Lubricate mounting bracket pins and external slide pin O-ring with a light film of Polaris Premium All Season Grease (PN 2871423). Remove Caliper Push mounting bracket inward and slip the outer brake pad past the edge of the pin.

  • Page 287: Caliper Removal

    BRAKES CALIPER SERVICE Install the caliper and torque new mounting bolts to specification. Caliper Removal CAUTION Loosen the (4) wheel nuts. Elevate and support the side of the ATV in which the caliper New bolts have a pre-applied locking agent is being serviced.

  • Page 288: Caliper Inspection

    BRAKES Caliper Inspection Remove mounting bracket, pin assembly and dust boot. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Using a hammer and a small punch, remove the piston from the caliper body, then remove the square O-rings (see “BRAKE CALIPER - Exploded View”).

  • Page 289: Caliper Installation

    Perform brake bleeding procedure as outlined earlier in this Lubricate the mounting bracket pins with Polaris Premium chapter. All Season Grease (PN 2871423), and install the rubber Install the wheel and (4) wheel nuts. Torque wheel nuts to dust seal boots.

  • Page 290: Brake Disc Service

    BRAKES BRAKE DISC SERVICE Disc Inspection Visually inspect the brake disc for scoring, scratches, or gouges. Replace the disc if any deep gouges are evident. Measure the disc thickness at 8 different points around the pad contact surface using a 0–1” micrometer. Replace disc if worn beyond service limit.
  • Page 291 BRAKES Remove the two brake caliper mounting bolts. 10. Install wheel hub assembly, cone washers, and hand tighten CAUTION: Do not hang the caliper by the brake line. Use the castle nut. Install washers with domed side out. wire to hang caliper to prevent damage to the brake line. Cone Washers Rear Caliper Shown Wheel...

  • Page 292: Troubleshooting

    BRAKES TROUBLESHOOTING 12. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. Brake Squeal • Dirty/contaminated friction pads 80 ft. lbs. • Improper alignment (108 Nm) • Worn disc •...
  • Page 293 ELECTRICAL CHAPTER 12 ELECTRICAL GENERAL INFORMATION ..........12.3 SPECIAL TOOLS / ELECTRICAL SERVICE NOTES .
  • Page 294 ELECTRICAL ELECTRONIC POWER STEERING (EPS) ........12.32 ELECTRONIC POWER STEERING (EPS) CIRCUITS .

  • Page 295: General Information

    ELECTRICAL GENERAL INFORMATION Component Locations Special Tools PART NUMBER TOOL DESCRIPTION Fluke™77 Digital PV-43568 Multimeter 2870836 Battery Hydrometer 2870630 Timing Light PA-49466 Test Relay Electrical Service Notes Keep the following notes in mind when diagnosing an electrical problem. • Refer to wiring diagram for stator and electrical component resistance specifications.

  • Page 296: Instrument Cluster

    ELECTRICAL INSTRUMENT CLUSTER Overview The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions. NOTE: Some features are not applicable to all models. 12.4...

  • Page 297: Rider Information Display

    ELECTRICAL Rider Information Display 11. Check Engine MIL - Illuminated when the ECU has detected a Diagnostic Trouble Code in the engine The rider information display is located in the instrument management system. Icon will flash when DTC display cluster. All segments will light up for 1 second at start-up. mode is active.
  • Page 298 ELECTRICAL Speed Information Odometer The top section of the instrument cluster is dedicated to displaying either vehicle speed or engine RPM. Trip Meters 1 and 2 Select N or P gear position. Function will not work through REVERSE OVERRIDE button when reverse gear is selected.
  • Page 299 ELECTRICAL Engine hours are logged anytime the engine is running. Total Clock hours are not re-settable. Programmed Service Interval The clock displays the time in a 12-hour or 24-hour format depending on whether the instrument cluster units are set to Standard or Metric on early-build vehicles.

  • Page 300: Diagnostic Mode

    ELECTRICAL Method 2 The first number is located in the information area and can be 2 to 6 digits in length. This number equates to the With the ignition key in the OFF position, press and hold suspected area of fault. the MODE button.

  • Page 301: Ignition Switch

    ELECTRICAL Instrument Cluster Pinouts IGNITION SWITCH Function Test Use a multimeter to test for continuity between the 3 sets of ignition switch outputs (OFF / ON / START). Ignition Switch Test NOTE: Some functions not found on all models. Instrument Cluster Pinouts START FUNCTION Turn the key to ON.

  • Page 302: Adc / 4X4 / 2X4 Switch

    ELECTRICAL ADC / 4X4 / 2X4 SWITCH OFF / RUN LH SWITCH Function Test Function Test Use a multimeter to test for continuity between the 2 sets of Use a multimeter to test for continuity when the LH switch is switch outputs (ADC / 4x4).

  • Page 303: Reverse Override / Mode Button

    ELECTRICAL REVERSE OVERRIDE / HEAD LAMP SWITCH MODE BUTTON Function Test Function Test Use a multimeter to test for continuity with the 3 head lamp control outputs (OFF / LOW / HIGH) in the LH control Use a multimeter to test for continuity when pressing the assembly.

  • Page 304: Electronic Throttle Control (Etc) Switch

    ELECTRICAL ELECTRONIC THROTTLE CONTROL GEAR SELECTOR SWITCH (ETC) SWITCH Selector Switch Function Test Electronic Throttle Control (ETC) Switch Locate the gear selector switch on the transmission. Remove the wiring harness connector and insert the The Electronic Throttle Control (ETC) switch is designed to multimeter probes into the switch.

  • Page 305: Speed Sensor

    ELECTRICAL SPEED SENSOR Vehicle Speed Sensor The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear. Battery voltage is supplied to the sensor on the ORANGE circuit and is energized when the OFF/RUN and ignition switches are in the RUN and ON positions.

  • Page 306: Brake Switch

    ELECTRICAL BRAKE SWITCH AWD / ADC COILS Function Test Operation Overview Applying the brakes closes a switch to activate the brake lamps. • Battery voltage is always present at the AWD and ADC Use a multimeter to test for continuity when the brakes are coils when the CHASSIS relay is active.

  • Page 307: Relays

    ELECTRICAL RELAYS Fan Relay The fan relay provides power to the following system: Relay Overview • Fan Motor Each relay leg, or corner, performs the same function. Fan Relay Color Function 20A Circuit breaker-protected 12 Vdc RD / WHT battery voltage. ORG / YEL ECU relay control circuit for relay coil.
  • Page 308 ELECTRICAL Bumper Lights Relay Power Steering Relay NOTE: The power steering relay is not located The bumper lights relay provides power to the following system: inside the fuse box. • Front Bumper Head Lights The power steering relay provides power to the following system: Bumper Lights Relay •...

  • Page 309: Fuse Box Layout

    ELECTRICAL FUSES FUSE BOX LAYOUT Protected Circuits The fuse box is located under the front rack assembly. Fuse Table To gain access, remove the front rack assembly by unlatching the two rack interlocks. Fuse Protected Circuits FUSE BOX 20A Circuit Fan Motor Breaker Starter Solenoid...

  • Page 310: Lights

    ELECTRICAL LIGHTS Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Headlight Adjustment WARNING The headlight beam is adjustable. Place the vehicle on a level surface with the headlight Due to the nature of ATVs and where they are operated, approximately 25 ft.

  • Page 311: Tail / Brake Bulb Replacement

    ELECTRICAL Headlight Replacement Tail / Brake Bulb Replacement Remove the 4 side-mounted pod screws. Before replacing the bulb, use a digital multimeter to test the harness to ensure the lamp is receiving 12 volts and that a ground Carefully remove the headlight lens from the pod. path is present.

  • Page 312: Charging System

    ELECTRICAL CHARGING SYSTEM Battery Charge Test Charging System Diagram CAUTION The charging system consists of:. Do not allow the battery cables to become disconnected • Battery with the engine running. Follow the steps below as outlined to reduce the chance of damage to electrical •...

  • Page 313: Stator / Alternator Removal

    ELECTRICAL Stator / Alternator Removal TEST 1: Resistance Value of Each Stator Leg Remove the fuel tank (see Chapter 3). Measure the resistance value of each of the three stator legs. Remove the (4) screws retaining the engine skid plate and remove the plate from the vehicle.

  • Page 314: Stator / Alternator Installation

    ELECTRICAL Remove the coolant by-pass hose from the water pump Torque the stator and wire guide bolts to specification. cover fitting. Remove the (8) screws retaining the stator cover. Shown with engine removed for clarity. Install new O-rings on the coolant pipe and lightly lubricate for ease of installation.

  • Page 315: Battery Service

    NOTE: Battery charge can be maintained by using a Battery electrolyte is poisonous. It contains acid! Polaris battery tender charger or by charging once a Serious burns can result from contact with the skin, month to make up for normal self-discharge. Battery eyes, or clothing.

  • Page 316: Charging Procedure

    ELECTRICAL OCV - Open Circuit Voltage Test Charging Procedure Battery voltage should be checked with a digital multitester. If battery voltage is 12.6 Vdc or less, the battery may need Readings of 12.6 volts or less require further battery testing and recharging.

  • Page 317: Starter Motor

    ELECTRICAL STARTER MOTOR Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive Starter / Starter Lockout System Diagram • Faulty starter drive gears or starter motor gear The starter and starter lockout system consists of: • Faulty flywheel gear or loose flywheel •...

  • Page 318: Starter Motor Removal / Replacement

    ELECTRICAL Starter Motor Removal / Replacement Install the new starter motor assembly by reversing this procedure. IMPORTANT: The starter motor and solenoid can not be serviced. Removing the black protective coating Be sure to install new O-rings on the starter motor bell from the components will allow for premature housing.

  • Page 319: Instrument Cluster Troubleshooting

    ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING The following 4 diagnostic tests can be performed without using Digital Wrench. Troubleshooting functions not listed here can be found using Digital Wrench Guided Diagnostics. Instrument Cluster - Key OFF / No Power 12.27...

  • Page 320: Instrument Cluster - Key On / No Power

    ELECTRICAL Instrument Cluster - Key ON / No Power 12.28...

  • Page 321: Instrument Cluster - No High Beam Indicator

    ELECTRICAL Instrument Cluster - No High Beam Indicator 12.29...

  • Page 322: Instrument Cluster - No / Incorrect Fuel Level

    ELECTRICAL Instrument Cluster - No / Incorrect Fuel Level 12.30...

  • Page 323: Instrument Cluster Circuit

    ELECTRICAL Instrument Cluster Circuit 12.31...

  • Page 324: Electronic Power Steering (Eps)

    EPS system is detected, the system will illuminate a Key-On / Run Switch On Battery fault indicator and transition to a normal mechanically coupled ORANGE Voltage steering system. The system is Polaris Digital Wrench™ EPS Power compatible simplified diagnostics system troubleshooting through the vehicle’s diagnostic port.

  • Page 325: Eps 8-Way Wire Harness Connector

    ELECTRICAL EPS Troubleshooting NOTE: DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS. WARNING Electronic Power Steering (EPS) units are not interchangeable between ATV and RANGER product lines. NOTE: Refer to Chapter 10 “Steering / Suspension” for power steering unit removal and installation procedures.

  • Page 326: Electrical Breakout Diagrams

    ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS Battery Charging Circuits Wire Color Functions NOTE: If the temperature of the regulator / rectifier exceeds 194°F (90°C), the unit will turn itself off to cool down. The unit will turn on at approximately Wire Color Function 167°F (75°C).
  • Page 327 ELECTRICAL Battery Charging Circuits 12.35...

  • Page 328: Constant Power Circuits

    ELECTRICAL Constant Power Circuits Wire Color Functions Wire Color Function Battery Voltage EPS Fuse-Protected Voltage RED / WHT Constant Battery Voltage Unswitched Fuse / Circuit RED / BLK Breaker-Protected Battery Voltage EFI Fuse-Protected Battery RED / GRN Voltage 12.36...
  • Page 329 ELECTRICAL Constant Power Circuits 12.37...

  • Page 330: Key-On Power Circuits

    ELECTRICAL Key-On Power Circuits Wire Color Functions Wire Color Function RED / BLK Key-On Battery Voltage Key-On / Run Switch On Battery ORANGE Voltage RED / WHT Constant Battery Voltage 12.38...

  • Page 331: Chassis Power Circuits

    ELECTRICAL Chassis Power Circuits Wire Color Functions Wire Color Function Battery Voltage BROWN Ground Key-ON / Run Switch On ORANGE Battery Voltage Lights Fuse-Protected Battery RED / BRN Voltage Chassis Relay Output Battery WHITE Voltage Drive Fuse-Protected Battery RED / GRN Voltage Accessory Fuse-Protected ORG / WHT...

  • Page 332: Head Lamp Circuits

    ELECTRICAL Head Lamp Circuits Wire Color Functions Wire Color Function Lights Fuse-Protected Battery RED / BRN Voltage BROWN Ground DARK GREEN Bumper Lights Power Pod Light Power YELLOW High Beam Indicator Power NOTE: THE BUMPER LIGHTS RELAY IS ALWAYS ACTIVE WHEN THE HEADLAMP SWITCH IS IN LOW OR HIGH.

  • Page 333: Brake Lamp Circuits

    ELECTRICAL Brake Lamp Circuits Wire Color Functions Wire Color Function ORANGE Brake Signal Voltage BROWN Ground Lights Fuse-Protected Battery RED / BRN Voltage 12.41...

  • Page 334: Engine Start Command Circuits

    ELECTRICAL Engine Start Command Circuits Wire Color Functions Wire Color Function Battery Voltage BROWN Ground Key-On / Run Switch On Battery ORANGE Voltage Ignition Key Start Solenoid WHT / RED Battery Voltage ECU Start Solenoid Ground DG / WHT Command Line WHITE Gear Selector Return Signal VIOLET...
  • Page 335 ELECTRICAL Engine Start Command Circuits 12.43...

  • Page 336: Ecm Wake-Up Command Circuits

    ELECTRICAL ECM Wake-Up Command Circuits Wire Color Functions Wire Color Functions Wire Color Function Wire Color Function Key-On / Run Switch On Battery WHT / BLK Fuel Injector ECM Ground Line ORANGE Voltage EFI Fuse-Protected Battery RED / GRN Voltage EFI Relay Output Battery RED / BLU Voltage...

  • Page 337: Awd / Adc Circuits

    ELECTRICAL AWD / ADC Circuits Wire Color Functions Wire Color Function Drive Fuse-Protected Battery RED / GRN Voltage BRN / WHT ECM - AWD Coil Ground Line BRN / YEL ECM - ADC Coil Ground Line RH Control 4x4 Command GRAY Signal RH Control ADC Command...
  • Page 338 ELECTRICAL AWD / ADC Circuits 12.46...

  • Page 339: Awd / Adc Function Tests

    ELECTRICAL AWD / ADC Function Tests The following diagnostic test can be performed before using Digital Wrench. Troubleshooting functions not listed here can be found using Digital Wrench Guided Diagnostics. 12.47...

  • Page 340: Radiator Fan Circuit

    ELECTRICAL Radiator Fan Circuit Wire Color Functions Wire Color Function BLACK Ground BROWN Ground Battery Voltage Constant Battery Voltage RED / WHT 10 AMP Circuit Breaker- Protected Battery Voltage ORG / BLK Relay Output Fan Power YELLOW Coolant Temp. Sensor Signal VIOLET ECM Sensor Ground ORG / YEL...
  • Page 341 ELECTRICAL Radiator Fan Circuit 12.49...

  • Page 342: Gear Selector Switch Circuit

    ELECTRICAL Gear Selector Switch Circuit Wire Color Functions Wire Color Function YELLOW CAN High Signal GREEN CAN Low Signal VIOLET ECM Sensor Ground WHITE Gear Selector Return Signal NOTE: DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS. 12.50...
  • Page 343 ELECTRICAL Gear Selector Switch Circuit 12.51...

  • Page 344: Ground Speed Sensor Circuit

    ELECTRICAL Ground Speed Sensor Circuit Wire Color Functions Wire Color Function YELLOW CAN High Signal GREEN CAN Low Signal BROWN Ground Key-On / Run Switch On Battery ORANGE Voltage GRN / RED Speed Sensor Return Signal NOTE: DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS.

  • Page 345: Reverse Override Circuit

    ELECTRICAL Ground Speed Sensor Circuit Reverse Override Circuit 12.53...

  • Page 346: Controller Area Network (Can)

    ELECTRICAL CONTROLLER AREA NETWORK (CAN) Overview This vehicle uses a Controller Area Network (CAN) to perform some functions. Similar to a computer network, CAN establishes a communication network between the ECU and several on-board components. The Sportsman XP 850 CAN network includes: •...
  • Page 347 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (PAGE 1 OF 2) WD-3...
  • Page 348 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (PAGE 2 OF 2) WD-4...
  • Page 349 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (AWD / ADC) WD-6...
  • Page 350 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (BATTERY CHARGING) WD-8...
  • Page 351 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (BATTERY PLUS) WD-10...
  • Page 352 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (BRAKE LAMPS-START) WD-12...
  • Page 353 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (CHASSIS POWER) WD-14...
  • Page 354 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (COOLING FAN) WD-16...
  • Page 355 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (ECM WAKE-UP) WD-18...
  • Page 356 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (EFI) WD-20...
  • Page 357 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (ENGINE CRANK) WD-22...
  • Page 358 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (EPS) WD-24...
  • Page 359 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (FUEL PUMP & LEVEL) WD-26...
  • Page 360 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (GEAR SENSOR) WD-28...
  • Page 361 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (GROUND SPEED SENSOR) WD-30...
  • Page 362 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (KEY ON POWER) WD-32...
  • Page 363 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (LIGHTS) WD-34...
  • Page 364 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL (HAZARD LIGHTS) WD-35...
  • Page 365 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (PAGE 1 OF 2) WD-1...
  • Page 366 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (PAGE 2 OF 2) WD-2...
  • Page 367 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (AWD / ADC) WD-5...
  • Page 368 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (BATTERY CHARGING) WD-7...
  • Page 369 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (BATTERY PLUS) WD-9...
  • Page 370 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (BRAKE LAMPS-START) WD-11...
  • Page 371 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (CHASSIS POWER) WD-13...
  • Page 372 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (COOLING FAN) WD-15...
  • Page 373 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (ECM WAKE-UP) WD-17...
  • Page 374 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (EFI) WD-19...
  • Page 375 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (ENGINE CRANK) WD-21...
  • Page 376 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (EPS) WD-23...
  • Page 377 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (FUEL PUMP & LEVEL) WD-25...
  • Page 378 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (GEAR SENSOR) WD-27...
  • Page 379 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (GROUND SPEED SENSOR) WD-29...
  • Page 380 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (KEY ON POWER) WD-31...
  • Page 381 WIRE DIAGRAM 2009 SPORTSMAN XP 850 (HEADLAMPS) WD-33...

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