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Polaris 2009 Sportsman XP 850 User Manual

Polaris 2009 Sportsman XP 850
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7.25
CLUTCHING (PVT)
7
6. Install the roller pin into the sheave assembly on both sides.
The flat side of the roller pin faces downward when the
shaft side is laying flat on the bench.
7. Install the spring pins (C) to secure the roller pins. Install
until flush with sheave surface.
8. Install the spring over the shaft.
9. Install the clutch rollers (D) onto each side of the outside
spider. Install the washers (E) and E-clips (F) to secure the
rollers. The rollers should spin freely.
10. Install the spider dampener (G) inside the outer spider and
install the inside spider plate (H).
11. Install the spider assembly onto the shaft with the retaining
ring on top of the spider. NOTE: Use the marks previously
made to align the skip tooth spider, or use the “X” on top
of the spider and align it with the skip tooth on the shaft.
Flat Side Down
C
Outer Spider
H
G
D
E
F
Align Marks
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Table of Contents

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Polaris 2009 Sportsman XP 850 Specifications

General IconGeneral
BrandPolaris
Model2009 Sportsman XP 850
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

Vehicle Identification

Details on identifying the vehicle, including model and serial numbers.

Vehicle Information

Information about publications, replacement keys, and special tools.

Specifications

Technical specifications for the 2009 Sportsman XP 850 and XP 850 EPS models.

Maintenance

Periodic Maintenance Chart

Overview of inspection, adjustment, and lubrication tasks for vehicle maintenance.

Maintenance Intervals

Schedule of maintenance items with intervals based on hours, calendar, or miles.

Engine Oil Level

Procedure for checking and maintaining the engine oil level.

Engine Oil and Filter Change

Instructions for changing engine oil and filter at specified intervals.

Transmission and Gearcases

Procedures for transmission lubrication and fluid level checks.

Cooling System

Details on coolant level inspection, hoses, and strength.

Brake System

Inspection procedures for brake fluid, pads, hoses, and fittings.

Electronic Fuel Injection

Special Tools

List of special tools required for EFI system service and testing.

Fuel System Troubleshooting

Diagnosing issues related to fuel starvation, lean/rich mixtures, and poor idle.

EFI System Break-Out Diagrams

Wiring diagrams for various EFI system components for troubleshooting.

Cooling System

Cooling System Layout and Testing

Overview of the cooling system and procedures for pressure testing.

Water Pump Service

Procedures for water pump impeller, mechanical seal, and shaft/bearing replacement.

Thermostat

Instructions for thermostat removal and installation.

Engine

Engine Specifications

Detailed specifications for the EH085OLE-011 engine.

Engine Disassembly and Inspection

Procedures for disassembling and inspecting engine components.

Troubleshooting

Common engine issues and their probable causes and remedies.

Transmission

Transmission Specifications

Torque and lubrication specifications for the transmission.

Transmission Service

Procedures for transmission removal and reinstallation.

Transmission Disassembly

Step-by-step instructions for disassembling the transmission.

Troubleshooting

Diagnosing and resolving shifting difficulties in the transmission.

Clutching (PVT)

PVT System Overview

Explanation of the Polaris Variable Transmission (PVT) system operation.

Drive Belt

Procedures for drive belt removal, inspection, and installation.

Drive Clutch Service

Specifications and service procedures for the drive clutch springs.

Troubleshooting

Diagnosing and resolving common PVT system issues.

Final Drive

Wheels

Procedures for wheel removal and installation, including torque specifications.

Front Bearing Carrier

Inspection, removal, and bearing replacement for the front bearing carrier.

Front Drive Shaft

Procedures for front drive shaft removal and installation.

Front Gearcase - Centralized Hilliard

Exploded view and operation of the front gearcase AWD/ADC system.

Rear Bearing Carrier

Inspection, removal, bearing, and bushing replacement for the rear bearing carrier.

Rear Gearcase

Procedures for rear gearcase removal and disassembly.

Body / Frame

Seat and Side Panels

Procedures for removing and installing the seat and side panels.

Front Rack

Procedure for removing and installing the front rack assembly.

Front Cab

Instructions for removing and installing the front cab assembly.

Main Frame

Exploded view of the main frame and its support components.

Steering / Suspension

Handlebar

Procedures for removing and installing the handlebar assembly.

Steering Post Removal

Step-by-step instructions to remove the steering post.

Steering (EPS Models)

Procedures for removing and installing the power steering unit.

Front A-Arms

Exploded view and removal/replacement of front A-arms.

Shocks / Springs

Procedures for shock removal, installation, and spring replacement.

Brakes

Specifications

General brake specifications and torque values for front and rear brakes.

Hydraulic Brake System Operation

Explanation of how the hydraulic brake system functions.

Brake Bleeding

Procedure for bleeding the front and rear brake systems.

Brake Pads

Procedures for brake pad removal, inspection, and installation.

Troubleshooting

Common brake system issues like squeal, poor performance, and drag.

Electrical

Instrument Cluster

Overview of the instrument cluster and its rider information display.

Charging System

Tests and procedures for the vehicle's charging system.

Starter Motor

Troubleshooting and procedures for starter motor removal/replacement.

Electronic Power Steering (EPS)

Explanation of EPS circuits and operation.

Electrical Breakout Diagrams

Wiring diagrams for various electrical circuits.

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