Table Of Contents
📚 Polaris 2009 Sportsman XP 850 Service Manual
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TABLE OF CONTENTS
- VEHICLE IDENTIFICATION
- VEHICLE INFORMATION
- SPECIFICATIONS
- General information
- MISC. SPECIFICATIONS AND CHARTS
- STANDARD TORQUE SPECIFICATIONS
- SAE TAP / DRILL SIZES
- GLOSSARY OF TERMS
- Periodic maintenance chart
- MAINTENANCE INTERVALS
- GREASE LUBRICATION POINTS
- MAINTENANCE QUICK REFERENCE
- MAINTENANCE QUICK REFERENCE, CONTINUED
- LUBRICANTS / SERVICE PRODUCTS
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Fuel filters
- AIR FILTER / PRE-FILTER SERVICE
- ENGINE
- Engine breather hose
- VALVE CLEARANCE ADJUSTMENT
- COMPRESSION AND LEAKDOWN TESTS
- EXHAUST SILENCER CLEANING
- TRANSMISSION AND GEARCASES
- FRONT GEARCASE LUBRICATION
- FRONT GEARCASE ADC FLUID
- REAR GEARCASE LUBRICATION
- COOLING SYSTEM
- PVT / FINAL DRIVE / WHEEL AND TIRE
- WHEEL AND HUB TORQUE TABLE
- ELECTRICAL AND IGNITION SYSTEM
- SPARK PLUG SERVICE
- ENGINE / CHASSIS GROUND
- STEERING
- Toe alignment
- TOE ALIGNMENT ADJUSTMENT
- BRAKE SYSTEM
- AUXILIARY BRAKE PEDAL
- MAINTENANCE LOG
- Electronic fuel injection
- Fuel tank
- Fuel line
- Efi components
- Ecu service
- Fuel pump
- Fuel sender test
- Fuel pump / fuel tank removal
- Fuel injectors
- Fuel injector replacement
- Cps replacement
- Temp / manifold absolute pressure sensor (t-map)
- Iac replacement
- Checking tps reading
- Tps adjustment
- Tps replacement
- Ignition coil
- Efi diagnostics
- Fuel system troubleshooting
- Torque specifications
- Radiator cleaning
- Troubleshooting
- General information - engine
- Oil flow diagram
- Cylinder head / valve / iafm
- Piston / connecting rod
- Water pump coupler
- Engine removal
- Engine installation notes
- Engine disassembly and inspection
- Camshaft / camshaft bore inspection
- Cylinder head warp inspection
- Valve inspection
- Combustion chamber
- Valve seat reconditioning
- Cylinder head assembly
- Cylinder head installation
- Camshaft / carrier assembly
- Camshaft timing
- Cam chain tensioner installation
- Crankcase disassembly
- Crankcase (lower) / oil pump disassembly
- Crankcase disassembly (upper)
- Counterbalance shaft removal / inspection
- Crankshaft / cam chain removal
- Connecting rod inspection
- Connecting rod big end bearing selection
- Piston pin bore inspection
- Piston-to-cylinder clearance
- Engine assembly
- Crankshaft installation
- Balance shaft installation
- Crankcase preparation (lower)
- Crankcase assembly
- Transmission service
- Transmission disassembly
- Transmission assembly
- Transmission installation
- Transmission exploded view
- Special tools and supplies
- Shift weights
- Overheating / diagnosis
- Pvt system service
- Drive belt
- Belt inspection
- Drive clutch service
- Spider removal
- Button to tower clearance inspection
- Clutch inspection
- Moveable sheave bushing inspection
- Clutch assembly
- Driven clutch service
- Final drive
- Wheel hubs
- Front bearing carrier
- Bearing replacement
- Front drive shaft
- Front propshaft
- Awd operation
- Adc operation
- Awd diagnosis
- Gearcase removal
- Gearcase disassembly / inspection
- Gearcase assembly
- Setting ring gear backlash
- Gearcase installation
- Rear bearing carrier
- Bushing replacement
- Rear drive shaft
- Drive shaft service
- Drive shaft exploded view
- Rear propshaft
- Rear gearcase
- Gearcase disassembly and inspection
- Gearcase bearing and seal replacement
- Gearcase exploded view
- Decal replacement
- Seat and side panels
- Front bumper
- Front cab
- Rear rack
- Headlight pod
- Steering post removal
- Steering post installation
- Steering (eps models)
- Power steering unit removal
- Power steering unit installation
- Steering tie rod
- Ball joint service
- Rear stabilizer bar
- Linkage removal / installation
- Shocks / springs
- General brake specifications
- Brake system service notes
- Hydraulic brake system operation
- Brake caliper exploded view
- Bleeding procedure
- Hand brake master cylinder
- Foot brake master cylinder
- Brake pads
- Caliper removal
- Caliper inspection
- Caliper installation
- Brake disc service
- Poor brake performance
- BATTERY REMOVAL / INSTALLATION
- Component locations
- Instrument cluster
- Rider information display
- Diagnostic mode
- Ignition switch
- Adc / 4x4 / 2x4 switch
- Reverse override / mode button
- Electronic throttle control (etc) switch
- Speed sensor
- Diagnosing system failures
- Fuse box layout
- Headlight adjustment
- Tail / brake bulb replacement
- Charging system
- Stator / alternator removal
- Stator / alternator installation
- Battery service
- Charging procedure
- Starter motor
- Starter motor removal / replacement
- Instrument cluster troubleshooting
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