General Information; Handlebar Removal / Replacment; Removal / Replacement (Sportsman); Installation - Polaris Sportsman 850 Service Manual

GENERAL INFORMATION

HANDLEBAR REMOVAL / REPLACMENT

REMOVAL / REPLACEMENT (SPORTSMAN)

1. Remove the upper and lower headlight pods from
the handlebar bracket.
NOTE
It is recommended to take a photo prior to disassembly
to note the routing of lines, wires and cables upon
reassembly. Take note of vent line, wire harness and
throttle cable routing for reassembly purposes.
2. Mark the handlebar and block for proper positioning
upon reassembly.
3. Remove the (4) fasteners retaining the handlebar
bracket and block to the steering post.
4. Remove the handlebar assembly from the steering
post.
NOTE
Take care not to bend the throttle cable or brake line
while the handlebar is removed.
5. 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
STEERING / SUSPENSION

INSTALLATION

1. Locate 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 handlebar properly and install the (4) bolts.
3. Evenly tighten the pin side (front) bolts first. Torque
the (2) front bolts to specification.
TORQUE
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
8
8.3