2009 Polaris Sportsman XP 850 ATV Service Manual

Description

This Official 2009 Polaris Sportsman XP 850 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for :

2009 Polaris Sportsman XP 850 ATVs

2009 Polaris Sportsman XP 850 International ATVs

2009 Polaris Sportsman XP EPS 850 ATVs

2009 Polaris Sportsman XP EPS 850 International ATVs

2009 Polaris Sportsman XP 850 ATV Service Manual Table of Contents

General Information
Maintenance
Electronic Fuel Injection
Cooling System
Engine
Transmission
Clutching (PVT)
Final Drive
Body/frame
Steering / Suspension
Brakes
Electrical

2009 Polaris Sportsman XP 850 ATV Service Manual Index of Topics

A
Active Descent Control (ADC)
ADC Fluid
ADC, Coil Resistance
Adjustment, Valve Clearance
Air Filter Service
All Wheel Drive (AW’D) Coil
Assembly View, Camshaft
Assembly View, Camshaft Timing
Assembly View, Connecting Rod
Assembly View, Crankcase Complete
Assembly View, Crankcase Lower
Assembly View, Crankcase Upper
Assembly View, Crankshaft
Assembly View, Cylinder Head
Assembly View, Oil Pump
Assembly View, Piston and Rings
Assembly View, Rocker Arm
Assembly View, Rocker Cover
Assembly View, Valve
Assembly Views, Engine
Assembly, Connecting Rod and Piston
Assembly, Crankcase
Assembly, Crankcase Upper
Assembly, Lower Crankcase
Assembly, Upper Crankcase
AW’D, Coil Resistance
AW’D Diagnosis
B
Balance Shaft
Balance Shaft Installation
Balance Shaft Removal, Inspection
Balance Shaft Split Gear
Balance Shaft Timing
Ball Joint Sendee
Battery Maintenance
Battery Sendee
Battery Storage
Battery, Installation
Battery, Removal
Bearing Inspection, Crankshaft Main
Bearing Selection Chart, Con Rod
Brake Bleeding
Brake Burnishing
Brake Caliper Assembly
Brake Caliper Exploded View
Brake Caliper Inspection
Brake Caliper Installation
Brake Caliper Piston Bore ID
Brake Caliper Removal
Brake Disc Service
Brake Disc, Inspection
Brake Fitting Inspection
Brake Hose Inspection
Brake Pad Inspection
Brake Pad Installation
Brake Pads
Brake Pedal Inspection
Brake System Inspection
Brake System, Exploded View
Brake System, Operation
Brakes, Troubleshooting
Break-In Period
Breather Filter Inspection
Breather Hose
Breather Valve
Breather, Removal
Bumper Lights Relay
c
Cam Chain Inspection
Camshaft Bore Inspection
Camshaft Carrier
Camshaft Chain Removal
Camshaft Chain Tensioner Installation
Camshaft Installation
Camshaft Timing
Camshaft Timing, Quick Reference
Camshaft, Removal
Centralized Hilliard, Exploded View
Chain Tensioner, Camshaft
Chain, Cam, Removal
Charging System
Chart, Con Rod Bearing Selection
Chassis Relay
Chassis, Exploded View
Compression Test
Connecting Rod Assembly
Connecting Rod Bearing Selection Charts
Connecting Rod Inspection
Connecting Rod Installation
Connecting Rod, Assembly View
Controls
Conversion Table
Coolant Level Inspection
Coolant Strength and Type
Cooling System
Cooling System Hoses
Cooling System, Bleeding Procedure
Cooling System, Specifications
Cooling System, Troubleshooting
Counterbalance Shaft
Counterbalance Shaft Installation
Counterbalance Shaft Removal
Counterbalance Shaft Timing
Counterbalance Split Gear Replacement
Coupler, Drive
Coupler, Water Pump
Cover, Stator
Cover, Valve, Removal
Crankcase Assembly
Crankcase Assembly View, Complete
Crankcase Assembly View’, Lower
Crankcase Assembly View’, Upper
Crankcase Assembly, Lower
Crankcase Assembly, Upper
Crankcase Disassembly
Crankcase Disassembly (Low’er)
Crankcase Disassembly (Upper)
Crankcase Inspection, Low’er
Crankshaft Assembly View’
Crankshaft Installation
Crankshaft Position Sensor (CPS)
Crankshaft Removal
Crankshaft, Inspection
Cylinder Head
Cylinder Head Assembly
Cylinder Head Disassembly
Cylinder Head Installation
Cylinder Head Removal
Cylinder Head Torque Procedure
Cylinder Head, Inspection
Cylinder Head, Warp Inspection
Cylinder Honing
Cylinder Inspection
D
Daily Inspection
Decal Replacement
Decimal Equivalent Chart
Diagnostic Code Table
Diagnostic Codes, Instrument Cluster
Disassembly, Crankcase
Disassembly, Low’er Crankcase
Disassembly, Upper Crankcase
Drive Belt, Break-In
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt Removal
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Button to Tower Clearance
Drive Clutch, Cover Bushing Remove/Install
Drive Clutch, Disassembly
Drive Clutch, Exploded View’
Drive Clutch, Moveable Sheave Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spider Removal
Drive Clutch, Spring
Drive Coupler
Drive Shaft / CV Joint, Handling Tips
Drive Shaft Boot Inspection
Driven Clutch, Assembly
Driven Clutch, Bushing Service
Driven Clutch, Disassembly
Driven Clutch, Exploded View’
Driven Clutch, Operation
Driven Clutch, Service
E
EFI Circuit Break-Out Diagrams
EFI Operation Overview’
EFI Priming / Starting Procedure
EFI Relay
EFI, Component Locations
EFI, Diagnostic Codes
EFI, Exploded View’
EFI, Service Notes
Electrical Breakout Diagrams
Electronic Control Unit (ECU)
Electronic Power Steering (EPS) Circuits
Electronic Throttle Control (ETC)
Engine Assembly Views
Engine Cylinder Inspection
Engine Installation Notes
Engine Lubrication
Engine Model Number
Engine Piston Ring Installed Gap
Engine Piston to Cylinder Clearance
Engine Removal, EH0850LE-011
Engine Serial Number
Engine Specifications
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Accessible Components
Engine, Combustion Chamber
Engine, Cooling System
Engine, Crankcase, Disassembly
Engine, Cylinder Head Assembly
Engine, Cylinder Head Inspection
Engine, Cylinder Head Removal
Engine, Cylinder Head Warp
Engine, Flywheel Removal
Engine, Oil and Filter Change
Engine, Oil Level
Engine, Special Tools
Engine, Starter Removal
Engine, Thermostat
Engine, Troubleshooting
Engine, Valve Inspection
Engine, Valve Sealing Test
Engine, Valve Seat Reconditioning
EPS, Cleaning
EPS, Power Steering Unit Installation
EPS, Power Steering Unit Removal
EPS, Upper Steering Post Installation
EPS, Upper Steering Post Removal
F
Fan Relay
Foot (Auxiliary’) Brake Master Cylinder
Footwell, Removal / Installation
Footwells
Frame Supports
Frame, Nuts, Bolts, Fasteners
Front A-arm, Replacement
Front A-arms
Front A-arms, Exploded View
Front Bearing Carrier
Front Bumper
Front Cab
Front Drive Shaft, Installation
Front Drive Shaft, Removal
Front Gearcase ADC Fluid
Front Gearcase Lubrication
Front Gearcase, Assembly
Front Gearcase, Disassembly / Inspection
Front Gearcase, Installation
Front Gearcase, Removal
Front Propshaft, Sendee
Front Rack
Fuel Filters
Fuel Injectors
Fuel Line
Fuel Lines
Fuel Pressure Regulator
Fuel Pump
Fuel Pump / Fuel Level Sensor Circuit
Fuel Sender Test
Fuel System
Fuel System Troubleshooting
Fuel Tank
Fuse Box
Fuses
G
Gear Position Swatch
Gear Selector Removal
General Specifications
Guide, Valve
H
Hand Brake Master Cylinder Removal
Hand Master Cylinder, Exploded View
Handlebar, Removal / Replacement
Head Lights
Head, Cylinder
Head, Cylinder, Disassembly
Head, Cylinder, Inspection
Headlight Pod
Honing, Cylinder
I
IAFM, Torque Sequence
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Impeller, Water Pump
Inner Plunging Joint / Boot Replacement
Inspection, Cam Chain
Inspection, Camshaft Bore
Inspection, Connecting Rod
Inspection, Counterbalance Shaft
Inspection, Crankcase, Lower
Inspection, Crankshaft Journals
Inspection, Cylinder Head
Inspection, Piston
Inspection, Piston Ring
Inspection, Valve
Installation, Camshaft
Installation, Camshaft Chain Tensioner
Installation, Connecting Rod
Installation, Counterbalance Shaft
Installation, Crankshaft
Installation, Cylinder Head
Installation, Piston
Installation, Piston Ring
Instrument Cluster
Integrated Air Fuel Manifold, Torque Sequence
K
Keys, Replacement
L
Lash Adjustment, Valve
LeakdownTest
Lubrication Diagram
Lubrication Grease Points
Lubrication Specifications
M
Main Frame
Maintenance and Sendee Products
Maintenance Quick Reference Chart
Maintenance Schedule
Mechanical Seal, Water Pump
Model Number
Mud Guards
o
Oil Flow Diagram
Oil Passage Tube
Oil Pressure Specifications
Oil Pressure Test
Oil Pump
Oil Pump Assembly View
Oil Pump Rotor Clearance
Outer CV Joint / Boot Replacement
P
Piston Pin Bore Inspection
Piston Removal, Inspection
Piston Ring Inspection
Piston Ring Installation
Piston Ring Installed Gap
Piston Ring, Compressor
Piston to Cylinder Clearance
Piston, Assembly View
Piston, Installation
Power Steering Relay
Power Steering Unit, Cleaning
Pre-Filter Service
Pre-Ride Inspection
Pressure Test, Oil
Propshaft, U-Joint Service
Publication Part Numbers
Pump, Oil
Pump, Water
Pump, Water, Mechanical seal Replacement
PVT System, Assembly
PVT System, Disassembly
PVT System, Maintenance
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Drain Plug
PVT, Drying
R
Radiator
Radiator, Removal
Rear A-arm, Replacement
Rear A-arms
Rear A-arms, Exploded View
Rear Bearing Carrier
Rear Bumper Covers
Rear Cab
Rear Cab, Removal / Installation
Rear Drive Shaft, Installation
Rear Drive Shaft, Removal
RearGearcase
Rear Gearcase Lubrication
Rear Gearcase, Assembly
Rear Gearcase, Disassembly
Rear Gearcase, Exploded View
Rear Gearcase, Installation
Rear Gearcase, Removal
Rear Propshaft, Service
Rear Rack
Rear Stabilizer Bar, Exploded View
Relays
Removal, Breather
Removal, Camshaft
Removal, Counterbalance Shaft
Removal, Cylinder Head
Removal, Engine, Accessible Components
Removal, Valve Cover
Removal, Valve Guide
Replacement Keys
Ring Gear, Starter
Rings, Piston, Assembly View
Rocker Ann
Rocker Arm, Installation
Rocker Arm, Removal and Inspection
Rocker Carrier, Removal
Rocker Cover
Rocker Cover, Removal
s
Seat
Sequence, Engine Cover Torque
Shaft, Rocker Arm
Shaft, Rocker Arm Installation
Shift Linkage Inspection
Shocks and Springs
Side Panels
SparkPlug
Special Tool, Electrical
Special Tools, Body/Frame
Special Tools, Clutching
Special Tools, Cooling System
Special Tools, EFI
Special Tools, Engine
Special Tools, Final Drive
Specification, Cylinder Head Warp
Specification, Cylinder Taper Limit
Specification, Cylinder Warp Limit
Specification, Fuel Pressure
Specification, Oil Pump Rotor Clearance
Specification, Valve Seat Contact Width
Specification, Valve Spring Free Length
Specification, Valve Stem Diameter
Specification, Valve Stem Guide ID
Specifications, Brake Disc Runout
Specifications, Brake Pad Thickness
Specifications, Brakes
Specifications, Clutching
Specifications, Cooling System
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Specifications, Final Drive Torque
Specifications, Hub Nut Torque
Speed Sensor, Operation Overview
Speedometer
Split Gear, Balance Shaft
Sprocket, Cam Chain, Inspection
Start Solenoid Relay
Starter Motor, Removal / Disassembly
Starter Ring Gear
Starter System
Starter System, Troubleshooting
Stator
Stator, Installation
Stator, Removal
Steering
Steering Inspection
IX4
Steering Post Installation
Steering Post Removal
Steering, Electronic Power Steering (EPS)
Steering, Exploded View
Steering, Exploded View (EPS)
Steering, Tie Rod Replacement
Suspension Inspection
Suspension Spring Preload Adjustment
T
Tap/Drill Sizes
Temp / Manifold Absolute Pressure Sensor (T-MAP)
Tensioner, Camshaft, Installation
Thermostat
Throttle Cable Adjustment
Throttle Operation
Throttle Position Sensor (TPS)
Tie Rod Ends
Timing, Balance Shaft
Timing, Camshaft
Timing, Counterbalance Shaft
Tire Inspection
Tire Pressure
Toe Alignment
Toe Alignment Adjustment
Torque Chart
Torque Patterns, Engine Components
Torque Procedure, Cylinder Head
Torque Specifications, Body/Frame
Torque Specifications, Clutching
Torque Specifications, Cooling System
Torque Specifications, Steering/Suspension
Torque Specifications, Transmission
Torque Specifications, Wheel and Hub
TPS Adjustment
TPS Replacement
Transmission Lubrication
Transmission, Assembly
Transmission, Disassembly
Transmission, Exploded View
Transmission, Installation
Transmission, Lubrication
Transmission, Removal
Transmission, Shaft Sendee
Troubleshooting, Brake Noise
Troubleshooting, Clutching
Troubleshooting, Engine
Troubleshooting, Transmission
Tube, Oil Passage
V
Valve Clearance Adjustment
Valve Cover Assembly View
Valve Cover Removal
Valve Cover, Removal
Valve Guide Inspection
Valve Guide, Removal
Valve Inspection
Valve Installation Detail
Valve Sealing Test
Valve Seat Reconditioning
Valve Spring Free Length
Valve Spring Installation Detail
Valve Spring Removal
Valve Stem Diameter
Valve, Assembly View
Vehicle Identification Number (VIN)
Vehicle Identification Numbers
Vent Line
VIN Location
Voltage Drop Test
w
Water Pump
Water Pump Coupler
Water Pump Impeller
Water Pump Mechanical Seal Replacement
Water Pump Removal
Wheel Removal / Installation