Polaris Sportsman 850 (2009) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 850 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 850 (2009).

 
CONTENTS:

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
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
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)
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
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 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
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
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
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
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
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
GENERAL INFORMATION
- Special Tools
- Electrical Service Notes
- Component Locations
INSTRUMENT CLUSTER
- Overview
- Rider Information Display
- Speed Information
- Information Display Area
- Diagnostic Mode
- Instrument Cluster Pinouts
IGNITION SWITCH
- Function Test
ADC / 4X4 / 2X4 SWITCH
- Function Test
OFF / RUN LH SWITCH
- Function Test
REVERSE OVERRIDE / MODE BUTTON
- Function Test
HEAD LAMP SWITCH
- Function Test
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
- Electronic Throttle Control (Etc) Switch
GEAR SELECTOR SWITCH
- Selector Switch Function Test
- Resistor Module Function Test
SPEED SENSOR
- Vehicle Speed Sensor
BRAKE SWITCH
- Function Test
AWD / ADC COILS
- Operation Overview
- Diagnosing System Failures
RELAYS
- Relay Overview
- Chassis Relay
- Fan Relay
- Efi Relay
- Bumper Lights Relay
- Start Solenoid Relay
- Power Steering Relay
FUSES
- Protected Circuits
FUSE BOX LAYOUT
LIGHTS
- Headlight Adjustment
- Bumper Lamp Adjustment
- Headlight Replacement
- Bumper Lamp Replacement
- Tail / Brake Bulb Replacement
CHARGING SYSTEM
- Charging System Diagram
- Charging System Testing
- 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
- 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
- Instrument Cluster Circuit
ELECTRONIC POWER STEERING (EPS)
- Electronic Power Steering (Eps) Circuits
- Eps Operation
- Eps 8-Way Wire Harness Connector
- Eps Troubleshooting
ELECTRICAL BREAKOUT DIAGRAMS
- Battery Charging Circuits
- Constant Power Circuits
- Key-On Power Circuits
- Chassis Power Circuits
- Head Lamp Circuits
- Brake Lamp Circuits
- Engine Start Command Circuits
- Ecm Wake-Up Command Circuits
- Awd / Adc Circuits
- Awd / Adc Function Tests
- Radiator Fan Circuit
- Gear Selector Switch Circuit
- Ground Speed Sensor Circuit
- Reverse Override Circuit
CONTROLLER AREA NETWORK (CAN)
- Overview
- Can Troubleshooting