General Specifications; Torque Specifications; Handlebar; Removal / Replacement - Polaris 2009 Sportsman XP 850 Service Manual

STEERING / SUSPENSION

GENERAL SPECIFICATIONS

Torque Specifications

Item
Aluminum Wheels
Steel Wheels
Wheel Hub Retaining Nuts
(front and rear)
Steering Post to Bulkhead
Steering Post to Gearcase
Tie Rod Jam Nuts
Tie Rod to Bearing Carrier
Tie Rod to Steering Frog
Handlebar Block Bolts
Shock Mounting Bolts
Front Ball Joint Pinch Bolts
(upper and lower)
Front A-arm to Frame Bolts
(upper and lower)
Rear A-arm to Frame Bolts
(upper and lower)
Rear Upper A-Arm to
Bearing Carrier Bolts
Rear Lower A-Arm to
Bearing Carrier Bolts
CAUTION
Locking nuts, and bolts with pre-applied locking agent
should be replaced if removed.
The self-locking properties of the nut or bolt
are reduced or destroyed during removal
NOTE: Refer to exploded views throughout this
chapter for more torque specifications, component
identification, and location of components.
10.2
Specification
75 ft. lbs. (102 Nm)
45 ft. lbs. (61 Nm)
80 ft. lbs. (108 Nm)
20 ft. lbs. (27 Nm)
22 ft. lbs. (30 Nm)
12 ft. lbs. (16 Nm)
44 ft. lbs. (60 Nm)
14 ft. lbs. (19 Nm)
37 ft. lbs. (50 Nm)
21 ft. lbs. (28 Nm)
40 ft. lbs. (54 Nm)
45 ft. lbs. (61 Nm)
40 ft. lbs. (54 Nm)
45 ft. lbs. (61 Nm)

HANDLEBAR

Removal / Replacement

1. Remove the upper and lower headlight pods from the
handlebar bracket (see Chapter 9).
IMPORTANT: Take note of all vent line, wire harness
and throttle cable routing for reassembly purposes.
2. Remove the (4) fasteners retaining the handlebar bracket
and block to the steering post.
3. Remove the handlebar assembly from the steering post
IMPORTANT: Take care not to bend the throttle cable
or brake line while the handlebar is removed.
4. If replacing the handlebar:
• Remove the RH and LH controls
• Remove the hand grips
• Pry open the upper and lower handlebar blocks and
remove them from the handlebar