2009 POLARIS SPORTSMAN XP 850 EFI/HD/EPS Series ATV Service & Repair Manual - !

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2009 SPORTSMAN XP 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2009 SPORTSMAN XP 850 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2009 SPORTSMAN XP 850 / XP 850 EPS. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number EH085OLE............................................................. Twin Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start Vehicle Identification Number (VIN) Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). The engine serial number can be found on top of the engine located on the valve cover (see Figure 1-2). } Machine Model Number Identification } } Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option A 0 9 Z N 8 5 A L } 4 X A Z N 8 5 A * 9 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier } Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions VIN Figure 1-1 Engine Serial Number Figure 1-2

1.3 GENERAL INFORMATION 1 VEHICLE INFORMATION Publication Numbers NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. Special Tools Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN 2009 SPORTSMAN XP 850 A09ZN85AL, AQ, AS, AT, AX, FL 9921973 9922173 (INT’L) 9921857 9922081 (INT’L) 2009 SPORTSMAN XP 850 EPS A09ZX85AG, AL, AQ, AR, AS, AX, FS 9921973 9922173 (INT’L) 9921977 9922085 (INT’L) Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

1.4 GENERAL INFORMATION SPECIFICATIONS 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 * Data based on EU Directive 76/432/EEC Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 784 lbs. / 356 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Unbraked Trailer Towing Capacity (EU)* 1913.6 lbs. / 868 kg Hitch Tongue Weight 150 lbs. / 68 kg Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 796 lbs. / 361 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Unbraked Trailer Towing Capacity (EU)* 1913.6 lbs. / 868 kg Hitch Tongue Weight 150 lbs. / 68 kg

1.5 GENERAL INFORMATION 1 2009 SPORTSMAN XP 850 / XP 850 EPS XP MODELS: A09ZN85AL,AQ,AS,AT,AX,FL XP EPS MODELS: A09ZX85AG,AL,AQ,AR,AS,AX,FS ENGINE MODEL: EH085OLE CLUTCH CHART Engine Platform Domestic Twin Cylinder, 4-Cycle Engine Model Number EH085OLE011 Engine Displacement 850 cc Number of Cylinders 2 Bore & Stroke (mm) 87 x 71.5 mm Compression Ratio 11.0:1 Compression Pressure 210 - 250 psi Engine Idle Speed 1200 ± 50 RPM Cooling System / Cap. Liquid Cooled / 2 qt. (1.9 l) Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump Engine Oil Requirement PS-4 Plus / 2 qt. (1.9 l) Exhaust System Stainless Steel Dual Header Pipe w/ Dual Outlet Silencer Fuel System Fuel System Type Bosch Multi-Port Sequential Electronic Fuel Injection Throttle Body / Size Mikuni Dual Bore / 40 mm Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43 psi Fuel Capacity XP: 5.25 gal. (20 l) XP EPS: 4.5 gal. (17 l) Fuel Requirements 87 Octane (minimum) Electrical Alternator Output 475 W @ 1200 RPM / Peak 575 W Voltage Regulator 3-Phase / 32 Amp Head Lights Pod: 12V / 50 Watts Bumper: 12V / 50 Watts x 2 Brake Light 12V / 27 Watts Tail Light 12V / 7 Watts Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° ± 5° BTDC @ 1200 RPM Spark plug / Gap REA8MCL / .035 in. (.90 mm) Battery / Model / AH / CCA Deka / ETX30L / 30 AH / 365 Instrumentation Multifunction Instrument Cluster DC Outlet Standard Relays (Located in Relay/Fuse Box) Chassis / Start Solenoid / Fan / EFI / Bumper Lights Circuit Breaker Fan Motor: 20A Fuses (Located in Relay/Fuse Box) Lights: 20A / Drive: 20A / Accessory: 20A / EFI: 20A / Unswitched: 10A / EPS: 30A Drivetrain Transmission Type Automatic PVT In-Line H-L-N-R-P Transmission Fluid Type / Fluid Capacity Synthetic Sportsman XP Transmission Fluid / 32 oz. (946 ml) Front Gearcase Fluid Type / Fluid Capacity Premium LT Demand Drive Fluid / 9.3 oz. (275 ml) Front Gearcase ADC Reservoir Fluid Type Premium ADC Front Drive Fluid Rear Gearcase Fluid Type / Fluid Capacity ATV Angle Drive Fluid / 7.1 oz. (210 ml) Clutch Type PVT w/EBS Belt 3211123 Steering / Suspension Toe Out 0-1/16 in. (0-.159 mm) Front Suspension Dual A-arm Front Travel 9.2 in. / 23.4 cm Rear Suspension Dual A-arm w/Rolled IRS Rear Travel 10.2 in. / 25.9 cm Shock Preload Adjustment Front / Rear Cam Adjustable Wheels / Brakes Front Wheel Size / Bolt Pattern Tire Model / Size 14 x 6 / 4-156 Carlisle Terrathon / 26 x 8 - 14 Rear Wheel Size / Bolt Pattern Tire Model / Size 14 x 8 / 4-156 Carlisle Terrathon / 26 x 10 - 14 Tire Air Pressure Front: 7 psi (48 kPa) Rear: 5 psi (34.5 kPa) Brakes - Front & Rear Single Control Hydraulic 4-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1800 (0-6000) 24-63 5632215 Red / Wht 7043349 Red / Wht 3235621 1800-3700 (6000 - 12000) 24-60 5632216 Red / Wht 7043349 Red / Wht 3235621

1.6 GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F - 32) = °C

1.7 GENERAL INFORMATION 1 Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

1.8 GENERAL INFORMATION SAE Tap / Drill Sizes Metric Tap / Drill Sizes Decimal Equivalents

1.9 GENERAL INFORMATION 1 Glossary of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. DCV: Direct current voltage CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm²: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in²: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

NOTES GENERAL INFORMATION 1.10

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2009 POLARIS SPORTSMAN XP 850 EFI/HD/EPS Series ATV Service & Repair Manual - !

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