Installation; Steering; Steering Post Removal - Polaris 2009 Sportsman XP 850 Service Manual

Installation

1. Locate the the alignment pin on the bottom side of the
upper block. The pin should line up with the alignment
hole in the lower block and should face the front.
2. Position the handlebar properly and install the (4) bolts.
3. Evenly tighten the pin side (front) bolts first. Torque the
(2) front bolts to specification.
Handlebar Bolts:
14 ft. lbs. (19 Nm)
4. Install the rear bolts and tighten evenly. Torque the (2) rear
bolts to specification.
NOTE: There will be a slight gap on the backside of
the handlebar blocks after installation.
5. If handlebar was replaced:
• Install the hand grips
• Install the RH and LH controls
6. Reassemble the headlight pod (see Chapter 9) .
NOTE: Make sure to route all vent lines, wire
harness and throttle cable correctly into the lower
headlight pod.
= T
STEERING / SUSPENSION

STEERING

Steering Post Removal

1. Remove the front rack and front cover (see Chapter 9).
2. 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.
3. Remove the (4) fasteners retaining the handlebar bracket
and block to the steering post.
4. Carefully remove the handlebar assembly from the steering
post and place it on the front cab.
IMPORTANT: Take care not to bend the throttle cable
or brake line while the handlebar is removed.
5. Remove the cotter pin and nut from each tie rod end at the
steering post frog.
Cotter Pin
10
Nut
Rod End
10.3