2010 Polaris Sportsman 850 Service Manual
This manual covers all models and sub models of the Sportsman 850 including 850 XP, X-2, Touring and all EPS models.
This is the actual 2010 Polaris manual, not a reworked 2009 manual.
Manual chapters:
- GENERAL INFORMATION
- MAINTENANCE
- ELECTRONIC FUEL INJECTION
- COOLING SYSTEM
- ENGINE
- TRANSMISSION
- CLUTCHING (PVT)
- FINAL DRIVE
- BODY / FRAME
- STEERING / SUSPENSION
- BRAKES
- ELECTRICAL
- Wiring Diagrams
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Full list of manual chapters:
Cover
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: 2010 SPORTSMAN XP 850
MODEL: 2010 SPORTSMAN XP 850 EPS / INT'L
2010 SPORTSMAN XP 850 / XP 850 EPS
MODEL: 2010 SPORTSMAN TOURING 850 EPS
2010 SPORTSMAN TOURING 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
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
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 - 2201519-A
Digital Wrench Diagnostic Software PU-47063-A
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 / Regulator
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
DIGITAL WRENCH OPERATION
Digital Wrench Diagnostic Software Overview
Special Tools (also refer to page 3.2)
Diagnostic Software Version
ECU Replacement
Guided Diagnostic Available
Digital Wrench Communication Errors
Digital Wrench - Diagnostic Connector
Digital Wrench Version and Update ID
Digital Wrench Serial Number Location
Digital Wrench Updates
Digital Wrench Feature Map
Engine Controller Reprogramming (Reflash)
FUEL SYSTEM TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Poor Idle
EFI SYSTEM BREAK-OUT DIAGRAMS
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 and 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 - EH085OLE013
ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
Torque Specification and Torque Sequence - Main Engine Components
Valve Cover / Breather Valve
Camshaft Carrier / Camshaft / Rocker Arm
Cylinder Head / Valve / IAFM
Valve and 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)
Engine Removal
Engine Installation Notes
ENGINE DISASSEMBLY / 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
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
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
PVT Disassembly (XP Models)
PVT Disassembly (TOURING Models)
PVT Assembly (XP Models)
PVT Assembly (TOURING Models)
DRIVE BELT
Belt Removal (XP Models)
Belt Removal (TOURING Models)
Belt Inspection
Belt Installation (XP Models)
Belt Installation (TOURING Models)
PVT Break-In (Drive Belt / Clutches)
DRIVE CLUTCH SERVICE
Spring Specifications
Shift Weights
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 (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)
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 (XP Models)
Gearcase Removal (TOURING Models)
Gearcase Disassembly and Inspection
Gearcase Bearing and Seal Replacement
Gearcase Assembly
Gearcase Exploded View
Gearcase Installation (XP Models)
Gearcase Installation (TOURING Models)
BODY / FRAME
TORQUE SPECIFICATIONS
DECAL REPLACEMENT
SPECIAL TOOLS
Plastic Push Rivet Removal
Multi-Function Pliers
HEADLIGHT POD
Disassembly / Removal
Assembly / Installation
SEAT AND SIDE PANELS
Removal / Installation (XP)
Removal / Installation (TOURING)
FRONT RACK / STORAGE BOX
Removal / Installation
FRONT BUMPER
Removal / Installation
MUD GUARDS
Removal / Installation
FOOTWELLS
Removal / Installation
FRONT CAB
Removal
Installation
REAR RACK
Removal / Installation (XP Models)
Removal / Installation (TOURING Models)
REAR CAB
Removal / Installation (XP Models)
Removal / Installation (TOURING Models)
REAR BUMPER COVERS (XP)
Removal / Installation
PASSENGER SEAT (TOURING)
Seat Removal / Installation
Seat Suspension Removal or Adjustment
Seat Back Exploded View
MAIN FRAME (XP)
Frame Support Exploded View
MAIN FRAME (TOURING)
Frame Support Exploded View
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 (TOURING Models)
EPS Unit Removal (XP Models)
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
Removal
Installation
REAR A-ARMS (XP MODELS)
Exploded View
Removal
Installation
REAR A-ARMS (TOURING MODELS)
Exploded View
Removal
Installation
REAR STABILIZER BAR (XP MODELS)
Exploded View
Linkage Removal / Installation
Stabilizer Bar Removal / Installation
REAR STABILIZER BAR (TOURING MODELS)
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
XP 850 / XP 850 EPS / 850 TOURING Models
Brake Caliper Exploded View
Hand Master Cylinder Exploded View
INTERNATIONAL BRAKE SYSTEM OPERATION
Hand Master Cylinder Hydraulic Operation
Foot Master Cylinder Hydraulic Operation
850 INT'L Models
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 Assembly
Caliper Installation
BRAKE DISC SERVICE
Disc Inspection
Disc Removal / Replacement
TROUBLESHOOTING
Brake Squeal
ELECTRICAL
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
Brake Switch
Function Test
Ignition Switch
Function Test
Function Test (INT'L)
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
AWD / ADC Coils
Operation Overview
Diagnosing System Failures
AWD / ADC Function Tests
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
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
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
EPS 8-Way Wire Harness Connector
Proper EPS System Diagnosing
EPS Troubleshooting
EPS Circuits (XP EPS / INT'L Models)
EPS Circuits (TOURING Models)
SPORTSMAN XP 850 / TOURING: Electrical Breakout Diagrams
Battery Charging Circuits (TOURING Models)
Constant Power Circuits (XP Models)
Constant Power Circuits (TOURING Models)
Key-On Power Circuits (XP Models)
Key-On Power Circuits (TOURING Models)
ECM Wake-Up Command / Fuel Level Circuits
Light Circuits
Chassis Power Circuits
Engine Start Command / Gear Selector Switch Circuits
Radiator Fan Circuit
AWD / ADC / Ground Speed Circuits
SPORTSMAN XP 850 INTERNATIONAL: Electrical Breakout Diagrams
Fuel Pump / Fuel Level Sensor Circuits
Constant Power Circuits
Key-On Power Circuits
Engine Start Command Circuits
ECM Wake-Up Command Circuits
Light Circuits
Chassis Power Circuits
Brake Lamp Circuits
Hazard Light Circuits
Radiator Fan Circuit
Gear Selector Switch Circuit
Ground Speed Sensor Circuit
AWD / ADC Circuits
Controller Area Network (CAN)
Overview
CAN Troubleshooting
Wiring Diagrams