Polaris Sportsman 850 EFi/HD/EPS Series Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Sportsman 850 EFi/HD/EPS Series has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL: 2009 SPORTSMAN XP 850
MODEL NUMBER: A09ZN85AL, AQ, AS, AT, AX, FL
ENGINE MODEL: EH085OLE

MODEL: 2009 SPORTSMAN XP 850 EPS
MODEL NUMBER: A09ZX85AG, AL, AQ, AR, AS, AX, FS
ENGINE MODEL: EH085OLE

TABLE OF CONTENTS :

GENERAL INFORMATION
MAINTENANCE
ELECTRONIC FUEL INJECTION
COOLING SYSTEM
ENGINE
TRANSMISSION
CLUTCHING (PVT)
FINAL DRIVE
BODY / FRAME
STEERING / SUSPENSION
BRAKES
WIRE DIAGRAMS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 310

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Identification
Engine Designation Number
Vehicle Identification Number (VIN)
Vehicle and Engine Serial Number Locations
VEHICLE INFORMATION
Publication Numbers
Replacement Keys
Special Tools
SPECIFICATIONS
MODEL: 2009 SPORTSMAN XP 850
MODEL: 2009 SPORTSMAN XP 850 EPS
2009 SPORTSMAN XP 850 / XP 850 EPS
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Glossary of Terms

MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Break-In Period
Maintenance Chart Key
Maintenance Intervals
Grease Lubrication Points
Maintenance Quick Reference
Maintenance Quick Reference, Continued…..
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants,Maintenance and Service Products
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-ride / Daily Inspection
Frame, Nuts, Bolts, Fasteners
Controls
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Lines
Fuel Filters
Vent Line
Throttle Operation
Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment
Air Filter / Pre-Filter Service
ENGINE
Engine Oil Level
Engine Oil and Filter Change
Engine Breather Hose
Engine Breather Assembly
Valve Clearance Adjustment
Compression and Leakdown Tests
Exhaust Silencer Cleaning
Engine Mount Fastener Torque
TRANSMISSION AND GEARCASES
Transmission Lubrication
Front Gearcase Lubrication
Front Gearcase ADC Fluid
Rear Gearcase Lubrication
COOLING SYSTEM
Cooling System Overview
Coolant Level Inspection
Cooling System Hoses
Coolant Strength / Type
PVT / FINAL DRIVE / WHEEL AND TIRE
PVT Drying
Drive Belt Removal
Drive Shaft Boot Inspection
Wheel and Hub Torque Table
Wheel Removal
Wheel Installation
Tire Pressure
Tire Inspection
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Removal
Battery Installation
Spark Plug Service
Engine / Chassis Ground
STEERING
Steering Inspection
Power Steering Unit (EPS Models)
Tie Rod End / Steering Inspection
Toe Alignment
Toe Alignment Adjustment
SUSPENSION
Suspension Inspection
Suspension Spring Pre-Load Adjustment
BRAKE SYSTEM
Brake Fluid Inspection
Brake Pad Inspection
Hose / Fitting Inspection
Auxiliary Brake Pedal
MAINTENANCE LOG

ELECTRONIC FUEL INJECTION
SPECIAL TOOLS
Part Numbers / Descriptions
Fuel Pressure Gauge Kit – PU-43506-A
Fuel Pressure Gauge Adaptor – PS-48762
Throttle Position Sensor Tester Kit – 2201519
Digital Wrench™ Diagnostic Software PU-47063
Digital Wrench™ SmartLink Module Kit – PU-47471
Digital Wrench™ – Diagnostic Connector
Digital Wrench™ – Download Website
FUEL TANK
Exploded View
FUEL LINE
Quick Connect Removal / Installation
EFI SERVICE NOTES
EFI SYSTEM LAYOUT
Exploded View
EFI COMPONENTS
Identification / Location
ELECTRONIC FUEL INJECTION
General Information
EFI Operation Overview
Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
ECU Service
ECU Removal / Replacement
FUEL PUMP
Operation
Fuel Sender Test
Fuel Pump Test
Fuel Pump / Fuel Tank Removal
Fuel Pump / Fuel Tank Installation
FUEL PRESSURE REGULATOR
Operation Overview
FUEL INJECTORS
Operation Overview
Fuel Injector Service
Fuel Injector Test
Fuel Injector Replacement
CRANKSHAFT POSITION SENSOR (CPS)
Operation Overview
CPS Test
CPS Replacement
TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
Operation Overview
T-MAP Test
T-MAP Replacement
IDLE AIR CONTROL VALVE (IAC)
Operation Overview
IAC Test
IAC Replacement
THROTTLE POSITION SENSOR (TPS)
Operation Overview
TPS Resistance Tests
TPS Tester Kit
Checking TPS Reading
TPS Adjustment
TPS Replacement
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Operation Overview
ECT Sensor Test
ECT Sensor Replacement
IGNITION COIL
Operation Overview
Ignition Coil Tests
Ignition Coil and HT Lead Replacement
EFI DIAGNOSTICS
Instrument Cluster Trouble Code Display
FUEL SYSTEM TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Poor Idle
EFI SYSTEM BREAK-OUT DIAGRAMS
Fuel Injector Circuit (PTO)
Fuel Injector Circuit (MAG)
Idle Air Control (IAC) Circuit
Crankshaft Position Sensor (CPS) Circuit
Fuel Pump / Fuel Level Sensor Circuit
Fuel Pump Circuit
Fuel Gauge Circuit
Engine Coolant Temperature Sensor (ECT) Circuit
Throttle Position Sensor (TPS) Circuit
Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
Diagnostic Connector Circuit
Diagnostic Connector Circuit (EPS Models)

COOLING SYSTEM
SPECIAL TOOLS
TORQUE SPECIFICATIONS
COOLING SYSTEM
Cooling System Layout and Testing
Cooling System Specifications
Cooling System Bleeding Procedure
RADIATOR
Radiator Cleaning
Coolant Drain / Radiator Removal
WATER PUMP SERVICE
Water Pump Impeller Removal
Water Pump Mechanical Seal Replacement
Water Pump Shaft & Bearing Replacement
Stator Cover Installation
Water Pump Assembly / Torque Specifications
Stator Cover Assembly Torque Specifications
THERMOSTAT
Removal (Engine Installed)
Installation
TROUBLESHOOTING
Cooling System

ENGINE
GENERAL INFORMATION – ENGINE
Special Tools
Engine Lubrication Specifications
Oil Pressure Test
Oil Flow Diagram
Engine Specifications – EH085OLE-011
ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
Torque & Torque Sequence – Main Engine Components
Valve Cover / Breather Valve
Camshaft Carrier / Camshaft / Rocker Arm
Cylinder Head / Valve / IAFM
Valve & Spring Height Detail
Piston / Connecting Rod
Crankshaft
Crankcase
Crankcase – Upper
Balance Shaft / Balance Shaft Timing
Crankcase (Lower) With Oil Pump
Water Pump Coupler
Water Pump / Water Pump Coupler / Stator / Flywheel
Drive Coupler (Rear) / Starter Gear
ENGINE SERVICE
Accessible Engine Components
Top-End Service (Engine in Chassis)
Crankcase Cylinder Service Information
Engine Removal
Engine Installation Notes
ENGINE DISASSEMBLY AND INSPECTION
Valve Cover / Breather Valve
Rocker Carrier / Camshaft Removal
Rocker Arm / Rocker Arm Shaft Inspection
Camshaft / Camshaft Bore Inspection
Cylinder Head Removal
Cylinder Head Cleaning
Cylinder Head Warp Inspection
Cylinder Head
Valve Inspection
Combustion Chamber
Valve Guide Removal / Installation
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Cylinder Head Installation
Camshaft / Carrier Assembly
Camshaft / Camshaft Carrier Installation
Camshaft Timing
Cam Chain Tensioner Installation
Camshaft Timing – Quick Reference
Crankcase Disassembly
Crankcase (Lower) / Oil Pump Disassembly
Crankcase Disassembly (Upper)
Piston / Connecting Rod Removal
Counterbalance Shaft Removal / Inspection
Counterbalance Split Gear Replacement
Crankshaft / Cam Chain Removal
Cam Chain / Sprocket Inspection
Crankcase Inspection (Lower)
Crankshaft Inspection
Connecting Rod Inspection
Connecting Rod Big End Bearing Selection
Piston / Piston Ring Inspection
Piston Ring Removal
Piston Ring Installed Gap
Piston Pin Bore Inspection
Cylinder Inspection
Piston-to-Cylinder Clearance
Honing – Important Information
ENGINE ASSEMBLY
Crankcase Preparation – Upper
Piston Ring Installation
Piston / Connecting Rod Assembly
Piston / Connecting Rod Installation
Crankshaft Installation
Oil Passage Tube
Crankcase Assembly – Upper
Balance Shaft Installation
Balance Shaft Timing
Crankcase Preparation (Lower)
Crankcase Sealant and Torque Values
Crankcase Assembly
WATER PUMP
Water Pump Impeller Removal
Water Pump Mechanical Seal Replacement / Coupler Shaft & Bearing Replacement
TROUBLESHOOTING
Engine

TRANSMISSION
TRANSMISSION SPECIFICATIONS
Torque Specifications
Lubrication Specifications
SHIFT LINKAGE / GEAR SELECTOR
Shift Linkage Inspection
Gear Selector Removal
TRANSMISSION SERVICE
Transmission Removal
Transmission Disassembly
Transmission Shaft Service
Transmission Assembly
Transmission Installation
Transmission Exploded View
TROUBLESHOOTING
Troubleshooting Checklist

CLUTCHING (PVT)
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
Drive Clutch Operation
Shift Weights
Driven Clutch Operation
PVT Break-In (Drive Belt / Clutches)
Maintenance / Inspection
Overheating / Diagnosis
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
Disassembly
Assembly
DRIVE BELT
Belt Removal
Belt Inspection
Belt Installation
PVT Break-In (Drive Belt / Clutches)
DRIVE CLUTCH SERVICE
Spring Specifications
Exploded View
Clutch Disassembly
Spider Removal
Roller, Pin, and Thrust Washer Inspection
Button To Tower Clearance Inspection
Shift Weight Inspection
Bearing Inspection
Clutch Inspection
Moveable Sheave Bushing Inspection
Bushing Service
Clutch Assembly
DRIVEN CLUTCH SERVICE
Clutch Disassembly
Bushing Service
Clutch Assembly
Exploded View
TROUBLESHOOTING

FINAL DRIVE
GENERAL SPECIFICATIONS
Torque Specifications
Special Tools
WHEELS
Removal
Installation
WHEEL HUBS
Front Hub Exploded View
Rear Hub Exploded View
FRONT BEARING CARRIER
Inspection / Removal
Bearing Replacement
Installation
FRONT DRIVE SHAFT
Removal
Installation
FRONT PROPSHAFT
Removal
Installation
PROPSHAFT U-JOINT SERVICE
Disassembly
Assembly
FRONT GEARCASE – CENTRALIZED HILLIARD
Exploded View
AWD Operation
ADC Operation
AWD Diagnosis
Gearcase Removal
Gearcase Disassembly / Inspection
Gearcase Assembly
Setting Ring Gear Backlash
Gearcase Installation
ADC System Fluid Bleeding
REAR BEARING CARRIER
Inspection / Removal
Bearing Replacement
Bushing Replacement
Installation
REAR DRIVE SHAFT
Removal
Installation
DRIVE SHAFT SERVICE
Drive Shaft / CV Joint Handling Tips
Outer CV Joint / Boot Replacement
Inner Plunging Joint / Boot Replacement
Drive Shaft Exploded View
REAR PROPSHAFT
Removal
Installation
REAR GEARCASE
Gearcase Removal
Gearcase Disassembly and Inspection
Gearcase Bearing and Seal Replacement
Gearcase Assembly
Gearcase Installation
Gearcase Exploded View

BODY / FRAME
TORQUE SPECIFICATIONS
DECAL REPLACEMENT
SPECIAL TOOLS
Plastic Push Rivet Removal
Multi-Function Pliers
SEAT AND SIDE PANELS
Removal / Installation
FRONT RACK
Removal / Installation
FRONT BUMPER
Removal / Installation
MUD GUARDS
Removal / Installation
FOOTWELLS
Removal / Installation
FRONT CAB
Removal
Installation
REAR RACK
Removal / Installation
REAR BUMPER COVERS
Removal / Installation
REAR CAB
Removal / Installation
HEADLIGHT POD
Disassembly / Removal
Assembly / Installation
MAIN FRAME
Frame Support Exploded View
CHASSIS
Body Plastic Removed View

STEERING / SUSPENSION
GENERAL SPECIFICATIONS
Torque Specifications
HANDLEBAR
Removal / Replacement
Installation
STEERING
Steering Post Removal
Steering Post Installation
Steering Exploded View
STEERING (EPS MODELS)
Upper Steering Post Removal
Upper Steering Post Installation
Power Steering Unit Removal
Power Steering Unit Installation
Steering Exploded View (EPS Models)
STEERING TIE ROD
Tie Rod / Tie Rod End Replacement
FRONT A-ARMS
Exploded View
Removal / Replacement
BALL JOINT SERVICE
Removal
Installation
REAR A-ARMS
Exploded View
Removal
Installation
REAR STABILIZER BAR
Exploded View
Linkage Removal / Installation
Stabilizer Bar Removal / Installation
SHOCKS / SPRINGS
Exploded View
Shock Removal / Installation
Shock / Spring Replacement

BRAKES
SPECIFICATIONS
General Brake Specifications
General Torque Specifications
Special Tools / Brake Fluid
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
Brake Caliper Exploded View
Hand Master Cylinder Exploded View
BRAKE BLEEDING
Fluid Replacement
Bleeding Procedure
HAND BRAKE MASTER CYLINDER
Removal
Disassembly
Installation
Brake Switch Replacement
FOOT BRAKE MASTER CYLINDER
Operation Overview
Foot Master Cylinder Removal / Installation
Brake Pedal Removal / Installation
BRAKE PADS
Pad Removal
Pad Inspection
Pad Installation
Brake Burnishing Procedure
CALIPER SERVICE
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Reassembly
Caliper Installation
BRAKE DISC SERVICE
Disc Inspection
Disc Removal / Replacement
TROUBLESHOOTING
Brake Squeal

WIRE DIAGRAMS
SPORTSMAN XP 850 (PAGE 1 OF 2)
SPORTSMAN XP 850 (PAGE 2 OF 2)
AWD / ADC
BATTERY CHARGING
BATTERY PLUS
BRAKE LAMPS-START
CHASSIS POWER
COOLING FAN
ECM WAKE-UP
EFI
ENGINE CRANK
EPS
FUEL PUMP & LEVEL
GEAR SENSOR
GROUND SPEED SENSOR
KEY ON POWER
HEADLAMPS