$12.85
Polaris Scrambler XP 850 H.O. / EPS / INT’L Repair Service Manual 2013
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This workshop repair service manual PDF download for the 2003 Polaris Scrambler XP 850 H.O. / EPS / INT’L 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 :
YEAR - MODEL - MODEL NO.
2013 - SCRAMBLER XP 850 H.O. - A13GH85AJ
2013 - SCRAMBLER XP 850 H.O. EPS - A13GH8EAK
2013 - SCRAMBLER XP 850 H.O. EPS INT’L - A13GH8EFK
TABLE OF CONTENTS :
Chapter_01_General_Information
Chapter_02_Maintenance
Chapter_03_Electronic_Fuel_Injection
Chapter_04_Cooling_System
Chapter_05_Engine
Chapter_06_Transmission
Chapter_07_Clutching(PVT)
Chapter_08_Final_Drive
Chapter_09_Body_Frame
Chapter_10_Steering_Suspension
Chapter_11_Brakes
Chapter_12_Electrical
Wiring_Diagrams
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9924122
Total Pages : 386
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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Chapter_01_General_Information
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Number Designation
Engine Designation Number
Vehicle Identification Number (VIN) Designation
Vehicle and Engine Serial Number Locations
VEHICLE INFORMATION
Publication Numbers
Replacement Keys
SPECIAL TOOLS
SPECIFICATIONS
MODEL: 2013 SCRAMBLER XP 850 H.O.
MODEL: 2013 SCRAMBLER XP 850 H.O. EPS / INT’L
2013 SCRAMBLER XP 850 H.O. / EPS / INT’L
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Bolt Torque Specification
Metric Bolt Torque Specification
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Chapter_02_Maintenance
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
Throttle Release Switch / Throttle Cable Adjustment
Air Filter / Pre-Filter Service
ENGINE
Engine Oil Level
Engine Oil and Filter Change
Engine Breather Hose
Valve Clearance Adjustment
Compression and Leakdown Tests
Exhaust Silencer Cleaning
Engine Mount Fastener Torque
TRANSMISSION AND GEARCASES
Transmission Lubrication
Front Gearcase Lubrication
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
Extreme Use 30 AH Battery
Engine / Chassis Ground
Spark Plug Service
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
Adjustable Shocks (FOX™)
FOX™ Shock Spring Preload Adjustment
Shock Compression Adjustment
BRAKE SYSTEM
Brake Fluid Inspection
Brake Pad Inspection
Hose / Fitting Inspection
Auxiliary Brake Pedal
Chapter_03_Electronic_Fuel_Injection
ELECTRONIC FUEL INJECTION
SPECIAL TOOLS
Part Numbers / Descriptions
Fuel Pressure Gauge Kit - PU-43506-A
Fuel Pressure Gauge Adaptor - PS-48762
Digital Wrench® - Diagnostic Connector
Digital Wrench® Diagnostic Software PU-47063-B
Digital Wrench® SmartLink Module Kit - PU-47471
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 ASSEMBLY
Operation Overview
Fuel Sender Test
Fuel Pump Test
Fuel Tank Removal
Fuel Pump Replacement
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 Replacement / Adjustment
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
DIGITAL WRENCH® OPERATION
Digital Wrench® Diagnostic Software Overview
Special Tools
Diagnostic Software Version
ECU Replacement
Guided Diagnostic Available
Digital Wrench® Communication Errors
Digital Wrench® - Diagnostic Connector
Digital Wrench® Serial Number Location
Digital Wrench® Version and Update ID
Digital Wrench® Updates
Digital Wrench® Feature Map
Engine Controller Reprogramming (Reflash)
FUEL SYSTEM TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Poor Idle
Chapter_04_Cooling_System
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 Service
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
Chapter_05_Engine
ENGINE
GENERAL INFORMATION - ENGINE
Special Tools
Engine Lubrication Specifications
Oil Pressure Test
Oil Flow Diagram
Engine Specifications - SPM850-12
ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
Torque Specification and Torque Sequence - Main Engine Components
Valve Cover
Camshaft Carrier / Camshaft / Rocker Arm
Cylinder Head / Valves / Integrated Throttle Body
Valve and Spring Height Detail
Piston / Connecting Rod
Crankshaft
Crankcase
Crankcase - Upper
Balance Shaft / Balance Shaft Timing
Crankcase (Lower) With Oil Pump
Stator Cover / Flywheel / Water Pump Coupler
Water Pump / Water Pump Coupler / Stator
Drive Coupler (Rear) / Starter Gear
ENGINE SERVICE
Accessible Engine Components
Top-End Service (Engine in Chassis)
Engine Removal
Engine Installation Notes
ENGINE DISASSEMBLY / INSPECTION
Valve Cover Removal / Inspection
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
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
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 and Bearing Replacement
TROUBLESHOOTING
Engine
Chapter_06_Transmission
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
Chapter_07_Clutching(PVT)
CLUTCHING (PVT)
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
HIGH ALTITUDE CLUTCH CHART
2013 850 Scrambler
PVT SYSTEM OVERVIEW
General Operation
Drive Clutch Operation
Driven Clutch Operation
Shift Weights
PVT Break-In (Drive Belt / Clutches)
Maintenance / Inspection
Overheating / Diagnosis
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
PVT Disassembly
PVT Assembly
DRIVE BELT
Belt Removal
Belt Inspection
Belt Installation
PVT Break-In (Drive Belt / Clutches)
DRIVE CLUTCH SERVICE
Exploded View
Shift Weights
Clutch Disassembly
Bearing Inspection
Drive Clutch Spring Inspection
Shift Weight Inspection
Button To Tower Clearance Inspection
Spider Removal
Roller, Pin, and Thrust Washer Inspection
Clutch Inspection
Moveable Sheave Bushing Inspection
Bushing Service
Clutch Assembly
DRIVEN CLUTCH SERVICE
Clutch Disassembly
Clutch Inspection
Clutch Assembly
Exploded View
TROUBLESHOOTING
Chapter_08_Final_Drive
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
AWD Diagnosis
Gearcase Removal (Non-EPS Models)
Gearcase Removal (EPS Models)
Gearcase Disassembly / Inspection
Gearcase Assembly
Setting Ring Gear Backlash
Gearcase Installation (Non-EPS Models)
Gearcase Installation (EPS Models)
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 Exploded View
Gearcase Installation
Chapter_09_Body_Frame
BODY / FRAME
TORQUE SPECIFICATIONS
DECAL REPLACEMENT
SPECIAL TOOLS
Plastic Push Rivet Removal
Multi-Function Pliers
Handlebar POD
Disassembly / Removal
Assembly / Installation
SEAT AND SIDE PANELS
Removal / Installation
FRONT RACK
Removal / Installation
FRONT BUMPER
Removal / Installation
FRONT FASCIA
Removal / Installation
MUD GUARDS
Removal / Installation
FOOTWELLS
Removal / Installation
FRONT CAB
Removal
Installation
REAR RACK
Removal / Installation
REAR FENDERS
Removal / Installation
REAR CAB/STORAGE BOX
Removal / Installation
SKID PLATES
Removal / Installation
MAIN FRAME
Frame Support Exploded View
Chapter_10_Steering_Suspension
STEERING / SUSPENSION
GENERAL SPECIFICATIONS
Torque Specifications
HANDLEBAR
Removal / Replacement
Installation
STEERING (NON-EPS MODELS)
Steering Post Removal
Steering Post Installation
Steering Exploded View (Non-EPS Models)
STEERING (EPS MODELS)
Upper Steering Post Removal
Upper Steering Post Installation
EPS Unit Removal
EPS 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
Service Preparation
Ball Joint Removal
Ball Joint Installation
REAR A-ARMS
Exploded View
Removal
Installation
REAR STABILIZER BAR
Exploded View
Linkage Removal / Installation
Stabilizer Bar Removal / Installation
SHOCKS / SPRINGS / FASTENERS
Shock Exploded View - Base Model
Shock Exploded View - EPS/INTL. Models
Shock Removal / Installation
Shock / Spring Replacement
Shock Removal / Installation
Shock Replacement
FOX™ SHOCK EXPLODED VIEWS
FOX™ Piggyback Shock
FOX™ SHOCK SERVICE
General Service Information
Front Shock Service Information
Rear Shock Service Information
FOX™ Shock Rebuild Information
Special Tools
FOX™ Shock Disassembly
FOX™ Shock Body and Reservoir Service
FOX™ Shock Component Rebuild
FOX™ Shock Assembly
Chapter_11_Brakes
BRAKES
General Brake Specifications
FRONT BRAKES
REAR BRAKES
General Torque Specifications
Special Tools / Brake Fluid
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
XP 850 / XP 850 EPS Models
850 INT’L Models
Brake Caliper Exploded View
Hand Master Cylinder Exploded View
INTERNATIONAL BRAKE SYSTEM OPERATION
Hand Master Cylinder Hydraulic Operation
Foot Master Cylinder Hydraulic Operation
BRAKE BLEEDING
Fluid Replacement
Always wear safety glasses during these procedures. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces.
1. Clean reservoir cover thoroughly.
2. Remove screws, cover and diaphragm from master cylinder reservoir.
3. Inspect vent slots in cover and remove any debris or blockage.
4. If changing fluid, remove old fluid from reservoir and lines at the bleeders with a Mity Vacä or similar tool.
5. Add brake fluid to .25” - .30” (6 - 8 mm) from the top of the reservoir.
Polaris DOT 4 Brake Fluid
PN: 2872189
Bleeding Procedure
1. Remove the reservoir cover from the hand brake master cylinder and verify fluid is at specified level.
2. If fluid level is low, add brake fluid to .25” - .30” (6 - 8 mm) from the top of the reservoir.
3. Install a box end wrench on foot master cylinder bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting.
4. Slowly pump the hand brake lever until pressure builds and holds.
5. While maintaining lever pressure, open bleeder screw.
6. Close bleeder screw and release brake lever.
7. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
Maintain at least 1/2” (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
8. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm).
9. Repeat the procedure on the two remaining front calipers.
10. Add DOT 4 brake fluid to .25” - .30” (6 - 8 mm) from the top of the reservoir.
11. Install diaphragm, cover and screws. Torque the screws to 7 in. lbs. (0.8 Nm).
12. Proceed to “Rear Brake System Bleeding” to complete bleeding procedure.
1. Thoroughly clean the fluid reservoir cover before removal.
2. Remove the cap and diaphragm from the reservoir and verify fluid level is at the MAX level mark.
3. If changing fluid, remove old fluid from reservoir with a Mity Vacä (PN 2870975) or similar tool.
4. Using a funnel, add brake fluid to the MAX level mark on the reservoir.
5. Install a box end wrench on the rear caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting.
6. Slowly pump the foot brake pedal until pressure builds and holds.
7. While maintaining pedal pressure, open bleeder screw.
8. Close bleeder screw and release brake pedal.
9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
10. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm).
11. Repeat the procedure on the remaining rear caliper.
12. Using a funnel, add brake fluid to the MAX level mark on the reservoir.
13. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2”, (1.3 cm) from handlebar.
14. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found.
HAND BRAKE MASTER CYLINDER
Removal
1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components.
2. Place a shop towel or suitable catch container under the master cylinder brake line connection. Remove the banjo bolt fitting that connects the brake line to the master cylinder. Discard the sealing washers.
Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces.
3. Remove the Torx screws from the master cylinder clamp.
4. Hold master cylinder upright and lift the master cylinder from the handlebars. Cover brake line orifice to avoid spilling fluid.
Disassembly
Installation
1. Install master cylinder on handlebars. Torque bolt furthest from the reservoir first, followed by the bolt closest to the reservoir. Torque clamp bolts to 70 in. lbs. (8 Nm).
2. Place new sealing washers on each side of banjo line and torque banjo bolt to specification.
3. Fill reservoir with DOT 4 brake fluid (PN 2872189).
4. Follow brake bleeding procedures. Check all connections for leaks and repair if necessary.
Brake Switch Replacement
1. Set the parking brake lock and locate the brake switch behind the hand brake lever.
2. Using a small screwdriver or similar tool, push up on the mounting tabs through the holes on the bottom side while rotating the switch to disengage the tabs from the holes.
3. Install the new switch. The tabs should snap in place.
FOOT BRAKE MASTER CYLINDER
Foot Master Cylinder Removal / Installation
1. Remove the RH mud guard and footwell (see Chapter 9).
2. Remove the front and rear brake line from the master cylinder. Use a suitable container to catch the brake fluid. Dispose of brake fluid properly.
3. Remove the (2) through-bolts retaining the master cylinder to the mount bracket. Replace components as needed.
4. Reverse this procedure when reinstalling and torque mounting fasteners to specification.
5. Reinstall the brake line and torque the banjo bolt (with new sealing washers installed) to specification.
6. Bleed the master cylinder following the procedure outlined in the “Brake Bleeding” section of this chapter.
Brake Pedal Removal / Installation
1. Remove the RH mud guard and footwell (see Chapter 9).
2. Remove the through-bolt retaining the brake pedal to the mount bracket.
3. Remove the bolt, bushings, spacer, spring and brake lever.
4. Inspect and replace components as needed.
5. Reverse this procedure when reinstalling and torque mounting fastener to specification.
BRAKE PADS
Pad Removal
1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the caliper brake pads are being serviced.
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
3. Remove the wheel nuts and wheel.
4. Remove the (2) brake caliper mounting bolts and caliper.
5. Push mounting bracket inward and slip the outer brake pad past the edge of the pin. Remove the inner brake pad.
Pad Inspection
1. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
Pad Installation
1. Lubricate mounting bracket pins and external slide pin O-ring with a light film of silicone grease.
2. Compress mounting bracket. Install pads with friction material facing each other.
If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean brake pads.
3. Install the caliper and torque new mounting bolts to specification.
New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
4. Slowly pump the brake lever/pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
5. Verify fluid level in reservoir is at specified level inside reservoir and install reservoir cap.
6. Install the wheel(s) and wheel nuts. Torque wheel nuts to specification.
Brake Burnishing Procedure
CALIPER SERVICE
Caliper Removal
1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the caliper is being serviced.
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
3. Remove the wheel nuts and wheel.
4. Place a suitable container under the caliper to catch brake fluid draining from brake line. Using a wrench, loosen and remove brake line from the caliper.
5. Remove (2) caliper mounting bolts and remove the caliper assembly from the bearing carrier.
Caliper Disassembly
1. Push mount bracket inward and slip outer brake pad past the edge of the pin. Remove the inner brake pad.
2. Remove mount bracket, pin assembly and dust boot.
3. Using a hammer and a small punch, remove the piston from the caliper body, then remove the square O-rings (see “BRAKE CALIPER - Exploded View”).
4. Clean the caliper body, piston, and mounting bracket with brake cleaner or denatured alcohol.
Caliper Inspection
1. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.
2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit.
3. Inspect the brake pad and disc as outlined in this chapter (see “Pad Inspection” and “Brake Disc Inspection”).
Caliper Assembly
1. Install new O-rings (A) in the caliper body (B). Be sure grooves are clean or brakes may drag upon assembly.
2. Coat piston with DOT 4 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of the bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with silicone grease, and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the dust seals are fully seated.
5. Install the brake pads.
6. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
Caliper Installation
1. Install caliper assembly over the brake disc and onto the bearing carrier. Torque mounting bolts to specification.
New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
2. Install brake line and torque the banjo bolt fitting to specification.
3. Perform brake bleeding procedure as outlined earlier in this chapter.
4. Install the wheel and (4) wheel nuts. Torque wheel nuts to specification.
BRAKE DISC SERVICE
Disc Inspection
1. Visually inspect brake disc for scoring, scratches, or gouges. Replace disc if deep gouges are evident.
2. Measure the disc thickness at 8 different points around the pad contact surface using a 0–1” micrometer. Replace disc if worn beyond service limit.
3. Mount a dial indicator as shown and measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification.
Disc Removal / Replacement
1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the brake disc is being serviced.
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
3. Remove the wheel nuts and wheel.
4. Remove the cotter pin, castle nut and cone washers.
5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line.
6. Remove the wheel hub assembly from the bearing carrier.
7. Press out the wheel studs and remove the brake disc.
8. Clean the wheel hub mating surface.
9. Install the new disc and press new wheel studs into the hub until they are flush with the mating surface.
Always use new wheel studs if removed from the wheel hub assembly.
10. Install wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out.
11. Install the brake caliper and torque the new mounting bolts to specification.
New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
12. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
13. Install the wheel and (4) wheel nuts. Torque wheel nuts to specification.
14. Field test the ATV for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation.
TROUBLESHOOTING
Brake Squeal
Chapter_12_Electrical
ELECTRICAL
General Information
Special Tools
Electrical Service Notes
Component Locations
Instrument Cluster (EPS Models)
Overview
Rider Information Display
Speed Information
Information Display Area
Diagnostic Mode
Instrument Cluster Pinouts
Instrument Cluster (NON-EPS Models)
Overview
Rider Information Display
Information Display Area
Diagnostic Mode
Instrument Cluster Pinouts
Brake Switch
Function Test
Ignition Switch
Function Test
Function Test (INT’L)
4x4 / 2x4 Switch
Function Test
LH Switch Function Tests
Base/EPS Models
International Models
THROTTLE RELEASE SWITCH (TRS)
Throttle Release Switch (TRS)
Gear Selector Switch
Selector Switch Function Test
Resistor Module Function Test
Speed Sensor
Vehicle Speed Sensor
AWD Coils
Operation Overview
Diagnosing System Failures
AWD Function Tests
Fuse/Relay Box Layout
Fuses
Protected Circuits
Relays
Relay Overview
Chassis Relay
Fan Relay
EFI Relay
Low Beam Relay - Base Models
High Beam Relay - Base Models
Start Solenoid Relay
Power Steering Relay (EPS Models)
Low Beam Relay - International Models
High Beam Relay - International Models
Lights
Headlamp Adjustment - Base Models
Headlamp Adjustment - EPS/INTL. Models
Headlamp Replacement - Base Models
Headlamp Replacement - EPS Models
Headlamp Installation - EPS Models
Headlamp / DRL Replacement - International Models
Tail / Brake Lamp Replacement
Charging System
Charging System Diagram
Voltage Rectifier / Regulator (600 Watt)
Current Draw - Key Off
Battery Charge Test
Stator / Alternator Tests
Stator / Alternator Removal
Stator / Alternator Installation
BATTERY SERVICE
Battery Specifications
General Battery Information
Battery Removal / Installation
Battery Off Season Storage
Battery Testing
OCV - Open Circuit Voltage Test
Load Test
Battery Conductance Analyzer
Extreme Use 30 AH Battery
Charging Procedure
Starter Motor
Starter/Starter Lockout System Diagram
Troubleshooting
Voltage Drop Testing
Starter Motor Removal / Replacement
Instrument Cluster Troubleshooting
Instrument Cluster - Key OFF / No Power
Instrument Cluster - Key ON / No Power
Instrument Cluster - No High Beam Indicator
Instrument Cluster - No / Incorrect Fuel Level
Electronic Power Steering (EPS)
EPS Operation
Proper EPS System Diagnosing
EPS Troubleshooting
Controller Area Network (CAN)
Overview
CAN Troubleshooting
9924122_Wiring_Diagrams
2013 Scrambler 850_1.pdf
2013 Scrambler 850_2
2013 Scrambler 850 EPS.pdf
2013 Scrambler 850 EPS_1.pdf
2013 Scrambler 850 EPS_2
2013 Scrambler 850 Intl.pdf
2013 Scrambler 850 Intl_1.pdf
2013 Scrambler 850 Intl_2
2013 Scrambler 850 Intl.pdf
2013 Scrambler 850 Intl_1.pdf
2013 Scrambler 850 Intl_2
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