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2009 Sportsman XP 850
Polaris 2009 Sportsman XP 850 User Manual
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12.41
ELECTRICAL
12
Brake Lamp Circuit
s
Wire Color Functions
Wire Color
Function
ORANGE
Brake Signal V
oltage
BROWN
Ground
RED / BRN
Lights Fuse-Protect
ed Battery
Vo
l
t
a
g
e
PartShark.com
877-999-5686
332
334
Table of Contents
General Information Chapter
1
Table of Contents
1
Chapter 1
2
Engine Designation Number
2
Model Identification
2
Vehicle and Engine Serial Number Locations
2
Vehicle Identification
2
Vehicle Identification Number (Vin)
2
Vehicle Information
3
Publication Numbers
3
Replacement Keys
3
Special Tools
3
Specifications
4
General: 2009 Sportsman Xp 850 Eps
5
Misc. Specifications and Charts
6
Conversion Table
6
Standard Torque Specifications
7
Sae Tap / Drill Sizes
8
Metric Tap / Drill Sizes
8
Glossary of Terms
9
Maintenance Chapter 2 Maintenance 2
11
Break-In Period / Maintenance Chart Key
12
Chapter 2
12
Periodic Maintenance Chart
12
Maintenance Intervals
13
Grease Lubrication Points
15
Maintenance Quick Reference
16
Maintenance Quick Reference, Continued
17
Lubricants / Service Products
18
Fuel System and Air Intake
19
Fuel Lines
19
Fuel Filters / Vent Line
20
Throttle Operation / Etc Switch / Throttle Cable Adjustment
20
Air Filter / Pre-Filter Service
21
General Vehicle Inspection and Maintenance
19
Engine
22
Engine Oil Level / Oil and Filter Change
22
Engine Breather Hose / Breather Assembly
23
Valve Clearance Adjustment
24
Compression and Leakdown Tests
25
Exhaust Silencer Cleaning
26
Engine Mount Fastener Torque
26
Transmission and Gearcases
27
Transmission Lubrication
27
Front Gearcase Lubrication
28
Front Gearcase Adc Fluid
29
Rear Gearcase Lubrication
30
Cooling System
31
Coolant Level Inspection
31
Cooling System Hoses / Coolant Strength / Coolant Type
32
Pvt / Final Drive / Wheel and Tire
33
Pvt Drying / Drive Belt Removal
33
Drive Shaft Boot Inspection
33
Wheel and Hub Torque Table
34
Wheel Removal / Installation
34
Wheel Installation/Removal
34
Tire Pressure / Tire Inspection
35
Electrical and Ignition System
35
Battery Maintenance
35
Battery Removal / Installation
36
Spark Plug Service
36
Engine / Chassis Ground
37
Steering
38
Steering Inspection
38
Power Steering Unit (Eps Models)
38
Toe Alignment
39
Toe Alignment Adjustment
40
Suspension
40
Suspension Inspection / Suspension Spring Pre-Load Adjustment
40
Brake System
41
Brake Fluid / Brake Pad / Hose / Fitting Inspection
41
Auxiliary Brake Pedal
42
Maintenance Log
43
Electronic Fuel Injection Chapter 3 Electronic Fuel Injection
45
Chapter 3
46
Special Tools
46
Electronic Fuel Injection
46
Fuel Tank
48
Efi Service Notes
49
Fuel Line
49
Efi System Layout
50
Efi Components
51
Electronic Fuel Injection
51
Electronic Control Unit (Ecu)
54
Ecu Service
54
Ecu Removal / Replacement
55
Fuel Pump
55
Fuel Sender Test
56
Fuel Pump Test
56
Fuel Pump / Fuel Tank Removal
57
Fuel Pump / Fuel Tank Installation
58
Fuel Injectors
58
Fuel Injector Service
58
Fuel Injector Test / Replacement
59
Fuel Injector Replacement
59
Fuel Pressure Regulator
58
Crankshaft Position Sensor (Cps)
60
Cps Test / Replacement
60
Cps Replacement
60
Idle Air Control Valve (Iac)
61
Iac Test
61
Iac Replacement
62
Temp / Manifold Absolute Pressure Sensor (T-Map)
61
T-Map Test / Replacement
61
Throttle Position Sensor (Tps)
63
Tps Resistance Tests / Tps Tester Kit
63
Checking Tps Reading
64
Tps Adjustment
65
Tps Replacement
66
Engine Coolant Temperature Sensor (Ect)
66
Ect Sensor Test
66
Ect Sensor Replacement
67
Ignition Coil
67
Ignition Coil Tests
67
Ignition Coil and Ht Lead Replacement
68
Efi Diagnostics
69
Instrument Cluster Trouble Code Display
69
Fuel System Troubleshooting
72
Efi System Break-Out Diagrams
73
Fuel Injector Circuits
74
Idle Air Control (Iac) Circuit
75
Crankshaft Position Sensor (Cps) Circuit
75
Fuel Pump / Fuel Level Sensor Circuit
76
Fuel Pump Circuit
77
Fuel Gauge Circuit
77
Engine Coolant Temperature Sensor (Ect) Circuit
78
Throttle Position Sensor (Tps) Circuit
78
Diagnostic Connector Circuit
79
Diagnostic Connector Circuit (Eps Models)
80
Cooling System Chapter 4 Cooling System
81
Chapter 4
82
Cooling System
82
Cooling System Layout and Testing
82
Special Tools
82
Torque Specifications
82
Cooling System Specifications
83
Cooling System Bleeding Procedure
84
Radiator
84
Radiator Cleaning
84
Coolant Drain / Radiator Removal
84
Water Pump Service
86
Water Pump Impeller Removal
86
Water Pump Mechanical Seal Replacement
87
Water Pump Shaft & Bearing Replacement
88
Stator Cover Installation
89
Water Pump Assembly / Torque Specifications
90
Stator Cover Assembly Torque Specifications
91
Thermostat
92
Troubleshooting
92
Chapter 5 Engine
93
Engine Lubrication Specifications
95
General Information - Engine
95
Oil Pressure Test
95
Special Tools
95
Oil Flow Diagram
96
Engine Specifications - Eh085Ole-011
97
Engine Assembly Views and Torque Values
99
Torque & Torque Sequence - Main Engine Components
99
Valve Cover / Breather Valve
100
Camshaft Carrier / Camshaft / Rocker Arm
101
Cylinder Head / Valve / Iafm
102
Valve & Spring Height Detail
103
Piston / Connecting Rod
104
Crankshaft
105
Crankcase
106
Crankcase - Upper
107
Balance Shaft / Balance Shaft Timing
108
Crankcase (Lower) with Oil Pump
109
Water Pump Coupler
110
Water Pump / Water Pump Coupler / Stator / Flywheel
111
Drive Coupler (Rear) / Starter Gear
112
Engine Service
113
Accessible Engine Components
113
Top-End Service (Engine in Chassis)
113
Crankcase Cylinder Service Information
113
Engine Removal
113
Engine Installation Notes
117
Engine Disassembly and Inspection
118
Valve Cover / Breather Valve
118
Rocker Carrier / Camshaft Removal
118
Rocker Arm / Rocker Arm Shaft Inspection
119
Camshaft / Camshaft Bore Inspection
120
Cylinder Head Removal
120
Cylinder Head Cleaning
120
Cylinder Head Warp Inspection
121
Cylinder Head Disassembly
121
Valve Inspection
122
Combustion Chamber
123
Valve Guide Removal / Installation
123
Valve Seat Reconditioning
124
Valve Seat Inspection
124
Cylinder Head Assembly
126
Valve Sealing Test
126
Cylinder Head Installation
127
Camshaft / Carrier Assembly
128
Camshaft / Camshaft Carrier Installation
128
Camshaft Timing
129
Cam Chain Tensioner Installation
130
Camshaft Timing - Quick Reference
131
Crankcase Disassembly
132
Crankcase (Lower) / Oil Pump Disassembly
133
Crankcase Disassembly (Upper)
135
Piston / Connecting Rod Removal
135
Counterbalance Shaft Removal / Inspection
136
Counterbalance Split Gear Replacement
136
Crankshaft / Cam Chain Removal
138
Cam Chain / Sprocket Inspection
138
Crankcase Inspection (Lower)
138
Crankshaft Inspection
138
Connecting Rod Inspection
139
Connecting Rod Big End Bearing Selection
140
Piston / Piston Ring Inspection
140
Piston Ring Removal
140
Piston Ring Installed Gap
141
Piston Pin Bore Inspection
141
Cylinder Inspection
141
Piston-To-Cylinder Clearance
142
Honing - Important Information
142
Engine Assembly
143
Crankcase Preparation - Upper
143
Piston Ring Installation
143
Piston / Connecting Rod Assembly
144
Piston / Connecting Rod Installation
144
Crankshaft Installation
145
Oil Passage Tube
145
Crankcase Assembly - Upper
146
Balance Shaft Installation
147
Balance Shaft Timing
148
Crankcase Preparation (Lower)
149
Crankcase Sealant and Torque Values
150
Crankcase Assembly
151
Water Pump
151
Water Pump Impeller Removal
151
Troubleshooting
152
Engine
152
Transmission Chapter 6 Transmission
155
Chapter 6
156
Lubrication Specifications
156
Shift Linkage / Gear Selector
156
Shift Linkage Inspection
156
Gear Selector Removal
156
Torque Specifications
156
Transmission Specifications
156
Transmission Service
157
Transmission Removal
157
Transmission Disassembly
158
Transmission Shaft Service
162
Transmission Assembly
164
Transmission Installation
168
Transmission Exploded View
170
Troubleshooting
172
Clutching (Pvt) Chapter 7 Clutching (Pvt)
173
Chapter 7
174
Drive Clutch Operation
174
General Operation
174
Pvt System Overview
174
Special Tools and Supplies
174
Torque Specifications
174
Driven Clutch Operation
175
Maintenance / Inspection
175
Pvt Break-In (Drive Belt / Clutches)
175
Shift Weights
175
Overheating / Diagnosis
176
Pvt System Service
177
Pvt Sealing and Ducting Components
177
Disassembly
178
Assembly
179
Drive Belt
181
Belt Removal
181
Belt Inspection
182
Belt Installation
182
Pvt Break-In (Drive Belt / Clutches)
182
Drive Clutch Service
183
Spring Specifications
183
Exploded View
184
Clutch Disassembly
184
Spider Removal
185
Roller, Pin, and Thrust Washer Inspection
186
Button to Tower Clearance Inspection
186
Shift Weight Inspection
186
Bearing Inspection
187
Clutch Inspection
187
Moveable Sheave Bushing Inspection
188
Bushing Service
189
Clutch Assembly
191
Driven Clutch Service
192
Clutch Disassembly
192
Bushing Service
194
Clutch Assembly
196
Exploded View
199
Troubleshooting
200
Final Drive Chapter 8 Final Drive
203
General Specifications
204
Wheels
204
Wheel Hubs
205
Chapter 8
206
Front Bearing Carrier
206
Inspection / Removal
206
Bearing Replacement
207
Installation
208
Front Drive Shaft
209
Removal
209
Installation
210
Front Propshaft
211
Propshaft U-Joint Service
211
Disassembly
211
Assembly
212
Front Gearcase - Centralized Hilliard
213
Exploded View
213
Awd Operation
214
Adc Operation
215
Awd Diagnosis
216
Gearcase Removal
217
Gearcase Disassembly / Inspection
218
Gearcase Assembly
222
Setting Ring Gear Backlash
224
Gearcase Installation
225
Adc System Fluid Bleeding
227
Rear Bearing Carrier
228
Inspection / Removal
228
Bearing Replacement
229
Bushing Replacement
230
Installation
230
Rear Drive Shaft
232
Removal
232
Installation
233
Drive Shaft Service
234
Drive Shaft / CV Joint Handling Tips
234
Outer CV Joint / Boot Replacement
234
Inner Plunging Joint / Boot Replacement
236
Drive Shaft Exploded View
238
Rear Propshaft
239
Rear Gearcase
240
Gearcase Removal
240
Gearcase Disassembly and Inspection
242
Gearcase Bearing and Seal Replacement
243
Gearcase Assembly
244
Gearcase Installation
245
Gearcase Exploded View
246
Body / Frame Chapter 9 Body / Frame
247
Chapter 9
248
Decal Replacement
248
Multi-Function Pliers
248
Plastic Push Rivet Removal
248
Special Tools
248
Torque Specifications
248
Front Rack
249
Seat and Side Panels
249
Removal / Installation
249
Footwells
250
Front Bumper
250
Removal / Installation
250
Mud Guards
250
Front Cab
251
Removal
251
Installation
251
Rear Bumper Covers
252
Rear Cab
252
Rear Rack
252
Removal / Installation
252
Headlight Pod
253
Disassembly / Removal
253
Assembly / Installation
253
Frame Support Exploded View
254
Main Frame
254
Chassis
255
Body Plastic Removed View
255
Steering / Suspension Chapter 10 Steering / Suspension
257
Chapter 10 Torque Specifications
258
General Specifications
258
Handlebar
258
Removal / Replacement
258
Installation
259
Steering
259
Steering Post Removal
259
Steering Post Installation
260
Steering Exploded View
261
Steering (Eps Models)
262
Power Steering Unit Removal
263
Power Steering Unit Installation
264
Steering Exploded View (Eps Models)
266
Steering Tie Rod
267
Tie Rod / Tie Rod End Replacement
267
Front A-Arms
268
Exploded View
268
Removal / Replacement
269
Ball Joint Service
270
Removal
270
Installation
270
Rear A-Arms
272
Exploded View
272
Rear Stabilizer Bar
274
Exploded View
274
Linkage Removal / Installation
275
Stabilizer Bar Removal / Installation
275
Shocks / Springs
276
Exploded View
276
Shock Removal / Installation
276
Shock / Spring Replacement
276
Brakes Chapter 11 Brakes
277
Chapter 11
278
General Brake Specifications
278
General Torque Specifications
278
Special Tools / Brake Fluid
278
Specifications
278
Brake Noise Troubleshooting
279
Brake System Service Notes
279
Brake System Exploded View
280
Brake Caliper Exploded View
281
Hand Master Cylinder Exploded View
281
Hydraulic Brake System Operation
280
Brake Bleeding
282
Fluid Replacement
282
Bleeding Procedure
282
Hand Brake Master Cylinder
284
Brake Switch Replacement
284
Foot Brake Master Cylinder
285
Foot Master Cylinder Removal / Installation
285
Brake Pedal Removal / Installation
285
Brake Pads
286
Caliper Removal
287
Brake Burnishing Procedure
287
Caliper Disassembly
287
Caliper Service
287
Caliper Inspection
288
Caliper Installation
289
Caliper Reassembly
289
Brake Disc Service
290
Troubleshooting
292
Poor Brake Performance
292
Brakes Lock
292
Chapter 12 Electrical
293
Electrical Service Notes
295
General Information
295
Instrument Cluster
296
Rider Information Display
297
Diagnostic Mode
300
Ignition Switch
301
Instrument Cluster Pinouts
301
Adc / 4X4 / 2X4 Switch
302
Off / Run Lh Switch
302
Head Lamp Switch
303
Reverse Override / Mode Button
303
Electronic Throttle Control (Etc) Switch
304
Gear Selector Switch
304
Speed Sensor
305
Awd / Adc Coils
306
Brake Switch
306
Diagnosing System Failures
306
Relays
307
Fuse Box Layout
309
Lights
310
Headlight Adjustment
310
Tail / Brake Bulb Replacement
311
Charging System
312
Current Draw - Key off
312
Battery Charge Test
312
Stator / Alternator Tests
312
Stator / Alternator Removal
313
Stator / Alternator Installation
314
Battery Service
315
Battery Removal / Installation
315
Battery off Season Storage
315
Battery Testing
315
Charging Procedure
316
Starter Motor
317
Starter / Starter Lockout System Diagram
317
Troubleshooting
317
Voltage Drop Testing
317
Starter Motor Removal / Replacement
318
Instrument Cluster Troubleshooting
319
Instrument Cluster - Key off / no Power
319
Instrument Cluster - Key on / no Power
320
Instrument Cluster - no High Beam Indicator
321
Instrument Cluster - no / Incorrect Fuel Level
322
Instrument Cluster Circuit
323
Electronic Power Steering (Eps)
324
Electronic Power Steering (Eps) Circuits
324
Eps Operation
324
Eps 8-Way Wire Harness Connector
325
Eps Troubleshooting
325
Electrical Breakout Diagrams
326
Battery Charging Circuits
326
Constant Power Circuits
328
Key-On Power Circuits
330
Chassis Power Circuits
331
Head Lamp Circuits
332
Brake Lamp Circuits
333
Engine Start Command Circuits
334
Ecm Wake-Up Command Circuits
336
Awd / Adc Circuits
337
Awd / Adc Function Tests
339
Radiator Fan Circuit
340
Gear Selector Switch Circuit
342
Ground Speed Sensor Circuit
344
Reverse Override Circuit
345
Controller Area Network (Can)
346
Overview
346
Can Troubleshooting
346
4
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Polaris 2009 Sportsman XP 850 Specifications
General
Brand
Polaris
Model
2009 Sportsman XP 850
Category
Offroad Vehicle
Language
English
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