Front Cab; Removal; Installation - Polaris 2009 Sportsman XP 850 Service Manual

FRONT CAB

Removal

1. Remove the seat and upper side panels (see "SEAT AND
SIDE PANELS").
2. Remove the mud guards (see "MUD GUARDS").
3. Remove the (4) push rivets retaining the front cab to the
footwells on each side.
4. Remove the (2) screws retaining the front cover to the front
cab and remove the cover.
5. Remove the (2) screws retaining the rear portion of the front
cab to the airbox.
6. Remove the (4) push rivets retaining the front cab to the
frame.
7. Thoroughly clean the area around the fuel tank fill hose
located in the left front wheel well.
8. Loosen the upper clamp retaining the fuel fill hose to the
front cab.
9. Carefully lift up on the front cab to disengage the fuel fill
hose.
10. Using a clean shop rag or towel, cover the fuel fill hose inlet
to prevent dirt or debris from entering the fuel tank.
Fill Hose Inlet
CAUTION
Failure to cover the fuel fill hose inlet by allowing
dirt or debris to enter the fuel tank could lead to
premature fuel pump failure. Always take care
to not allow anything to enter the fuel tank.
11. Carefully lift up and pull the front cab toward the rear of
the ATV to clear in the headlight pod.

Installation

1. Carefully install the front cab onto the frame.
2. Uncover the fuel fill hose inlet and attach the hose to the
front cab. Torque the upper hose clamp to specification.
Upper Fuel Fill Hose Clamp:
24 in. lbs. (2.7 Nm)
3. Install the push rivets retaining the front cab to the frame.
4. Install the screws retaining the front cab to the airbox.
5. Install the front cover.
6. Install the push rivets retaining the front cab to the
footwells.
7. Install the mud guards, upper side panels and seat.
BODY / FRAME
= T
9.5
9