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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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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

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