Polaris Sportsman ATV Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Polaris Sportsman ATV, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Polaris Sportsman ATV workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Polaris '01 Sportsman 400_500_H.O._DUSE Service Repair Manual.pdf
Polaris '02-'03 Sportsman 700, 2002 Sportsman 600 Service Repair Manual.pdf
Polaris '02 Sportsman 400-500 MANUAL DE SERVICIO.pdf
Polaris '04 Sportsman 600 Parts Manual.pdf
Polaris '05 Sportsman 400_500 Service Repair Manual.pdf
Polaris '05 Sportsman 400 Parts Manual.pdf
Polaris '05 Sportsman 500 Parts Manual.pdf
Polaris '05 Sportsman 800 Parts Manual.pdf
Polaris '07 Sportsman 450-500 EFI Service Repair Manual.pdf
Polaris '07 Sportsman 700_800_800 X2 EFI Service Repair Manual.pdf
Polaris '07 Sportsman 700 EFI-800 EFI Owner's Manual.pdf
Polaris '08 Sportsman 500 EFI, X2, Touring, 500 H.O. Service Repair Manual.pdf
Polaris '08 Sportsman 500 Service Repair Manual.pdf
Polaris '09 Sportman 300, Sportman 400 H.O. Service Repair Manual.pdf
Polaris '09 Sportman XP 850, XP850 EPS Service Repair Manual.pdf
Polaris '09 Sportsman 6x6 800 EFI Big Boss Service Repair Manual.pdf
Polaris '09 Sportsman 500 Service Repair Manual.pdf
Polaris '09 Sportsman 850_EFI_HD_EPS Service Repair Manual.pdf
Polaris '09 Sportsman XP 550_EPS Service Repair Manual.pdf
Polaris '12-'13 Sportsman 850 Service Repair Manual.pdf
Polaris '96-'03 Sportsman400-500, Xplorer500 Service Repair Manual.pdf

PRODUCT DETAILS:
Total Pages: 6,183 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
Polaris  '01 Sportsman 400_500_H.O._DUSE Service Repair Manual......1
  CHAPTER 1 - GENERAL INFORMATION......2
  CHAPTER 2 - MAINTENANCE......28
  CHAPTER 3 - ENGINE......69
  CHAPTER 4 - FUEL SYSTEM/CARBURETION......150
  CHAPTER 5 - BODY AND STEERING......171
  CHAPTER 6 - PVT SYSTEM......184
  CHAPTER 7 - FINAL DRIVE......232
  CHAPTER 8 - TRANSMISSION SERVICE......269
  CHAPTER 9 - BRAKES......303
  CHAPTER 10 - ELECTRICAL......334
  INDEX......373
  WIRING DIAGRAM 2001 SPORTSMAN 400......379
  WIRING DIAGRAM 2001 SPORTSMAN 500 EARLY......380
  WIRING DIAGRAM 2001 SPORTSMAN 500 LATE......381
Polaris  '02 Sportsman 400-500 MANUAL DE SERVICIO......382
Polaris  '02- '03 Sportsman 700, 2002 Sportsman 600 Service Repair Manual......737
  Index......740
  Chapter 1 General Information......741
  Chapter 2 Maintenance......759
  Chapter 3 Engine......789
  Chapter 4 Fuel System/Carburetion......847
  Chapter 5 Body/Steering/Suspension......859
  Chapter 6 PVT System......871
  Chapter 7 Final Drive......897
  Chapter 8 Transmission Service......925
  Chapter 9 Brakes......941
  Chapter 10 Electrical......961
Polaris  '04 Sportsman 600 Parts Manual......999
Polaris  '05 Sportsman 400 Parts Manual......1059
Polaris  '05 Sportsman 400_500 Service Repair Manual......1119
  INTRODUCTION......1120
  TABLE OF CONTENTS......1122
  CHAPTER 1-GENERAL......1123
    MODEL IDENTIFICATION......1124
    SERIAL NUMBER LOCATION......1124
    PUBLICATION NUMBERS......1125
    PAINT CODES......1125
    REPLACEMENT KEYS......1125
    GENERAL SPECIFACTIONS -SPORTSMAN 400/500......1126
    SPECIAL TOOLS......1129
    STANDARD TORQUE SPECIFICATIONS......1135
    DECIMAL EQUIVALENT CHART......1136
    COVERSION TABLE......1137
    GLOSSARY OF TERMS......1138
  CHAPTER 2-MAINTENANCE......1139
    PERIODIC MAINTENANCE CHART......1140
    LUBRICANT AND MAINTENANCE PRODUCT NUMBERS......1144
    ATV COMPONENT LOCATIONS......1146
    LUBRICATION CHARTS......1147
    FRONT GEARCASE LUBRICATION......1148
    TRANSMISSION LUBRICATION......1149
    LUBRICATIONS POINTS......1150
    TRANSMISSION LINKAGE AJUSTMENTS......1151
    CARBURETOR/THROTTLE ADJUSTMENTS......1151
    FUEL SYSTEM......1154
    COMPRESSION TEST......1156
    BATTERY MAINTENANCE......1157
    COOLANT SYSTEM MAINTENANCE......1157
    AIR FILTER SERVICE......1159
    AIR BOX SEDIMENT TUBE SERVICE......1160
    BREATHER FILTER......1161
    RECOIL HOUSING......1161
    OIL CHANGE/FILTER......1162
    VALVE CLEARANCE......1164
    STEERING AND TOE ALIGNMENT......1165
    EXHAUST SYSTEM MAINTENANCE......1169
    BRAKE SYSTEM SERVICE......1169
    SUSPENSION SERVICE......1171
    CONTROLS......1171
    WHEEL REMOVAL/INSTALATION......1172
    TIRE INSPECTION......1172
    COMPARTMENT STORAGE......1173
    WARN™ WINCH OPERATION......1174
    CLEANING AND STORAGE OF ATV......1176
  CHAPTER 3-ENGINE......1179
    TORUE SPECIFICATIONS......1180
    SPECIAL TOOLS......1180
    EH50PL SERVICE DATA......1181
    TORQUE PATTERNS......1183
    PISTON IDENTIFICATION......1183
     COOLING SYSTEM PRESSURE TEST......1184
    COOLING SYSTEM SPECIFICATIONS......1185
    ENGINE REMOVAL......1185
    ENGINE INSTALLATION NOTES......1186
    CYLINDER HONEING......1186
    CRANKSHAFT RUNOUT INSPECTION......1187
    EH50PL ENGINE LUBRICATION......1188
    EH50PL OIL PUMP PRIMING PROCEDURE......1188
    EH50PL LUBRICATION/OIL FLOW......1189
    EH50PL ENGINE EXPLODED VIEW......1191
    EH50PL ENGINE TOP END DISASSEMBLY......1192
    EH50PL VALVE SEAT SERVICE......1201
    EH50PL CYLINDER HEAD ASSEMBLY......1204
    EH50PL ENGINE BOTTOM END DISASSEMBLY......1209
    EH50PL CRANKCASE & BEARING ASSEMBLY......1215
    EH50PL CRANKSHAFT END PLAY INSPECTION......1216
    EH50PL COUNTER BALANCER SHAFT END PLAY INSPECTION......1218
    EH50PL OIL PUMP SHAFT END PLAY INSPECTION......1218
    EH50PL ENGINE ASSEMBLY/INSPECTION......1219
    SEALED RECOIL DISASSEMBLY/INSPECTION......1229
    SEALED RECOIL ASSEMBLY......1230
    SPARK PLUG FOULING CHECKLIST......1231
    TROUBLESHOOTING......1231
  CHAPTER 4-FUEL/CARBURETION ......1233
    EXPLODED VIEW, MIKUNI BST 34/40 CARBURETOR......1234
    FUEL TANK ASM. EXPLODED VEIW......1236
    FUEL FLOW DIAGRAM......1236
    FUEL COMPONENT OVERVIEW......1237
    FUEL SENDER REMOVAL/INSTALL......1237
    SPECIAL TOOL & JETTING GUIDELINES......1238
    CARBURETOR JETTING......1239
    MAIN JET/PILOT JET PART NUMBERS......1239
    CV CARBURETOR SYSTEM FUNCTION (4 CYCLE)......1240
    CV CARBURETOR VENT SYSTEM (4 CYCLE)......1238
    CV CARBURETOR OPERATION......1240
    PILOT SCREW INFORMATION......1242
    DISASSEMBLY NOTES, CV CARBURETOR......1243
    CLEANING, CV CARBURETOR......1244
    INSPECTION, CV CARBURETOR......1244
    ASSEMBLY, CV CARBURETOR......1245
    FLOAT ADJUSTMENT, CV CARBURETOR......1246
    NEEDLE & SEAT LEAKAGE TEST......1247
    FUEL LEVEL......1247
    FUEL PUMP SERVICE......1247
    TROUBLESHOOTING......1249
  CHAPTER 5-BODY AND STEERING......1251
    TORQUE SPECIFICATIONS AND SPECIAL TOOLS......1252
    PLASTIC INSERT REMOVAL/INSTALL......1252
    SIDE PANEL REMOVAL......1253
    FRONT COVER REMOVAL......1254
    FOOT WELL REMOVAL/INSTALL......1254
    FRONT STORAGE REMOVAL/INSTALL......1255
    REAR RACK REMOVE/INSTALL......1257
    FRONT CAB / FENDER REMOVE/INSTALL......1258
    REAR CAB / FENDER REMOVE/INSTALL......1259
    RADIATOR SCREEN REMOVAL......1260
    BODY ASSEMBLY, EXPLODED VIEW......1261
    HEADLIGHT POD, EXPLODED VIEW......1263
    HANDLEBAR BLOCK INSTALLATION......1264
    STEERING ASSEMBLY, EXPLODED VIEW......1265
    A-ARM REPLACEMENT......1266
    REAR SUSPENSION ASSEMBLY......1267
    STRUT ASSEMBLY EXPLODED VIEW......1268
    FRONT STRUT CARTRIDGE REPLACEMENT......1269
    FRONT STRUT BALL JOINT REPLACEMENT......1269
    STEERING POST ASSEMBLY......1270
    DECAL REPLACEMENT......1270
  CHAPTER 6-CLUTCHING......1271
    SPECIAL TOOLS, SUPPLIES & TORQUES......1272
    PVT SYSTEM OPERATION......1272
    PVT MAINTENANCE/INSPECTION......1273
    PVT DISASSEMBLY......1275
    PVT ASSEMBLY......1276
    PVT SEALING AND DUCTING COMPONENTS......1277
    DRIVE CLUTCH EXPLODED VIEW......1277
    DRIVE CLUTCH SPRING SPECIFICATIONS......1278
    SHIFT WEIGHTS......1279
    DRIVE CLUTCH INSPECTION......1280
    DRIVE CLUTCH DISASSEMBLY......1280
    DRIVE CLUTCH ASSEMBLY......1282
    DRIVE BELT TENSION......1283
    DRIVE BELT REMOVAL/INSPECTION......1284
    DRIVE BELT INSTALLATION......1285
    CLUTCH ALIGNMENT/OFFSET......1286
    DRIVE CLUTCH BUSHING SERVICE......1287
    DRIVEN CLUTCH DISASSEMBLY/INSPECTION......1289
    DRIVEN CLUTCH ASSEMBLY......1291
    DRIVEN CLUTCH BUSHING SERVICE......1291
    EBS EXPLODED VIEW......1294
    EBS DRIVE CLUTCH DISASSEMBLY/INSPECTION......1294
    EBS DRIVE CLUTCH BUSHING SERVICE......1295
    EBS DRIVEN CLUTCH DISASS./INSP......1297
    EBS DRIVEN CLUTCH BUSHING SERV......1302
    TROUBLESHOOTING......1304
  CHAPTER 7-FINAL DRIVE......1307
    FINAL DRIVE TORQUE SPECIFICATIONS......1308
    AWD FRONT AXLE REMOVE/INSTALL......1308
    AWD FRONT CV JOINT BOOT REPLACE......1310
    AWD FRONT DRIVE AXLE EXPLODED VIEW......1314
    FRONT HUB DISASS./ASSEMBLE......1311
    AWD FRONT PROP SHAFT REMOVAL......1312
    U-JOINT DISASSEMBLE/ASSEMBLE......1312
    DRIVE AXLE / PROPSHAFT EXPLODED VIEW......1314
    AWD FRONT GEARCASE OPERATION......1315
    AWD FRONT GEARCASE SERVICE......1315
    REAR HUB REMOVE/INSTALL......1325
    REAR HUB DISASSEMBLY/ASSEMBLY......1327
    REAR DRIVE SHAFT REMOVAL......1328
    DRIVESHAFT / CV JOINT TIPS......1329
    REAR DRIVESHAFT INSTALLATION......1329
    REAR DRIVESHAFT SERVICE......1330
  CHAPTER 8-TRANSMISSION......1333
    TRANSMISSION MOUNTING......1334
    TORQUE SPECIFICATIONS......1335
    SPECIAL TOOLS......1335
    TRANSMISSION REMOVAL......1335
    TRANSMISSION INSTALLATION......1337
    TRANSMISSION DISASSEMBLY......1339
    TRANSMISSION ASSEMBLY......1346
    TROUBLESHOOTING......1352
    TRANSMISSION EXPLODED VIEW......1353
  CHAPTER 9-BRAKES......1355
    SPECIAL TOOLS/SPECIFICATIONS/TORQUES......1356
    BRAKE SYSTEM COMPONENTS......1357
    REAR CALIPER EXPLODED VIEW......1358
    FRONT CALIPER EXPLODED VIEW......1358
    REAR AUXILIARY MASTER CYLINDER EXPLODED VIEW......1359
    BRAKE SYSTEM SERVICE NOTES......1359
    BRAKE NOISE TROUBLESHOOTING......1359
    HYDRAULIC BRAKE SYSTEM OVERVIEW......1360
    HYDRAULIC CALIPER BLEEDING......1361
    BRAKE BLEEDING / FLUID CHANGE......1361
    MASTER CYLINDER REMOVAL......1363
    MASTER CYLINDER INSTALLATION......1363
    FRONT PAD REMOVAL......1364
    FRONT PAD ASSEMBLY......1366
    BRAKE BURNISHING......1367
    FRONT DISC INSPECTION......1367
    FRONT DISC REMOVAL/REPLACEMENT......1367
    FRONT CALIPER REMOVAL......1368
    FRONT CALIPER DISASSEMBLY......1368
    FRONT CALIPER INSPECTION......1369
    FRONT CALIPER REASSEMBLY......1369
    FRONT CALIPER INSTALLATION......1370
    REAR PAD REMOVAL......1371
    REAR PAD INSTALLATION......1372
    REAR CALIPER REMOVAL/INSPECTION......1373
    REAR CALIPER REASSEMBLY......1374
    REAR DISC INSPECTION......1375
    REAR (AUXILIARY) BRAKE REMOVE/INSTALL......1376
    TROUBLESHOOTING......1377
  CHAPTER 10-ELECTRICAL......1379
    SPECIAL TOOLS/SERVICE NOTES......1380
    GEAR POSITION SWITCH TEST......1380
    ECM OPERATION......1381
    ELECTRICAL COMPONENTS......1382
    INSTRUMENT CLUSTER OPERATION......1383
    SPEEDOMETER REMOVAL/INSTALLATION......1387
    SPEEDOMETER TROUBLESHOOTING......1388
    COOLANT SENSOR TESTS......1393
    FAN MOTOR TESTS......1393
    ELECTRONIC THROTTLE CIRCUIT SYSTEM OPERATION......1394
    IGNITION SYSTEM INFORMATION......1395
    IGNITION SYSTEM TESTING FLOW CHART......1397
    IGNITION SYSTEM TROUBLESHOOTING......1398
    CDI OUTPUT TESTS......1398
    CHARGING SYSTEM TESTING......1398
    TIMING CHECK PROCEDURE......1400
    BATTERY ACTIVATION/SERVICE......1402
    HEAD LIGHT/BRAKE LIGHT LAMP SERVICE......1409
    FUEL SENDER TEST......1413
    ACCESSORY WIRE HOOKUP......1414
    WARN™ WINCH WIRING SCHEMATIC......1415
    STARTER SYSTEM TROUBLESHOOTING......1416
    STARTER MOTOR SERVICE......1417
    STARTER DRIVE......1419
    STARTER ASSEMBLY EXPLODED VIEW......1419
    STARTER SYSTEM TESTING FLOW CHART......1420
  WIRING DIAGRAMS......1420
  INDEX......1423
    A-C......1423
    C-E......1424
    E-G......1425
    G-P......1426
    P-T......1427
    T-W......1428
Polaris  '05 Sportsman 500 Parts Manual......1431
Polaris  '05 Sportsman 800 Parts Manual......1491
Polaris  '07 Sportsman 450-500 EFI Service Repair Manual......1557
  9920560_Chapter_01......1557
    MODEL NUMBER INFORMATION 1.2 ......1557
      MODEL NUMBER INFORMATION......1558
        Model Number......1558
        Engine Designation Numbers......1558
        Vehicle Identification Number (VIN)......1558
        Transmission I.d. Location......1558
        Engine And Machine Serial Numbers......1558
        Publications......1559
        Paint Codes......1559
        Replacement Keys......1559
        Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison......1560
        Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison......1561
      2007 SPORTSMAN 450......1562
        Model Number: A07MH46AA, AZ ......1562
      2007 SPORTSMAN 500 EFI......1564
        Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC ......1564
      2007 SPORTSMAN X-2 500 EFI......1566
        Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA......1566
      MISC. NUMBERS/CHARTS......1568
        Standard Torque Specifications......1568
        SAE Tap Drill Sizes......1569
        Metric Tap Drill Sizes......1569
        Decimal Equivalents......1569
        Conversion Table......1570
        Glossary Of Terms......1571
  9920560_Chapter_02......1573
    MAINTENANCE 2.3 ......1573
      MAINTENANCE......1575
        Periodic Maintenance Chart......1575
        Maintenance Chart Key......1575
        Periodic Maintenance Chart......1576
      LUBRICATION / FLUIDS......1579
        SPORTSMAN Component Locations......1579
        SPORTSMAN X2 Component locations......1580
        Polaris Lubricants, Maintenance and Service Products......1581
        Polaris Lubricant Symbol Identification......1582
        Pre-ride / Daily Inspection......1582
        Lubrication Components......1583
        Front Gearcase Lubrication......1584
        Transmission Lubrication......1585
        ADC Differential Hydraulic Circuit Fluid Change......1586
      VEHICLE INSPECTION......1586
        Shift Link Rod Inspection......1586
        Throttle Inspection......1587
        Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment......1587
        Fuel System......1588
        Fuel Lines......1588
        Vent Lines......1588
        Fuel Filter......1589
        Compression Test......1589
        Engine Mounts......1589
        Spark Plug......1590
        Active Descent Control (ADC) Reservoir Level......1590
        Battery Maintenance......1590
        Liquid Cooling System Overview......1591
        Coolant Strength / Type......1591
        Cooling System Hoses......1591
        Radiator/Grill Screen......1591
        Cooling System Pressure Test......1592
        Coolant Level Inspection......1592
        Radiator Coolant Level Inspection......1592
        Air Filter/Pre-Filter Service......1592
        Air Box Sediment Tube......1593
        Breather Filter Inspection......1594
        Breather Hose......1594
        Recoil Housing......1594
        Engine Oil Level......1595
        Oil and Filter Change ......1595
        Oil Pump Priming Procedure......1597
        Valve Clearance......1597
        Intake Valve Clearance Adjustment......1598
        Exhaust Valve Clearance Adjustment......1598
        Steering......1598
        Tie Rod End/Steering Inspection ......1599
        Camber and Caster......1599
        Wheel Alignment......1599
        Toe Alignment Adjustment......1600
        Exhaust Pipe......1600
        Brake System Inspection......1601
        Brake Pad Inspection......1602
        Hose/Fitting Inspection......1602
        Auxiliary Brake Testing......1602
        Auxiliary Brake Adjustment (Hydraulic) ......1602
        Suspension Spring Preload Adjustment......1603
        Front Suspension......1603
        CV Shaft Boot Inspection......1603
        Controls......1603
        Wheels......1603
        Wheel, Hub, And Spindle Torque Table......1604
        Wheel Removal Front or Rear......1604
        Wheel Installation......1604
        Tire Pressure......1604
        Tire Inspection......1605
        Frame, Nuts, Bolts, Fasteners......1605
        Storage Compartments......1605
        Winch Operation (If Equipped)......1606
        ATV Cleaning & Storage......1608
        Maintenance Schedule......1610
  9920560_Chapter_03......1611
    Specifications 3.3 ......1611
      Specifications......1613
        Torque Specifications......1613
        Special Tools......1613
        Engine Fastener Torque Patterns......1613
        Engine Service Data......1614
        Engine Service Data......1615
      GENERAL ENGINE SERVICE......1616
        Piston Identification......1616
        Cooling System Specifications......1616
        Cooling System......1617
        Accessible Components......1618
        Engine Removal (TYPICAL)......1618
        Engine Installation Notes......1619
        Cylinder Hone Selection/ Honing Procedure......1619
        Honing To Oversize......1619
        Cleaning the Cylinder After Honing......1620
        Crankshaft Straightening......1620
        Engine Lubrication- EH 50PL......1621
        Oil Pressure Test - EH 50PL......1621
        Oil Pump Priming Procedure......1621
        Oil Flow - EH50PL......1621
        EH50PL Oil Flow Diagram......1622
        EH50PL Engine Exploded Views......1623
      ENGINE DISASSEMBLY......1624
        Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal......1624
        Cam Chain Tensioner Inspection......1624
        Rocker Arm/Shaft Inspection......1625
        Camshaft Removal......1626
        Automatic Compression Release Removal/ Inspection......1627
        Automatic Compression Release Installation......1628
        Camshaft Inspection......1628
        Cylinder Head Removal......1629
        Cylinder Head Exploded View, EH50PL......1630
        Cylinder Head Inspection......1631
        Cylinder Head Warp......1631
        Cylinder Head Disassembly......1631
        Valve Inspection......1632
        Combustion Chamber......1633
        Valve Seat Reconditioning......1633
        Cylinder Head Assembly......1636
        Valve Sealing Test......1636
        Valve Clearance Adjustment......1636
        Cylinder/Piston Removal and Inspection......1637
        Piston Removal......1638
        Cylinder Inspection......1638
        Piston-to-Cylinder Clearance......1639
        Piston/Rod Inspection......1639
        Piston Ring Installed Gap......1640
        Crankcase Disassembly......1640
        Starter Drive Removal/Inspection......1641
        Flywheel/Stator Removal/Inspection......1641
        Cam Chain/Tensioner Blade......1642
        One Way Valve Removal......1642
        Crankcase Separation......1643
        Oil Pump Removal/Inspection......1643
        Oil Pump Assembly......1644
        Counter Balancer Shaft Removal/Inspection......1644
        Crankshaft Removal/Inspection ......1645
        Crankcase Bearing Inspection ......1646
        Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)......1646
        Crankcase Inspection......1646
        Bearing Installation......1647
        End Play Inspection/Adjustment......1647
        Crankshaft End Play Adjustment......1647
        Counter Balancer Shaft End Play Adjustment......1648
        Oil Pump Shaft End Play Adjustment......1649
      ENGINE REASSEMBLY......1650
        Pump Shaft Oil Seal Installation......1650
        Crankshaft/Counter Balance/Oil Pump Installation......1650
        Crankcase Assembly......1651
        Water Pump Mechanical Seal Installation......1651
        Water Pump Mechanical Seal Removal - Engine Installed......1651
        One Way Valve Installation......1652
        Cam Chain Drive Sprocket Installation......1653
        Tensioner Blade Installation......1653
        Piston Ring Installation......1653
        Piston Installation......1654
        Cylinder Installation......1654
        Cylinder Head Installation......1655
        Cam Chain/Camshaft Installation......1655
        Camshaft Timing......1656
        CAMSHAFT TIMING......1658
        Cam Chain Tensioner Installation......1659
        Stator, Flywheel and Starter Drive Installation......1659
        Rocker Shaft/Rocker Arm Assembly Installation......1660
        Thermostat Installation......1660
        Oil Pipes......1660
      RECOIL......1661
        Recoil Disassembly/Inspection......1661
        Recoil Assembly......1662
      TROUBLESHOOTING......1663
        Spark Plug Fouling......1663
        Engine......1663
        Cooling System ......1664
  9920560_Chapter_04......1665
    Electronic Fuel Injection 4.3 - 4.30......1665
    Carburetor (sportsman 450) 4.31 - 4.47......1665
    SPECIAL TOOLS 4.5 ......1667
      SPECIAL TOOLS......1669
        Part Numbers / Descriptions......1669
      EFI SERVICE NOTES......1671
        General Service Information......1671
      EFI SYSTEM EXPLODED VIEW......1672
      EFI SYSTEM ......1673
        Component Locations/Identification......1673
      FUEL TANK......1674
        Exploded View......1674
      ELECTRONIC FUEL INJECTION......1674
        General Information......1674
        EFI Operation Overview......1674
        Initial Priming / Starting Procedure......1675
      FUEL LINES......1675
        Quick Connect Removal/Installation......1675
      ELECTRONIC CONTROL MODULE (ECM)......1676
        Operation Overview......1676
        ECM Replacement......1676
        ECM Service......1676
      FUEL PUMP ASSEMBLY......1677
        Operation / Testing......1677
        FUEL PUMP TEST......1677
        Fuel Pump / Tank Assembly Replacement......1678
      FUEL PRESSURE REGULATOR......1679
        General Information......1679
      FUEL FILTERS......1680
        General Information......1680
      FUEL INJECTOR......1680
        General Information......1680
      CRANKSHAFT POSITION SENSOR (CPS)......1681
        General Information......1681
      MANIFOLD AIR PRESSURE SENSOR (MAP)......1682
        Operation Overview......1682
        Map Sensor Test......1682
        Map Sensor Replacement......1682
      INTAKE AIR TEMPERATURE SENSOR (IAT)......1683
        Operation Overview......1683
        Intake Air Temperature Sensor Test......1683
        Intake Air Temperature Sensor Replacement......1683
      I DLE AIR CONTROL (IAC)......1683
        General Information......1683
      THROTTLE POSITION SENSOR (TPS)......1684
        Operation Overview......1684
        Throttle Position Sensor Test......1684
        Throttle Position Sensor Replacement......1685
        Throttle Position Sensor (Tps) Initialization......1685
      ENGINE TEMPERATURE SENSOR......1686
        General Information......1686
        Engine Temperature Sensor Test......1686
        Engine Temperature Sensor Replacement......1686
      FUEL SYSTEM TROUBLESHOOTING......1687
        FUEL STARVATION / LEAN MIXTURE......1687
      EFI DIAGNOSTICS USING ‘BLINK CODES’......1688
        Blink Codes - Operation......1688
      TROUBLESHOOTING DIAGRAMS......1690
        EFI CIRCUIT - Power On......1690
        EFI CIRCUIT - Crank Position Sensor......1690
        EFI CIRCUIT - Fuel Pump......1691
        EFI CIRCUIT - Ignition Coil......1691
        EFI CIRCUIT - Idle Air Control......1692
        EFI CIRCUIT - Throttle Position Sensor......1692
        EFI CIRCUIT - Manifold Absolute Pressure Sensor......1693
        EFI CIRCUIT - Engine Coolant Temperature......1693
        EFI CIRCUIT - Air Temperature Sensor......1694
        EFI CIRCUIT - Malfunction Indicator Light......1694
    General Information and Specifications 4.32 ......1695
      General Information and Specifications......1696
        Special Tools......1696
        Carburetor Jetting......1696
        Mikuni Jet Part Numbers......1696
        Carburetor Specifications......1696
      Carburetion......1697
        BST 34 Carburetor Exploded View 1 of 2......1697
        BST 34 Carburetor Exploded View 2 of 2......1698
        CV Carburetor System Function......1699
        Carburetor Venting......1699
        Mikuni CV Carb Operation......1699
        Starter System (Choke or Enrichment)......1700
        Pilot (Idle and Slow) System ......1700
        Main System......1701
        Float System ......1701
        Pilot Screw......1702
        Air/Fuel Mixture Ratio......1702
        Jet Needle......1703
        Needle Jet......1703
        Throttle Opening vs. Fuel Flow......1703
        Carburetor Disassembly - Mikuni CV......1703
        Carburetor Cleaning......1704
        Carburetor Inspection......1705
        Carburetor Assembly......1705
        Float Height Adjustment......1706
        Needle and Seat Leakage Test......1706
        Fuel Level Test......1707
      Fuel Tank/Fuel Delivery System......1708
        Fuel System Exploded View......1708
      Fuel Pump......1709
        Fuel Pump Testing......1709
        Fuel Pump Disassembly......1709
        Fuel Pump Inspection and Reassembly......1710
        Fuel Filter Replacement......1710
      Fuel Gauge Sending unit......1710
        Sending Unit Removal......1710
        Testing......1711
        Sending Unit Installation......1711
      Troubleshooting......1711
        Fuel Starvation/Lean Mixture......1711
  9920560_Chapter_05......1713
    GENERAL INFORMATION 5.2 ......1713
      GENERAL INFORMATION......1714
        Torque Specifications......1714
        Special Tools ......1714
        Decal Replacement......1714
        Plastic Insert Removal / Installation......1715
      BODY......1716
        Side Panel Removal......1716
        Front Cover Removal / Installation......1716
        Foot Well Removal / Installation......1717
        X2 Foot Well Removal / Installation......1717
        Front Storage Removal......1718
        Front Storage Installation......1720
        Sportsman Rear Rack Removal / Installation......1720
        Front Cab/Fender Removal/Installation......1721
        Sportsman Rear Cab / Fender Removal / Installation......1722
        X2 Rear Quarter Panel Removal / Installation......1722
        Sportsman Rear Storage Removal / Installation......1723
        Radiator Screen Removal......1723
        Sportsman Body Assembly Exploded View......1724
        X2 Body Assembly Exploded View......1725
        Body / Rack Exploded Views......1726
        Headlight Pod Exploded View......1727
      STEERING......1728
        Handlebar Block Installation Procedure......1728
        Steering / A-arm Exploded View......1729
        A-Arm Replacement......1730
        Ball Joint Replacement......1731
        Steering Post Removal......1732
        Steering Post Assembly......1732
      SUSPENSION......1732
        Front Strut Cartridge Replacement......1732
        Strut Assembly......1733
        Sportsman Rear Suspension Assembly......1734
        X2 Rear Suspension Exploded View......1735
        X2 Torsion Bar Exploded View......1736
      X2 CARGO BOX......1737
        Exploded View......1737
        Removal / Installation......1738
      X2 SEAT assembly......1740
        Exploded Views......1740
        X2 Seat Operation - Configuring Cargo Box For Passenger Riding......1741
        Driver Seat Backrest Removal / Installation......1742
        Passenger Seat Backrest Removal / Installation......1742
  9920560_Chapter_06......1743
    SPECIAL TOOLS AND SPECIFICATIONS 6.2 ......1743
      SPECIAL TOOLS AND SPECIFICATIONS......1744
        Special Tools......1744
        Component Fastener Torques......1744
      PVT EXPLODED VIEWS......1745
        PVT Sealing And Ducting Components......1745
        Drive Clutch Exploded Views (Standard and Deluxe)......1745
        Driven Clutch Exploded Views (Standard and Deluxe)......1746
        Engine Braking System (EBS) Exploded View......1747
      PVT SYSTEM......1748
        PVT Operation Overview......1748
        Drive Clutch Operation......1748
        Driven Clutch Operation......1748
        EBS Clutch Operation......1749
        PVT Maintenance / Inspection......1749
        Drive Clutch Spring......1750
        Optional Shift Weights......1751
        PVT Drying......1752
        PVT Disassembly ......1752
        PVT Installation......1753
        Drive Belt Removal / Inspection......1754
        DRIVE BELT INSTALLATION......1755
        Clutch Alignment......1756
        Clutch Offset......1756
      EBS DRIVE CLUTCH SERVICE......1757
        Drive Clutch Disassembly......1757
        Spider Removal......1757
        Button To Tower Clearance Inspection......1759
        Shift Weight Inspection......1759
        Drive Clutch Inspection......1759
        Moveable Sheave Bushing Inspection......1760
        Drive Clutch Bushing Service......1760
        One-Way Clutch Inspection (Drive Clutch)......1762
        Drive Clutch Reassembly......1762
      EBS DRIVEN CLUTCH SERVICE......1764
        Driven Clutch Disassembly ......1764
        DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION......1766
        EBS DRIVEN CLUTCH REASSEMBLY......1767
      STANDARD DRIVE CLUTCH......1770
        Drive Clutch Disassembly......1770
        Spider Removal......1771
        Button To Tower Clearance Inspection......1772
        Shift Weight Inspection......1772
        Sheave / Bushing Inspection......1773
        Drive Clutch Bushing Service......1773
        Drive Clutch Reassembly......1774
      STANDARD DRIVEN CLUTCH - 500 X2, 700, 800 EFI MODELS......1776
        Disassembly......1776
        Inspection......1776
        Assembly......1777
      STANDARD DRIVEN CLUTCH - 500 EFI AND 450......1778
        Exploded View......1778
        Clutch Disassembly / Inspection......1778
        Bushing Service......1779
        Moveable Sheave - Bushing Installation......1780
        Clutch Assembly......1781
      PVT TROUBLESHOOTING......1783
        Overheating......1783
        Problem, Cause and Remedy Chart......1784
  9920560_Chapter_07......1787
    SPECIFICATIONS 7.2 ......1787
      SPECIFICATIONS......1788
        Torque Table......1788
        Special Tools......1788
        Gearcase Fluid / Capacity......1788
      FRONT DRIVE AXLE......1788
        Removal......1788
        Installation......1790
      FRONT DRIVE SHAFT (CV) BOOT......1790
        Inspection......1790
        Replacement......1790
      FRONT HUB......1792
        Disassembly......1792
        Assembly......1792
      PROP SHAFT - FRONT OR REAR......1793
        Removal and Installation......1793
      U-JOINT......1793
        Disassembly......1793
        Assembly......1794
      DRIVE AXLE EXPLODED VIEWS......1796
        Drive Shafts and Propshafts......1796
      FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MoDELS)......1797
        Exploded View (Standard Models)......1797
        Operation......1798
        Gearcase Removal......1798
        Disassembly / Inspection......1799
        Reassembly / Inspection......1803
        Setting Ring Gear Backlash......1804
        Front Gearcase Diagnosis......1805
        Gearcase Installation......1806
      FRONT GEARCASE - Active descent control (deluxe models)......1807
        ADC Gearcase Exploded View (Deluxe Models)......1807
        ADC Coil Testing......1809
        ADC Differential Hydraulic Circuit Bleeding......1809
        Disassembly / Inspection......1809
        ADC Gearcase Piston Replacement Procedure......1813
        Assembly......1815
      REAR HUB......1818
        Removal......1818
        Disassembly......1819
        Assembly......1820
        Installation......1820
      REAR DRIVE (CV) SHAFT......1821
        Removal......1821
        Service......1822
        CV Boot Replacement......1823
        INSTALLATION......1824
        Drive Shaft and CV Joint Handling Tips......1825
  9920560_Chapter_08......1827
    TRANSMISSION - GENERAL 8.2 ......1827
      TRANSMISSION - GENERAL......1828
        Mounting Exploded View......1828
        Torque Specifications......1829
        Special Tools......1829
        Lubrication......1829
        Gear Selector Removal......1829
        Transmission Removal......1829
        Transmission Installation......1831
        Troubleshooting Checklist......1832
      TRANSMISSION SERVICE......1833
        Exploded View......1833
        Transmission Disassembly......1835
        Transmission Assembly......1840
        Transmission Front Output Shaft Backlash Procedure and Reassembly......1841
  9920560_Chapter_09......1847
    SPECIFICATIONS 9.2 ......1847
      SPECIFICATIONS......1848
        Torque Table......1848
        Component Service Limits......1848
      BRAKE SYSTEM Exploded Views......1849
        X2 System Component Exploded View......1849
        Sportsman System Component Exploded View......1850
      BRAKE CALIPER EXPLODED VIEWS......1851
        Sportsman and X2 Front Caliper Assembly......1851
        X2 Rear Caliper Assembly......1851
        Sportsman Rear Caliper Assembly......1852
      HYDRAULIC BRAKE SYSTEM......1852
        Operation Overview......1852
        Brake Noise Troubleshooting......1853
        Brake Bleeding / Fluid Change......1853
      FRONT MASTER CYLINDER......1855
        Removal......1855
        Installation......1855
      FRONT BRAKES......1856
        Pad Removal......1856
        Assembly......1857
        Brake Burnishing Procedure......1858
      FRONT BRAKE DISC......1858
        Inspection......1858
        Removal / Replacement......1859
      FRONT CALIPER......1860
        Removal......1860
        Inspection......1861
        Reassembly......1861
        Installation......1862
      REAR BRAKE PAD......1863
        X2 Pad Removal......1863
        X2 Pad Installation......1864
        Sportsman Rear Pad Removal......1865
        Sportsman Rear Pad Installation......1866
        Brake Burnishing Procedure......1866
      X2 REAR CALIPER......1867
        Removal......1867
        Inspection......1868
        Reassembly......1868
      Sportsman REAR CALIPER......1869
        Removal and Inspection......1869
        Assembly......1870
      REAR BRAKE DISC......1871
        Inspection......1871
      REAR MASTER CYLINDER......1872
        X2 Exploded View......1872
        Overview......1873
        X2 Rear Master Cylinder Removal and Installation......1873
        Sportsman Rear Master Cylinder Removal / Installation......1874
        Pedal Removal and Installation......1875
      TROUBLESHOOTING......1875
        Brakes Squeal......1875
        Poor Brake Performance......1875
        Lever Vibration......1875
        Caliper Overheats (Brakes Drag)......1875
        Brakes Lock......1875
  9920560_Chapter_10......1877
    GENERAL INFORMATION 10.3 ......1877
      GENERAL INFORMATION......1879
        Special Tools......1879
        Ignition System / Basic Electrical Components......1879
        Electrical Service Notes......1880
        Troubleshooting......1880
      POWER DISTRIBUTION MODULES (PDM)......1881
        Sportsman EFI Overview......1881
        Sportsman 450 Overview......1886
      INSTRUMENT CLUSTER......1889
        Overview......1889
        Instrument Cluster Diagnostic Mode......1890
        Setting A New Service Interval......1892
        EFI Diagnostic Mode ......1893
        Speedometer Removal......1894
        Speedometer Installation......1894
      ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING......1895
        TEST 1 - No All Wheel Drive......1895
        TEST 2 - No Speedometer Display......1896
        TEST 3 - No Reverse Speed Limit......1896
        TEST 4 - No AWD Hub Safety Limit......1897
        TEST 5 - Reverse Speed Limiter Activated In Forward Gear......1898
        TEST 6 - Wheel Speed Sensor......1898
        TEST 7 - Fuel Gauge Display Not Working......1899
        TEST 8 - Shift Indicator Not Working......1899
      ACTIVE DESCENT CONTROL (ADC) COIL......1900
        Operation Overview......1900
        Diagnosing System Failures......1900
      ALL WHEEL DRIVE (AWD) COIL......1900
        Operation Overview......1900
        Diagnosing System Failures......1900
      COOLING SYSTEM COMPONENTS......1901
        Fan Control Circuit Operation......1901
        Fan Control Bypass Test......1901
        Fan Motor Current Draw Test......1901
        Coolant Temperature Sensor......1902
      GEAR POSITION INDICATOR SWITCH......1902
        Test Diagram......1902
      ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......1903
        Operation Overview......1903
        ETC Test......1903
      IGNITION SYSTEM......1904
        Overview......1904
        Components of EFI Alternator and DC / CDI Ignition System......1905
        EFI Ignition System Testing Flow Chart......1906
        Crankshaft Position Sensor Gap......1907
        Ignition Troubleshooting......1907
        Ignition Output Test Using Gap Tester......1907
      CHARGING SYSTEM......1908
        Current Draw - Key Off......1908
        Break Even Test......1908
        Alternator Output Test......1908
        Charging System Testing Diagrams......1910
      DIFFERENTIAL SOLENOID......1912
        Testing......1912
        Replacement......1912
      LIGHTING......1912
        High Beam Headlight Bulb Replacement......1912
        Headlight Housing Relacement......1913
        High Beam Headlight Adjustment ......1914
        Lower Headlamp Removal / Installation......1914
        Low Beam Headlight Adjustment......1915
        Headlamp Switch Test......1915
        Work Light Switch......1916
        Brake Light / Work Light Replacement......1916
        Brake Light Switch Test......1917
      SPEED SENSOR......1918
        Testing......1918
        Replacement......1918
      FUEL SENDER......1918
        Testing......1918
      ACCESSORY POWER......1919
        Wire Connections......1919
      STARTER SYSTEM ......1920
        Troubleshooting......1920
        VOLTAGE DROP TEST......1920
        Starter Lockout Troubleshooting- EFI Models......1920
        Starter Lockout Troubleshooting- Sportsman 450......1920
        Starter Lockout Diagram- EFI......1921
        Starter Lockout Diagram- Sportsman 450......1921
        Starter Motor Removal / Disassembly......1922
        Brush Inspection / Replacement......1922
        Armature Testing......1923
        Starter Reassembly......1924
        Starter Solenoid Bench Test......1924
        Starter Exploded View......1924
      STARTER DRIVE......1925
        Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement......1925
      STARTER SYSTEM TESTING FLOW CHART......1926
        Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing.......1926
      BASIC WINCH WIRING......1927
        Pre-wired Models......1927
      TROUBLESHOOTING DIAGRAMS......1928
        Power On - EFI......1928
        Start Circuit - EFI......1928
        Ignition Coil - EFI......1929
        Fuel Pump - EFI......1929
        Fan - EFI......1930
        Charging System - EFI......1930
        All Wheel Drive - EFI......1931
        Transmission Switch - EFI......1931
        Reverse Override - EFI......1932
        Differential Solenoid - X2......1932
      BATTERY......1933
        Battery Identification......1933
        Battery Activation......1933
        Terminal Preparation......1934
        Battery Removal......1934
        Battery Installation......1934
        Off Season Storage......1935
        Low Maintenance Battery Off-Season Storage......1935
        Battery Testing......1935
        Conventional Battery OCV - Open Circuit Voltage Test......1935
        Conventional Battery Specific Gravity Test......1935
        Battery Load Test......1936
        Charging Procedure......1936
        Low Maintenance Battery Check:......1937
        Low Maintenance Battery Charging......1937
        Low Maintenance Battery - OCV- Open Circuit Voltage Test......1938
        Low Maintenance Battery Load Test......1938
        Low Maintenance Battery Charging Procedure......1938
  9920560_WIRE DIAGRAMS......1939
Polaris  '07 Sportsman 700 EFI-800 EFI Owner 's Manual......1951
Polaris  '07 Sportsman 700_800_800 X2 EFI Service Repair Manual......2094
  FOREWORD......2094
    understanding manual safety labels and directions......2095
    TRADEMARKS......2095
  CHAPTER INDEX......2096
  CH 1 - GENERAL INFORMATION......2098
    MODEL INFORMATION......2099
    Model Number/VIN Identification......2099
      Model Number......2099
      Engine Designation Numbers......2099
      VIN Identification......2099
      TRANSMISSION I.D. LOCATION......2099
      Engine and Machine Serial Numbers......2099
      PUBLICATIONS......2100
      Publication Numbers......2100
      PAINT CODES......2100
      Paint Codes......2100
      REPLACEMENT KEYS......2100
      Keys, Replacement......2100
      Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison......2101
      Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison......2102
    2007 SPORTSMAN 700 EFI......2103
    Specifications, Sportsman 700 EFI......2103
      MODEL NUMBER: A07MH68AX, AY, AZ ......2103
    2007 SPORTSMAN 800 EFI......2105
    Specifications, Sportsman 800 EFI......2105
      MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA......2105
    2007 SPORTSMAN X2 800 EFI......2107
    Specifications, Sportsman 800 X2 EFI......2107
      MODEL NUMBER: A07TH76AU, A07TN76AF......2107
    Misc. Tables......2109
    MISC. NUMBERS/CHARTS......2109
      Standard Torque Specifications......2109
      Specification, Standard Fastener Torques......2109
      SPECIAL TOOLS......2109
      SAE Tap Drill Sizes......2110
      Specification, Drill and Tap Sizes......2110
      Metric Tap Drill Sizes......2110
      Decimal Equivalents......2110
      Conversion Table......2111
      Conversion Table......2111
      Glossary Of Terms......2112
      Glossary of Terms......2112
  CH 2 - MAINTENANCE ......2114
    MAINTENANCE......2116
    Maintenance Chart, Periodic......2116
      Overview......2116
      Periodic Maintenance Chart......2117
    LUBRICATION / FLUIDS......2120
      SPORTSMAN Component Locations......2120
      SPORTSMAN X2 Component Locations......2121
      Polaris Lubricants, Maintenance and Service Products......2122
      Lubricants/Fluids, Polaris Brand Part Numbers......2122
      Polaris Lubricant Symbol Identification......2123
      Lubricants/Fluids, Polaris Brand Symbol Identification Chart......2123
      Pre-Ride / Daily Inspection......2123
      Pre-ride Checklist......2123
      Lubrication / Grease Points......2124
      Lubrication / Grease Points......2124
      Front Gearcase Lubrication......2125
      Front Gearcase Lubrication......2125
      Transmission Lubrication ......2126
      ADC Differential Hydraulic Circuit Fluid Change......2127
      Gearcase, ADC Hydraulic Fluid Change......2127
    VEHICLE INSPECTION......2127
      Shift Link Rod Inspection......2127
      Shift Linkage Inspection......2127
      Throttle Inspection......2128
      Throttle Inspection......2128
      Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment......2128
      Throttle Cable......2128
      Fuel System......2129
      Fuel Filter......2129
      Vent Lines......2129
      Vent Lines......2129
      Compression Test......2129
      Compression Test......2129
      Engine Mounts......2130
      Engine Mount......2130
      Spark Plug ......2130
      Spark Plug......2130
      Active Descent Control (ADC) Reservoir Level......2130
      ADC reservoir level inspection......2130
      Battery Maintenance......2131
      Battery Maintenance......2131
      Cooling System......2131
      Cooling System......2131
      Coolant Strength / Type......2132
      Cooling Hoses......2132
      Cooling System Hoses......2132
      Radiator......2132
      Radiator......2132
      Cooling System Pressure Test......2132
      Cooling System - Pressure Test......2132
      Reservoir Level Inspection......2132
      Cooling System - Coolant Level......2132
      Radiator Coolant Level......2133
      Cooling System - Radiator Level......2133
      Air Filter Service......2133
      Air Filter Service......2133
      Air Box Sediment Tube......2134
      Air Box Sediment Tube......2134
      Engine Breather......2134
      Engine Breather Hoses......2134
      PVT Inspection / Drying Procedure......2135
      PVT Drying......2135
      Engine Ground......2135
      Engine Ground......2135
      Engine Oil Level......2135
      Engine Oil Level......2135
      Oil/filter Change......2136
      Engine Oil and Filter Change......2136
      Steering Inspection......2137
      Steering......2137
      Tie Rod / Steering......2137
      Tie Rod / Steering Inspection......2137
      Camber/Caster......2137
      Camber / Caster......2137
      Wheel Alignment......2138
      Wheel Alignment......2138
      Toe Alignment......2138
      Exhaust Pipe......2139
      Exhaust Pipe......2139
      Brake System Inspection......2139
      Brake System Inspection......2139
      Brake Pads......2140
      Brake Pad Inspection......2140
      Brake Hose Inspection......2140
      Brake Hose Fitting Inspection......2140
      Auxiliary (Rear) Brake Test......2140
      Auxiliary (Rear) Brake Test......2140
      Auxiliary Brake Adjustment......2141
      Auxiliary Brake Adjustment......2141
      Suspension: Spring Preload Adjustment......2141
      Suspension  Adjustment......2141
      Front Suspension......2141
      Suspension, Front......2141
      Rear Suspension......2141
      Suspension, Rear......2141
      CV Shaft Boot Inspection......2141
      CV Shaft Boot Inspection......2141
      ATV Controls......2142
      Wheel Inspection......2142
      Wheel Removal: Front Or Rear......2142
      Wheel Removal......2142
      Wheel Installation......2142
      Wheel Installation......2142
      Tire Pressure......2143
      Tire Inspection......2143
      Tire Inspection......2143
      Frame, Nuts, Bolts, Fasteners......2143
      Frame, Nuts, Bolts Fastener Inspection......2143
      Front / Rear Storage Compartments......2143
      Storage Compartments, Front & Rear......2143
      Winch Operation (If Equipped)......2144
      Warn Winch Operation......2144
      Cleaning And Storage Of ATV......2146
      Cleaning and Storage of ATV......2146
      Exhaust, 800 EFI......2148
      Maintenance Schedule......2149
      Maintenance Schedule......2149
  CH 3 - ENGINE......2150
    SPECIFICATIONS......2151
      Crankcase Exploded Views......2151
      Engine Exploded Views......2152
      Engine Exploded Views......2152
      Engine Exploded Views......2153
      Engine Exploded Views......2154
      Engine Exploded Views......2155
      Engine Exploded Views......2157
      Engine Exploded Views......2157
      Engine Fastener Torque Patterns......2158
      Torque Specifications......2159
      Engine Torque Table......2159
      Torque Specs - Engine......2159
      700/800 EFI Engine Service Specifications......2160
      Engine Service Specifications......2160
      Special Tools......2162
      Special Tools, Engine......2162
    GENERAL ENGINE SERVICE......2163
      Accessible Components......2163
      Engine, Accessible Components......2163
      Piston Identification......2163
      Engine Piston Identification......2163
      Cooling System Specifications......2163
      Cooling System Specifications......2163
      Specifications, Cooling System......2163
      Engine Cooling System......2163
      Cooling System Pressure Test......2164
      Cooling System, Pressure Test......2164
      Engine Cooling System......2164
      Four Stroke - Coolant Air Bleeding Procedure......2164
      Cooling System Bleeding Procedure......2164
      Engine Removal (Typical)......2165
      Engine Removal / Install Procedure......2165
      Engine Installation Notes......2167
      Engine Installation Notes......2167
      Cylinder Hone Selection And Honing Procedure......2167
      Engine Cylinder Honing......2167
      Honing To Deglaze......2168
      Cylinder Honing To De-glaze......2168
      Cleaning the Cylinder After Honing......2168
      Oil Flow Chart......2169
      Engine Oil Flow Chart......2169
      Engine Lubrication Specifications......2169
      Specifications, Engine Lubrication......2169
      Engine Lubrication......2169
      OIL PRESSURE TEST......2169
      Engine Oil Pressure Test......2169
        Specifications, Engine Oil Pressure......2169
    ENGINE DISASSEMBLY AND INSPECTION......2170
      Cylinder Head Assembly Exploded View......2170
      Rocker Arms......2171
      Engine Rocker Arm Inspection......2171
      Push Rods......2171
      Engine  Pushrod Inspection......2171
      Cylinder Head Removal ......2171
      Engine  Cylinder Head Removal......2171
      Cylinder Head Inspection......2172
      Engine Cylinder Head Inspection......2172
      Cylinder Head Warp......2172
      Engine Cylinder Head Warp......2172
        Specification, Cylinder Head Warp......2172
      Valve Seal/Spring Service (On Engine)......2172
      Valve Seal/Spring Service......2172
      Engine Valve Seal/Spring Service......2172
      Cylinder Head Disassembly......2173
      Cylinder Head Disassembly......2173
        Specification, Valve Spring Free Length......2173
      Valve Inspection......2174
      Engine  Valve Inspection......2174
        Specification, Valve Stem Diameter......2174
        Specification, Valve Stem Guide I.D......2174
      Combustion Chamber......2175
      Combustion Chamber......2175
      Valve Seat Reconditioning......2175
      Valve Seat Reconditioning......2175
      Engine  Valve Seat Reconditioning......2175
        Specification, Valve Seat Contact Width......2176
      Cylinder Head Reassembly......2177
      Engine  Cylinder Head Assembly......2177
      Cylinder Head Assembly......2177
      Valve Sealing Test......2178
      Engine Valve Sealing Test......2178
      Valve Sealing Test......2178
      Cylinder Removal......2178
      Engine Cylinder Removal......2178
      Valve Lifter Removal/Inspection......2178
      Engine Valve Lifter Removal, Inspection......2178
      Piston Removal......2179
      Engine Piston Removal, Inspection......2179
      Cylinder Inspection......2180
      Engine Cylinder Inspection......2180
      Cylinder Inspection......2180
        Specification, Cylinder Warp Limit......2180
        Specification, Cylinder Taper Limit......2180
      Piston-To-Cylinder Clearance......2181
      Piston to Cylinder Clearance......2181
      Engine Piston to Cylinder Clearance......2181
      Piston/rod Inspection......2181
      Engine Piston to Rod Clearance......2181
      Piston to Rod Inspection......2181
      Piston Ring Installed Gap......2182
      Piston Ring Installed Gap......2182
      Engine Piston Ring Installed Gap......2182
      Starter Drive/Bendix Removal Inspection ......2182
      Starter Drive Removal......2182
      Engine Starter Drive Removal......2182
      Flywheel / Stator Removal / Inspection......2183
      Stator, Removal......2183
      Flywheel, Removal......2183
      Flywheel / Stator Removal......2183
      Engine Flywheel / Stator  Removal......2183
      Engine Crankcase Disassembly / Inspection......2184
        Engine Flywheel Removal......2184
        Engine Starter Removal......2184
        Engine Gear(s) Removal......2185
        Specification, Timing Gear Alignment......2185
        Timing Gear Mark Alignment......2185
        Cam Gear, Removal......2185
        Cam Gear, Reassembly......2186
        Special Tool, Cam Gear Installation Kit......2186
        Balance Shaft Gear, Removal......2187
        Crankshaft Gear, Removal......2188
        Engine Crankshaft Gear Removal......2188
        Oil Pump, Removal......2188
        Engine Oil Pump Removal......2188
        Oil Pump, Disassembly......2188
        Specification, Oil Pump Rotor Clearance......2189
        Oil Pump, Reassembly......2189
        Engine Balance Shaft Removal......2191
      Camshaft Inspection......2191
      Engine Camshaft Inspection......2191
        Specification, Cam Lobe Height......2191
        Specifications, Cam Shaft......2192
    ENGINE REASSEMBLY......2192
      CRANKCASE REASSEMBLY......2192
      Engine Crankcase Assembly......2192
        Specifications, Oil Baffle Bolt Torque......2192
        Specifications, Oil Pick-up Bolt Torque......2192
        Engine Camshaft Installation......2193
        Engine Crankshaft Installation......2193
        Specifications, Crankcase Fastener Torque......2193
        Engine Cylinder Installation......2194
        Engine Piston Installation......2194
        Specification, Cam Thrust Plate Fastener Torque......2195
        Engine Oil Pump Installation......2195
        Specification, Oil Pump Bolt Torque......2196
        Engine Gears,  Installation......2197
        Specification, Balance Shaft Gear Bolt Torque......2197
        Specification, Camshaft Gear Bolt Torque......2198
        Gear / Stator Housing Seal Replacement......2198
        Engine Stator Gear Cover Seal(s) Installation......2199
        Engine Stator Installation......2201
        Engine Oil Priming......2202
      Flywheel / Stator Installation......2203
      Engine Flywheel / Stator Installation......2203
      Cylinder Head Reassembly......2204
      Engine Head Assembly......2204
    TROUBLESHOOTING......2206
      Engine......2206
      Engine Troubleshooting......2206
      Cooling System......2207
      Engine Cooling System Troubleshooting......2207
    800 EFI Exhaust System (DELUXE)......2208
      Dual Exhaust Layout......2208
      Exhaust Breakdown, Sportsman 800 EFI......2208
      Exhaust, Dual 800 EFI......2208
  CH 4 - FUEL INJECTION......2210
    GENERAL INFORMATION......2211
      Special Tools......2211
      Fuel Injection, Special Tools......2211
      Service Notes......2212
      Fuel Injection, Service Notes......2212
      EFI System Exploded View......2213
      EFI System Component Locations......2214
      Fuel Injection, Component Locations......2214
      Fuel Tank Assembly......2215
      Fuel Lines - Quick Connect......2215
    ELECTRONIC FUEL INJECTION......2216
      Principal Components......2216
      EFI Operation Overview......2216
      EFI Operation Overview......2216
      Initial Priming / Starting Procedure......2216
      EFI Priming / Starting Procedure......2216
    ELECTRONIC CONTROL UNIT (ECU)......2217
      Operation Overview......2217
      Electronic Control Unit (ECU)......2217
      ECU Service......2217
      ECU Replacement......2217
    FUEL PUMP......2218
      Operation Overview......2218
      Fuel Pump / Tank Assembly......2218
      Fuel Pump Test......2218
      Fuel Pump / Tank Assembly Replacement......2219
    FUEL PRESSURE REGULATOR......2221
      Operation Overview......2221
      Fuel Pressure Regulator......2221
      Fuel Pressure Regulator Test......2221
      Fuel Pressure Regulator Replacement......2221
    FUEL FILTERS......2221
      General Information......2221
      Fuel Filter......2221
      Fuel Filter Service......2221
      Fuel Filter Replacement......2221
    FUEL INJECTORS......2222
      Operation Overview......2222
      Fuel Injector......2222
      Fuel Injector Service......2222
      Fuel Injector Replacement......2222
    CRANKSHAFT POSITION SENSOR (CPS)......2223
      Operation Overview......2223
      Crankshaft Position Sensor (CPS)......2223
      Crankshaft Position Sensor Test......2223
      Crankshaft Position Sensor (CPS) Replacement......2223
    TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)......2224
      Operation Overview......2224
      Temperature / Barometric Air Pressure Sensor (T-Bap)......2224
      Temperature and Barometric Air Pressure Sensor Test......2224
      Temperature and Barometric Air Pressure Sensor Replacement......2224
    THROTTLE POSITION SENSOR (TPS)......2224
      Operation Overview......2224
      Throttle Position Sensor......2224
      Throttle Position Sensor Replacement......2224
      Throttle Position Sensor Replacement......2224
      Throttle Position Sensor Test......2225
      Throttle Position Sensor Initialization......2225
      Throttle Position Sensor Initialization......2225
    ENGINE TEMPERATURE SENSOR......2227
      Operation Overview......2227
      Engine Temperature Sensor......2227
      Engine Temperature Sensor Test......2227
      Engine Temperature Sensor Test......2227
      Engine Temperature Sensor Replacement......2227
      Engine Temperature Sensor Replacement......2227
    TROUBLESHOOTING......2228
      Diagnostics Using “Blink Codes”......2228
      Engine Diagnostic Codes......2228
      EFI Troubleshooting......2229
      EFI Troubleshooting......2229
      EFI CIRCUIT - Power On......2230
      EFI CIRCUIT - Crank Position Sensor......2230
      EFI CIRCUIT - Fuel Pump......2231
      EFI CIRCUIT - Throttle Position Sensor......2231
      EFI CIRCUIT - Temperature - Barometric Air Pressure Sensor......2232
      EFI CIRCUIT - Engine Temperature......2232
      EFI CIRCUIT - Malfunction Indicator Light......2233
  CH 5 - BODY/STEERING/SUSPENSION......2234
    GENERAL INFORMATION......2235
      Torque Specifications......2235
      Specifications, Body and Steering Torque Values......2235
      Body and Steering Torque Values......2235
      Steering Torque Values......2235
      Special Tools ......2235
      Special Tools, Body & Steering......2235
      Decal Replacement......2235
      Decal Replacement......2235
      Plastic Insert Removal / Installation......2236
      Plastic Inserts......2236
    BODY......2237
      Side Panel Removal......2237
      Side Panel Removal......2237
      Front Cover Removal / Installation......2237
      Front Cover Removal / Installation......2237
      Foot Well Removal / Installation......2238
      Foot Well Removal / Installation......2238
      X2 Foot Well Removal / Installation......2238
      Foot Well Removal / Installation......2238
      Front Storage Removal......2239
      Front Storage Removal......2239
      Front Storage Installation......2241
      Front Storage Installation......2241
      Sportsman Rear Rack Removal / Installation......2241
      Rear Rack Removal / Installation......2241
      Front Cab/Fender Removal/Installation......2242
      Front Cab Removal / Installation......2242
      Sportsman Rear Cab / Fender Removal / Installation......2243
      Rear Cab Removal / Installation......2243
      X2 Rear Quarter Panel Removal / Installation......2243
      Sportsman Rear Storage Removal / Installation......2244
      Rear Storage Removal / Installation......2244
      Radiator Screen Removal......2244
      Radiator Screen Removal......2244
      Sportsman Body Assembly Exploded View......2245
      X2 Body Assembly Exploded View......2246
      Body / Rack Exploded Views......2247
      Headlight Pod Exploded View......2248
      Headlight Pod Exploded View......2248
    STEERING......2249
      Handlebar Block Installation Procedure......2249
      Handlebar Block Installation Procedure......2249
      Steering / A-arm Exploded View......2250
      Steering A-Arm Exploded View......2250
      A-Arm Replacement......2251
      A-Arm Replacement......2251
      Ball Joint Replacement......2252
      Ball Joint Replacement, Front......2252
      Steering Post Removal......2253
      Steering Post Assembly......2253
      Steering Post Assembly......2253
    SUSPENSION......2253
      Front Strut Cartridge Replacement......2253
      Strut Cartridge Replacement, Front......2253
      Strut Assembly......2254
      Sportsman Rear Suspension Assembly......2255
      X2 Rear Suspension Exploded View......2256
      X2 Torsion Bar Exploded View......2257
    X2 CARGO BOX......2258
      Exploded View......2258
      Removal / Installation......2259
      Cargo Box, Removal and Installation......2259
    X2 SEAT assembly......2261
      Exploded Views......2261
      X2 Seat Operation - Configuring Cargo Box For Passenger Riding......2262
      Passenger Seat, Operation......2262
      Driver Seat Backrest Removal / Installation......2263
      X2, Seat Disassembly......2263
      Passenger Seat Backrest Removal / Installation......2263
  CH 6 - CLUTCH SYSTEM......2264
    SPECIAL TOOLS AND SPECIFICATIONS......2265
      Special Tools......2265
      PVT Special Tools......2265
      Component Fastener Torques......2265
      PVT Torque Specs......2265
      Specification, PVT Component Torque Table......2265
    PVT EXPLODED VIEWS......2266
      PVT Sealing And Ducting Components......2266
      Drive Clutch Exploded Views (Standard and Deluxe)......2266
      Driven Clutch Exploded Views (Standard and Deluxe)......2267
      Engine Braking System (EBS) Exploded View......2268
    PVT SYSTEM......2269
      PVT Operation Overview......2269
      PVT Operation......2269
      Drive Clutch Operation......2269
      PVT Drive Clutch Operation......2269
      Drive Clutch, Operation......2269
      Driven Clutch Operation......2269
      PVT Driven Clutch Operation......2269
      Driven Clutch, Operation......2269
      EBS Clutch Operation......2270
      PVT, EBS Clutch Operation......2270
      EBS, Driven Clutch Operation......2270
      PVT Maintenance / Inspection......2270
      PVT Maintenance  / Inspection......2270
      Drive Clutch Spring......2271
      PVT Drive Clutch Specifications......2271
      Drive Clutch Springs......2271
      Optional Shift Weights......2272
      PVT Drive Clutch  Shift Weights......2272
      Drive Clutch Weights......2272
      PVT Drying......2273
      PVT Drying......2273
      PVT Disassembly ......2273
      PVT Disassembly......2273
      PVT Installation......2274
      PVT Assembly......2274
      Drive Belt Removal / Inspection......2275
      PVT, Drive Belt Removal/Inspection......2275
      Drive Belt, Removal/Inspection......2275
        Specification, PVT Drive Belt Width......2276
        Specification, PVT Center-to-Center Distance......2276
      DRIVE BELT INSTALLATION......2276
      PVT, Drive Belt Installation......2276
      Drive Belt, Installation......2276
      Clutch Alignment......2277
      PVT, Clutch Alignment......2277
      Clutch Alignment......2277
      Clutch Offset......2277
      PVT, Clutch Offset......2277
      Clutch Offset......2277
    EBS DRIVE CLUTCH SERVICE......2278
    EBS Drive Clutch Service......2278
      Drive Clutch Disassembly......2278
      PVT, Drive Clutch Disassembly......2278
      Spider Removal......2278
      PVT, Drive Clutch Spider Removal......2278
      Button To Tower Clearance Inspection......2280
      Shift Weight Inspection......2280
      PVT, Button to Tower Clearance......2280
      Drive Clutch Inspection......2280
      Moveable Sheave Bushing Inspection......2281
      PVT, Moveable Sheave Inspection......2281
      Drive Clutch Bushing Service......2281
      PVT, EBS Drive Clutch Bushing Service......2281
      PVT, EBS Drive Clutch Cover Bushing Remove/Install......2283
      One-Way Clutch Inspection (Drive Clutch)......2283
      Drive Clutch Reassembly......2283
      PVT, Drive Clutch Reassembly......2283
    EBS DRIVEN CLUTCH SERVICE......2285
    EBS Driven Clutch Service......2285
      Driven Clutch Disassembly ......2285
      PVT, Driven Clutch Disassembly......2285
      DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION......2287
      PVT, Driven Clutch Bushing Service......2287
      EBS DRIVEN CLUTCH REASSEMBLY......2288
      PVT, Driven Clutch Reassembly......2288
    standard drive clutch......2291
    Drive Clutch, Standard Service......2291
      Drive Clutch Disassembly......2291
      PVT, Drive Clutch Disassembly......2291
      Spider Removal......2292
      PVT, Drive Clutch Spider Removal......2292
      Button To Tower Clearance Inspection......2293
      Shift Weight Inspection......2293
      PVT, Button to Tower Clearance......2293
      Sheave / Bushing Inspection......2294
      PVT, Moveable Sheave Inspection......2294
      Drive Clutch Bushing Service......2294
      PVT, EBS Drive Clutch Bushing Service......2294
      PVT, EBS Drive Clutch Cover Bushing Remove/Install......2295
      Drive Clutch Reassembly......2295
      PVT, Drive Clutch Reassembly......2295
    standard driven clutch......2297
    Driven Clutch, Standard Service......2297
      Disassembly......2297
      Inspection......2297
      Assembly......2298
    PVT TROUBLESHOOTING......2299
    Clutch, Troubleshooting......2299
      Overheating......2299
      PVT Overheating Chart......2299
      Problem, Cause and Remedy Chart......2300
      PVT Troubleshooting Chart......2300
  CH 7 - FINAL DRIVE......2302
    SPECIFICATIONS......2303
      Torque Table......2303
      Specifications, Final Drive Torque Values......2303
      Final Drive Torque Specifications......2303
      Special Tools......2303
      Special Tools, Final Drive......2303
      Gearcase Fluid / Capacity......2303
      Specifications, Front Gearcase Lubrication Type/Capacity......2303
      Gearcase, Front Capacity and Fluid Type......2303
    FRONT DRIVE AXLE......2303
      Removal......2303
      Front Drive Axle Removal......2303
      Installation......2305
      Front Drive Axle Installation......2305
    FRONT DRIVE SHAFT (CV) BOOT......2305
      Inspection......2305
      Drive Shaft Boot Inspection......2305
      Replacement......2305
      CV Boot, Replacement......2305
    FRONT HUB......2307
      Disassembly......2307
      Front Hub, Disassembly......2307
      Assembly......2307
      Front Hub, Assembly......2307
    PROP SHAFT - FRONT OR REAR......2308
      Removal and Installation......2308
      Propshaft, Removal......2308
    U-JOINT......2308
    U-joint, Disassembly and Assembly......2308
      Disassembly......2308
      Assembly......2309
    DRIVE AXLE EXPLODED VIEWS......2311
      Drive Shafts and Propshafts......2311
    FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MoDELS)......2312
    Front Gearcase, Operation......2312
      Exploded View (Standard Models)......2312
      Front Gearcase, Exploded View......2312
      Operation......2313
      Gearcase Removal......2313
      Front Gearcase, Removal......2313
      Disassembly / Inspection......2314
      Front Gearcase, Disassembly / Inspection......2314
        Front Gearcase Coil Resistance......2315
      Reassembly / Inspection......2318
      Front Gearcase, Reassembly / Inspection......2318
      Setting Ring Gear Backlash......2319
      Front Gearcase Diagnosis......2320
      Front Gearcase, Diagnoses......2320
      Gearcase Installation......2321
      Front Gearcase, Installation......2321
    FRONT GEARCASE - Active descent control (deluxe models)......2322
      ADC Gearcase Exploded View (Deluxe Models)......2322
      Front Gearcase, Active Descent Control Exploded View......2322
      Operation......2323
      Active Descent Control Gearcase......2323
      ADC Coil Testing......2324
      ADC Differential Hydraulic Circuit Bleeding......2324
      Disassembly / Inspection......2324
      ADC Gearcase, Disassembly / Inspection......2324
        Front Gearcase Coil Resistance......2325
      ADC Gearcase Piston Replacement Procedure......2328
      ADC Gearcase Piston Service......2328
      Assembly......2330
      Front Gearcase, Reassembly......2330
    REAR HUB......2333
      Removal......2333
      Disassembly......2334
      Assembly......2335
      Installation......2335
    REAR DRIVE (CV) SHAFT......2336
      Removal......2336
      Service......2337
      CV Boot Replacement......2338
      INSTALLATION......2339
      Drive Shaft and CV Joint Handling Tips......2340
    REAR GEARCASE......2340
      Removal......2340
      Rear Gearcase, Removal......2340
      Disassembly and Inspection......2340
      Rear Gearcase, Disassembly......2340
      Reassembly......2342
      Rear Gearcase, Assembly......2342
      Installation ......2343
      Rear Gearcase, Installation......2343
      Rear Gearcase Exploded View......2344
    sPORTSMAN 8.3-8.18......2346
    sPORTSMAN X2 8.19-8.38......2346
  CH 8 - TRANSMISSION / SPORTSMAN......2348
    TRANSMISSION EXPLODED VIEW......2349
      Sportsman Transmission ......2349
      Transmission Exploded View......2350
    SPECIFICIATONS......2351
      Torque Specifications......2351
      Lubricant / Capacity......2351
    TRANSMISSION SERVICE......2351
      Transmission Removal......2351
      Transmission Gear Selector Removal......2351
      Transmission Removal......2351
      Disassembly......2352
      Transmission Disassembly......2352
      Assembly......2357
      Transmission Assembly......2357
      Transmission Installation......2362
      Transmission Installation......2362
      Troubleshooting......2363
      Transmission Troubleshooting......2363
  CH 8 - TRANSMISSION / X2......2364
    Transmission......2365
      TRANSMISSION EXPLODED VIEWS......2365
        X2 Transmission Exploded View......2365
        X2 Mounting Exploded View......2367
      sPECIFICATIONS......2368
        Torque Specifications......2368
        Special Tools......2368
        Transmission, Special Tools......2368
        Lubrication......2368
      TRANSMISSION SERVICE......2368
        Gear Selector Removal......2368
        Transmission Removal......2368
        Transmission, Removal......2368
        Transmission Installation......2370
        Transmission, Install......2370
        Troubleshooting Checklist......2371
        Transmission Disassembly......2372
        Transmission, Disassembly......2372
        Transmission assembly......2377
        Transmission, Reassembly......2377
        Transmission front output shaft backlash procedure......2378
        Transmission, Output Shaft Backlash Procedure......2378
          Specification, Transmission Silent Chain Length......2380
  CH 9 - BRAKES......2384
    SPECIFICATIONS......2385
      Torque Table......2385
      Brake, Torque Specifications......2385
      Specifications, Brake Component Torque Values......2385
      Component Service Limits......2385
      Specifications, Brake Component Service Limits......2385
    BRAKE SYSTEM Exploded Views......2386
    Brake System Exploded Views......2386
      X2 System Component Exploded View......2386
      Sportsman System Component Exploded View......2387
    BRAKE CALIPER EXPLODED VIEWS......2388
    Brake Caliper Exploded View......2388
      Sportsman and X2 Front Caliper Assembly......2388
      X2 Rear Caliper Assembly......2388
      Sportsman Rear Caliper Assembly......2389
    HYDRAULIC BRAKE SYSTEM......2389
    Hydraulic Brake System Operation Overview......2389
      Operation Overview......2389
      Brakes, Operation Overview......2389
      Brake Noise Troubleshooting......2390
      Brake Noise Troubleshooting......2390
      Brake Bleeding / Fluid Change......2390
      Brake Bleeding......2390
    FRONT MASTER CYLINDER......2392
    Brake,  Master Cylinder Removal......2392
      Removal......2392
      Installation......2392
    FRONT BRAKES......2393
    Brake Pad, Removal and Installation......2393
      Pad Removal......2393
      Assembly......2394
      Brake Burnishing Procedure......2395
      Brake Burnishing Procedure......2395
    FRONT BRAKE DISC......2395
    Brake Disc, Front......2395
      Inspection......2395
      Removal / Replacement......2396
    FRONT CALIPER......2397
    Brake Caliper, Front......2397
      Removal......2397
      Inspection......2398
      Reassembly......2398
      Installation......2399
    REAR BRAKE PAD......2400
    Brake Pad, Rear......2400
      X2 Pad Removal......2400
      X2 Pad Installation......2401
      Sportsman Rear Pad Removal......2402
      Brake Pad Removal, Rear......2402
        Specification, Brake Pad Thickness......2402
      Sportsman Rear Pad Installation......2403
      Brake Pad Install, Rear......2403
      Brake Burnishing Procedure......2403
    X2 REAR CALIPER......2404
    Brake Caliper Removal, Rear......2404
      Removal......2404
      Inspection......2405
      Reassembly......2405
    Sportsman REAR CALIPER......2406
      Removal and Inspection......2406
      Brake Caliper Removal, Rear......2406
      Assembly......2407
      Brake Caliper, Assembly......2407
    REAR BRAKE DISC......2408
    Brake Disc, Inspection......2408
      Inspection......2408
        Specification, Brake Disc Thickness......2408
        Specification, Brake Disc Service Limit......2408
    REAR MASTER CYLINDER......2409
    Brake, Rear Auxiliary Master Cylinder......2409
      X2 Exploded View......2409
      Overview......2410
      X2 Rear Master Cylinder Removal and Installation......2410
      Sportsman Rear Master Cylinder Removal / Installation......2411
      Brake, Rear Auxiliary Brake......2411
      Pedal Removal and Installation......2412
    TROUBLESHOOTING......2412
    Brakes, Troubleshooting......2412
      Brakes Squeal......2412
      Poor Brake Performance......2412
      Lever Vibration......2412
      Caliper Overheats (Brakes Drag)......2412
      Brakes Lock......2412
  CH 10 - ELECTRICAL......2414
    INSTRUMENT CLUSTER ......2416
    Instrument Cluster (Speedometer) Overview......2416
      Overview......2416
      Speedometer, Funtions Overview......2416
      Instrument Cluster Diagnostic Mode......2417
      Diagnostic Mode, Instrument Cluster......2417
      Clock, Setting Time of Day......2417
      Setting A New Service Interval......2419
      Instrument Cluster, Setting New Service Interval......2419
      Service Intervals, Speedometer......2419
      EFI Diagnostic Mode......2420
      EFI Diagnostic Mode Using Instrument Cluster......2420
      Diagnostic Mode, EFI System......2420
      Diagnostic Codes......2421
      Speedometer Removal......2421
      Speedometer Removal......2421
      Speedometer Installation......2422
      Speedometer Installation......2422
    SPEEDOMETER TROUBLESHOOTING......2423
      Test 1 - No All Wheel Drive......2423
      TEST 2 - No Display / TEST 3 - No Reverse Speed Limit......2424
      TEST 4 - No AWD Hub Safety Limiter......2425
      TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor ......2426
      TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch......2427
    ACTIVE DESCENT CONTROL (ADC) COIL......2428
    Active Descent Control (ADC) Coil......2428
      Operation Overview......2428
      Diagnosing System Failures......2428
    ALL WHEEL DRIVE (AWD) COIL......2428
    All Wheel Drive (AWD) Coil......2428
      Operation Overview......2428
      Diagnosing System Failures......2428
    COOLING SYSTEM COMPONENTS......2429
      Fan Control Circuit Operation / Testing......2429
      Fan Control Circuit Operation......2429
      Fan Control Circuit Bypass Test......2429
      Fan Control Circuit Operation / Testing......2429
      Coolant Temperature Sensor......2429
      Specification, Coolant Sensor Resistance......2429
      Fan Motor Current Draw......2430
      Fan Motor Current Draw......2430
    GEAR POSITION INDICATOR SWITCH......2430
      Test Diagram......2430
    ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......2431
      ETC Switch Operation......2431
      ETC Switch Operation......2431
      ETC Operation Test......2431
      ETC Operation Test......2431
    IGNITION SYSTEM......2432
      Flywheel Identification......2432
      Flywheel ID......2432
      EFI - DC/CDI Ignition Overview......2432
      Ignition Curve......2432
      Alternator/Ignition Components - 700/800 EFI......2433
      Crankshaft Position Sensor Gap......2434
      Crank Position Sensor Gap......2434
      Ignition System Troubleshooting......2434
      Ignition System Troubleshooting......2434
    CHARGING SYSTEM......2434
      Current Draw - Key Off......2434
      Current Draw  - Key Off Test......2434
      Charging System “Break Even” Test......2435
      Charging System - Break Even Test......2435
      Alternator Output Test......2435
      Alternator Output Test......2435
      Charging System Testing Flow Chart......2437
    RELAYS......2438
      Operation......2438
      Relays......2438
    FUSES/Circuit Breaker......2439
      Operation......2439
      Fuses......2439
      Circuit Breaker......2439
    LIGHTING......2439
      High Beam Headlight Bulb Replacement......2439
      High Beam Bulb Replacement......2439
      Headlight Housing Replacement......2440
      Headlight Housing Replacement......2440
      High Beam Headlight Adjustment ......2441
      High Beam Headlight Adjustment......2441
      Lower Headlamp Removal / Installation......2441
      Lower Headlamp  Removal......2441
        Lower Headlamp Housing Removal......2442
      Low Beam Headlight Adjustment......2442
      Low Beam Headlight Adjustment......2442
      Headlamp Switch Test......2442
      Headlamp Switch Test......2442
      Sportsman Work Light Switch (Deluxe)......2443
      Work Light Switch......2443
      Sportsman Brake Light / Work Light (Deluxe) Replacement......2443
      Brake Light / Work Light Switch Replacement......2443
      X2 BRAKE LIGHT / WORK LIGHT (Deluxe) REPLACEMENT......2444
      Brake Light / Work Light Switch Replacement......2444
      Brake Light Switch......2445
      Brake Light Switch......2445
    FUEL SENDER......2446
      Testing......2446
      Fuel Sender Test......2446
    X2 DIFFERENTIAL System......2446
      Solenoid Testing......2446
      Solenoid, Differential......2446
      Differential Solenoid......2446
      Specification, Differential Solenoid Resistance......2446
      Solenoid Replacement......2446
        Specification, Differential Solenoid Torque......2446
      Differential Relay Operation......2447
      Differential Relay Testing......2447
    X2 SPEED SENSOR......2447
      Testing......2447
      Speed Sensor......2447
      Special Tools, Speed Sensor......2447
      Specification,  Speed Sensor Bolt Torque......2447
      Specification, Differential Solenoid Resistance......2447
      Replacement......2447
      Speedometer Sensor, Replacement......2447
        Specification, Differential Solenoid Torque......2447
    ACCESSORY POWER......2448
      Wire Connections......2448
      Accessory Power Wiring......2448
    STARTER SYSTEM......2449
      700/800 Starter Lockout Overview and Diagnostic......2449
      Starter Interlock......2449
      Interlock, Starter, 700/800 EFI......2449
      800 X2 Starter Lockout Overview and Diagnostic......2450
      Starter Interlock......2450
      Interlock, Starter, 800 X2 EFI......2450
      Troubleshooting......2451
      Starter System, Troubleshooting......2451
      Voltage Drop Test......2451
      Voltage Drop Test......2451
      Starter Motor Removal / Disassembly ......2451
      Starter Motor, Removal......2451
      BRUSH INSPECTION / REPLACEMENT......2452
      Starter Brush Inspection / Replacement......2452
      Armature Testing......2453
      Starter Armature Testing......2453
      Starter Reassembly / Installation......2454
      Starter Reassembly / Installation......2454
      Starter Solenoid Bench Test......2454
      Starter Drive......2455
      Starter Drive......2455
      Starter Exploded View......2456
    STARTER SYSTEM TESTING FLOW CHART......2457
      Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test......2457
    BASIC WINCH WIRING- PRE-WIRED MODELS......2458
    BATTERY......2459
      Battery Identification......2459
      Battery Activation (Conventional)......2459
      Battery Activation, Conventional......2459
      Battery Terminals/Bolts......2460
      Battery Terminals/Bolts......2460
      Conventional Battery Inspection / Removal......2460
      Battery Removal / Inspection, Conventional......2460
      Conventional Battery Installation......2460
      Conventional Battery Testing......2461
      Conventional Battery OCV - Open Circuit Voltage Test......2461
      Conventional Battery Specific Gravity Test......2461
      Specific Gravity Test, Conventional Battery......2461
      Battery Load Test......2462
      Battery Load Test......2462
      Off Season Storage......2462
      Battery Off Season Storage......2462
      Charging Procedure......2462
      Charging Procedure......2462
      Low Maintenance Battery......2463
      Low Maintenance Battery Info......2463
      Low Maintenance Battery Charging......2463
      Low Maintenance Battery Charging......2463
      Low Maintenance Battery Inspection / Removal......2464
      Battery Inspection / Removal, Low Maintenance......2464
      Low Maintenance Battery Installation......2464
      Battery Installation, Low Maintenance......2464
      Low Maintenance Battery - OCV- Open Circuit Voltage Test......2465
      Battery Open Circuit Voltage (OCV), Low Maintenance......2465
      Low Maintenance Battery Load Test......2465
      Battery Load Test,  Low Maintenance......2465
      Low Maintenance Battery Off-season Storage......2466
      Battery Off Season Storage,  Low Maintenance......2466
      Low Maintenance Battery Charging Procedure......2466
      Battery Charging Procedure,  Low Maintenance......2466
  CH 11 - INTERNATIONAL......2468
    800 EFI International BRAKE SYSTEM......2469
    Brake System Overview, International......2469
      Overview......2469
      Exploded View......2470
    800 EFI International Steering Post and lock Assembly......2471
      Steering Lock, Exploded View......2471
      Steering Assembly Exploded View......2471
    800 EFI INTERNATIONAL ELECTRICAL......2472
      Turn / Hazard Signal Diagram......2472
  INDEX......2474
  WIRE DIAGRAMS......2480
Polaris  '08 Sportsman 500 EFI, X2, Touring, 500 H.O. Service Repair Manual......2487
  FOREWORD......2487
    FOREWORD......2487
    understanding manual safety labels and directions......2488
    TRADEMARKS......2488
  CHAPTER INDEX......2489
  CH 1 - GENERAL INFORMATION......2491
    MODEL NUMBER INFORMATION......2492
      Model Number......2492
      Engine Designation Numbers......2492
      Vehicle Identification Number (VIN)......2492
      Transmission I.d. Location......2492
      Engine And Machine Serial Numbers......2492
      Publications......2493
      Paint Codes......2493
      Replacement Keys......2493
    2008 SPORTSMAN 500......2494
      Model Number: A08MH50AX, AZ ......2494
    2008 SPORTSMAN 500 EFI......2496
      Model Number: A08MN50AF, AN, AQ, AS, AX......2496
    2008 SPORTSMAN X-2 500 EFI......2498
      Model Number: A08TN50AX, AZ / A08TN50EA ......2498
    2008 SPORTSMAN TOURING 500 EFI......2500
      Model Number: A08DN50AF, AS, AZ / A08DN50EA......2500
    MISC. NUMBERS/CHARTS......2502
      Standard Torque Specifications......2502
      SAE Tap Drill Sizes......2503
      Metric Tap Drill Sizes......2503
      Decimal Equivalents......2503
      Conversion Table......2504
      Glossary Of Terms......2505
  CH 2 - MAINTENANCE......2507
    MAINTENANCE......2509
      Periodic Maintenance Chart......2509
      Maintenance Chart Key......2509
      Periodic Maintenance Chart......2510
    LUBRICATION / FLUIDS......2513
      SPORTSMAN Component Locations......2513
      SPORTSMAN X2-Touring Component locations......2514
      Polaris Lubricants, Maintenance and Service Products......2515
      Polaris Lubricant Symbol Identification......2516
      Pre-ride / Daily Inspection......2516
      Lubrication Components......2517
      Front Gearcase Lubrication......2518
      Transmission Lubrication......2519
      ADC Differential Hydraulic Circuit Fluid Change......2520
    VEHICLE INSPECTION......2520
      Shift Link Rod Inspection......2520
      Throttle Inspection......2521
      Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment......2521
      Fuel System......2522
      Fuel Lines......2522
      Vent Lines......2522
      Fuel Filter......2523
      Choke (Enricher) Adjustment - (500 Carb)......2523
      Compression Test......2523
      Engine Mounts......2523
      Spark Plug......2524
      Active Descent Control (ADC) Reservoir Level......2524
      Battery Maintenance......2524
      Liquid Cooling System Overview......2525
      Coolant Strength / Type......2525
      Cooling System Hoses......2525
      Radiator/Grill Screen......2525
      Cooling System Pressure Test......2526
      Coolant Level Inspection......2526
      Radiator Coolant Level Inspection......2526
      Air Filter/Pre-Filter Service......2526
      Air Box Sediment Tube......2527
      Breather Filter Inspection......2528
      Breather Hose......2528
      Recoil Housing......2528
      Engine Oil Level......2529
      Oil and Filter Change ......2529
      Oil Pump Priming Procedure......2531
      Valve Clearance......2531
      Intake Valve Clearance Adjustment......2532
      Exhaust Valve Clearance Adjustment......2532
      Steering......2532
      Tie Rod End/Steering Inspection ......2533
      Camber and Caster......2533
      Wheel Alignment......2533
      Toe Alignment Adjustment......2534
      Exhaust Pipe......2534
      Brake System Inspection......2535
      Brake Pad Inspection......2536
      Hose/Fitting Inspection......2536
      Auxiliary Brake Testing......2536
      Auxiliary Brake Adjustment (Hydraulic) ......2537
      Suspension Spring Preload Adjustment......2537
      Front Suspension......2537
      CV Shaft Boot Inspection......2537
      Controls......2538
      Wheels......2538
      Wheel, Hub, And Spindle Torque Table......2538
      Wheel Removal Front or Rear......2538
      Wheel Installation......2539
      Tire Pressure......2539
      Tire Inspection......2539
      Frame, Nuts, Bolts, Fasteners......2539
      Storage Compartments......2540
      Winch Operation (If Equipped)......2540
      ATV Cleaning & Storage......2542
    SPORTSMAN 500 CARBURETED MAINTENENCE......2544
      Choke (Enricher) Adjustment......2544
      Pilot Screw......2544
      Pilot Screw Adjustment......2545
      Idle Speed Adjustment......2545
      Fuel Filter......2546
      Carburetor Draining......2546
      Maintenance Schedule......2547
      Maintenance Schedule......2548
  CH 3 - ENGINE......2549
    Specifications......2551
      Torque Specifications......2551
      Special Tools......2551
      Engine Fastener Torque Patterns......2551
      Engine Service Data......2552
      Engine Service Data......2553
    GENERAL ENGINE SERVICE......2554
      Piston Identification......2554
      Cooling System Specifications......2554
      Cooling System......2555
      Accessible Components......2556
      Engine Removal (TYPICAL)......2556
      Engine Installation Notes......2557
      Cylinder Hone Selection/ Honing Procedure......2557
      Honing To Oversize......2557
      Cleaning the Cylinder After Honing......2558
      Crankshaft Straightening......2558
      Engine Lubrication- EH 50PL......2559
      Oil Pressure Test - EH 50PL......2559
      Oil Pump Priming Procedure......2559
      Oil Flow - EH50PL......2559
      EH50PL Oil Flow Diagram......2560
      EH50PL Engine Exploded Views......2561
    ENGINE DISASSEMBLY......2562
      Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal......2562
      Cam Chain Tensioner Inspection......2562
      Rocker Arm/Shaft Inspection......2563
      Camshaft Removal......2564
      Automatic Compression Release Removal/ Inspection......2565
      Automatic Compression Release Installation......2566
      Camshaft Inspection......2566
      Cylinder Head Removal......2567
      Cylinder Head Exploded View, EH50PL......2568
      Cylinder Head Inspection......2569
      Cylinder Head Warp......2569
      Cylinder Head Disassembly......2569
      Valve Inspection......2570
      Combustion Chamber......2571
      Valve Seat Reconditioning......2571
      Cylinder Head Assembly......2574
      Valve Sealing Test......2574
      Valve Clearance Adjustment......2574
      Cylinder/Piston Removal and Inspection......2575
      Piston Removal......2576
      Cylinder Inspection......2576
      Piston-to-Cylinder Clearance......2577
      Piston/Rod Inspection......2577
      Piston Ring Installed Gap......2578
      Crankcase Disassembly......2578
      Starter Drive Removal/Inspection......2579
      Flywheel/Stator Removal/Inspection......2579
      Cam Chain/Tensioner Blade......2580
      One Way Valve Removal......2580
      Crankcase Separation......2581
      Oil Pump Removal/Inspection......2581
      Oil Pump Assembly......2582
      Counter Balancer Shaft Removal/Inspection......2582
      Crankshaft Removal/Inspection ......2583
      Crankcase Bearing Inspection ......2584
      Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)......2584
      Crankcase Inspection......2584
      Bearing Installation......2585
      End Play Inspection/Adjustment......2585
      Crankshaft End Play Adjustment......2585
      Counter Balancer Shaft End Play Adjustment......2586
      Oil Pump Shaft End Play Adjustment......2587
    ENGINE REASSEMBLY......2588
      Pump Shaft Oil Seal Installation......2588
      Crankshaft/Counter Balance/Oil Pump Installation......2588
      Crankcase Assembly......2589
      Water Pump Mechanical Seal Installation......2589
      Water Pump Mechanical Seal Removal - Engine Installed......2589
      One Way Valve Installation......2590
      Cam Chain Drive Sprocket Installation......2591
      Tensioner Blade Installation......2591
      Piston Ring Installation......2591
      Piston Installation......2592
      Cylinder Installation......2592
      Cylinder Head Installation......2593
      Cam Chain/Camshaft Installation......2593
      Camshaft Timing......2594
      CAMSHAFT TIMING......2596
      Cam Chain Tensioner Installation......2597
      Stator, Flywheel and Starter Drive Installation......2597
      Rocker Shaft/Rocker Arm Assembly Installation......2598
      Thermostat Installation......2598
      Oil Pipes......2598
    RECOIL......2599
      Recoil Disassembly/Inspection......2599
      Recoil Assembly......2600
    TROUBLESHOOTING......2601
      Spark Plug Fouling......2601
      Engine......2601
      Cooling System ......2602
    Electronic Fuel Injection 4.3 - 4.30......2603
    Carburetor (sportsman 500) 4.31 - 4.47......2603
  CH 4 - FUEL INJECTION......2605
    SPECIAL TOOLS......2606
      Part Numbers / Descriptions......2606
    EFI SERVICE NOTES......2608
      General Service Information......2608
    EFI SYSTEM EXPLODED VIEW......2609
    EFI SYSTEM ......2610
      Component Locations/Identification......2610
    FUEL TANK......2611
      Exploded View......2611
    ELECTRONIC FUEL INJECTION......2611
      General Information......2611
      EFI Operation Overview......2611
      Initial Priming / Starting Procedure......2612
    FUEL LINES......2612
      Quick Connect Removal/Installation......2612
    ELECTRONIC CONTROL UNIT (ECU)......2613
      Operation Overview......2613
      ECU Replacement......2613
      ECU Service......2613
    FUEL PUMP ASSEMBLY......2614
      Operation / Testing......2614
      FUEL PUMP TEST......2614
      Fuel Pump / Tank Assembly Replacement......2615
    FUEL PRESSURE REGULATOR......2616
      General Information......2616
    FUEL FILTER......2616
      General Information......2616
    FUEL INJECTOR......2617
      General Information......2617
    CRANKSHAFT POSITION SENSOR (CPS)......2618
      General Information......2618
    MANIFOLD AIR PRESSURE SENSOR (MAP)......2619
      Operation Overview......2619
      Map Sensor Test......2619
      Map Sensor Replacement......2619
    INTAKE AIR TEMPERATURE SENSOR (IAT)......2619
      Operation Overview......2619
      Intake Air Temperature Sensor Test......2619
      Intake Air Temperature Sensor Replacement......2619
    I DLE AIR CONTROL (IAC)......2620
      General Information......2620
    THROTTLE POSITION SENSOR (TPS)......2620
      Operation Overview......2620
      Throttle Position Sensor Test......2620
      Throttle Position Sensor Replacement......2621
      Throttle Position Sensor (Tps) Initialization......2622
    ENGINE TEMPERATURE SENSOR......2622
      General Information......2622
      Engine Temperature Sensor Test......2623
      Engine Temperature Sensor Replacement......2623
    FUEL SYSTEM TROUBLESHOOTING......2623
      FUEL STARVATION / LEAN MIXTURE......2623
    EFI DIAGNOSTICS USING ‘BLINK CODES’......2625
      Blink Codes - Operation......2625
    TROUBLESHOOTING DIAGRAMS......2626
      EFI CIRCUIT - Power On......2626
      EFI CIRCUIT - Crank Position Sensor......2626
      EFI CIRCUIT - Fuel Pump......2627
      EFI CIRCUIT - Ignition Coil......2627
      EFI CIRCUIT - Idle Air Control......2628
      EFI CIRCUIT - Throttle Position Sensor......2628
      EFI CIRCUIT - Manifold Absolute Pressure Sensor......2629
      EFI CIRCUIT - Engine Coolant Temperature......2629
      EFI CIRCUIT - Air Temperature Sensor......2630
      EFI CIRCUIT - Malfunction Indicator Light......2630
  CH 4 - CARBURETOR......2631
    General Information and Specifications......2632
      Special Tools......2632
      Carburetor Jetting......2632
      Mikuni Jet Part Numbers......2632
      Carburetor Specifications......2632
    Carburetion......2633
      BST 40 Carburetor Exploded View 1 of 2......2633
      BST 40 Carburetor Exploded View 2 of 2......2634
      CV Carburetor System Function......2635
      Carburetor Venting......2635
      Mikuni CV Carb Operation......2635
      Starter System (Choke or Enrichment)......2636
      Pilot (Idle and Slow) System ......2636
      Main System......2637
      Float System ......2637
      Pilot Screw......2638
      Air/Fuel Mixture Ratio......2638
      Jet Needle......2639
      Needle Jet......2639
      Throttle Opening vs. Fuel Flow......2639
      Carburetor Disassembly - Mikuni CV......2639
      Carburetor Cleaning......2640
      Carburetor Inspection......2641
      Carburetor Assembly......2641
      Float Height Adjustment......2642
      Needle and Seat Leakage Test......2642
      Fuel Level Test......2643
    Fuel Tank/Fuel Delivery System......2644
      Fuel System Exploded View......2644
    Fuel Pump......2645
      Fuel Pump Testing......2645
      Fuel Pump Disassembly......2645
      Fuel Pump Inspection and Reassembly......2646
      Fuel Filter Replacement......2646
    Fuel Gauge Sending unit......2646
      Sending Unit Removal......2646
      Testing......2647
      Sending Unit Installation......2647
    Troubleshooting......2647
      Fuel Starvation/Lean Mixture......2647
  CH 5 - BODY/STEERING/SUSPENSION......2649
    GENERAL INFORMATION......2650
      Torque Specifications......2650
      Special Tools ......2650
      Decal Replacement......2650
      Plastic Insert Removal / Installation......2651
    BODY......2652
      Side Panel Removal......2652
      Front Cover Removal / Installation......2652
      Foot Well Removal / Installation......2653
      X2-Touring Foot Well Removal / Installation......2653
      Front Storage Removal......2654
      Front Storage Installation......2656
      Sportsman Rear Rack Removal / Installation......2656
      Front Cab/Fender Removal/Installation......2657
      Sportsman Rear Cab / Fender Removal / Installation......2658
      X2-Touring Rear Quarter Panel Removal / Installation......2658
      Sportsman Rear Storage Removal / Installation......2659
      Radiator Screen Removal......2659
      Sportsman Body Assembly Exploded View......2660
      X2-Touring Body Assembly Exploded View......2661
      Touring Body/Rack Assembly Exploded View......2662
      Body / Rack Exploded Views......2663
      Touring Body/Seat Assembly Exploded View......2664
      Headlight Pod Exploded View......2665
    STEERING......2666
      Handlebar Block Installation Procedure......2666
      Steering / A-arm Exploded View......2667
      A-Arm Replacement......2668
      Ball Joint Replacement......2669
      Steering Post Removal......2670
      Steering Post Assembly......2670
    SUSPENSION......2670
      Front Strut Cartridge Replacement......2670
      Strut Assembly......2671
      Sportsman Rear Suspension Assembly......2672
      X2-Touring Rear Suspension Exploded View......2673
      X2-Touring Torsion Bar Exploded View......2674
    X2 CARGO BOX......2675
      Exploded View......2675
      Removal / Installation......2676
    X2 SEAT assembly......2678
      Exploded Views......2678
      X2 Seat Operation - Configuring Cargo Box For Passenger Riding......2679
      X2 Driver Seat Backrest Removal / Installation......2680
      X2 Passenger Seat Backrest Removal / Installation......2680
  CH 6 - CLUTCH SYSTEM......2683
    SPECIAL TOOLS AND SPECIFICATIONS......2684
      Special Tools......2684
      Service Note......2684
      Component Fastener Torques......2684
    PVT EXPLODED VIEWS......2685
      PVT Sealing And Ducting Components......2685
      Drive Clutch Exploded Views......2685
      Driven Clutch Exploded Views......2686
      Engine Braking System (EBS) Exploded View......2687
    PVT SYSTEM......2688
      PVT Operation Overview......2688
      Drive Clutch Operation......2688
      Driven Clutch Operation......2688
      EBS Clutch Operation......2689
      PVT Maintenance / Inspection......2689
      Drive Clutch Spring......2690
      Optional Shift Weights......2691
      PVT Drying......2692
      PVT Disassembly ......2692
      PVT Installation......2693
      Drive Belt Removal / Inspection......2694
      DRIVE BELT INSTALLATION......2695
      Clutch Alignment......2696
      Clutch Offset......2696
    EBS DRIVE CLUTCH SERVICE......2697
      Drive Clutch Disassembly......2697
      Spider Removal......2697
      Button To Tower Clearance Inspection......2699
      Shift Weight Inspection......2699
      Drive Clutch Inspection......2699
      Moveable Sheave Bushing Inspection......2700
      Drive Clutch Bushing Service......2700
      One-Way Clutch Inspection (Drive Clutch)......2702
      Drive Clutch Reassembly......2702
    EBS DRIVEN CLUTCH SERVICE......2704
      Driven Clutch Disassembly ......2704
      DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION......2706
      EBS DRIVEN CLUTCH REASSEMBLY......2707
    STANDARD DRIVE CLUTCH - 500 Carburetor......2710
      Drive Clutch Disassembly......2710
      Spider Removal......2711
      Button To Tower Clearance Inspection......2712
      Shift Weight Inspection......2712
      Sheave / Bushing Inspection......2713
      Drive Clutch Bushing Service......2713
      Drive Clutch Reassembly......2714
    STANDARD DRIVEN CLUTCH - 500 Carburetor......2716
      Exploded View......2716
      Clutch Disassembly / Inspection......2716
      Bushing Service......2717
      Moveable Sheave - Bushing Installation......2718
      Clutch Assembly......2719
    PVT TROUBLESHOOTING......2721
      Overheating......2721
      Problem, Cause and Remedy Chart......2722
  CH 7 - FINAL DRIVE......2725
    SPECIFICATIONS......2726
      Torque Table......2726
      Special Tools......2726
      Gearcase Fluid / Capacity......2726
    FRONT HUB......2726
      Disassembly......2726
      Assembly......2727
    FRONT DRIVE SHAFT (CV) SERVICE......2727
      Removal......2727
      Installation......2728
      Inspection......2729
      CV Joint/Boot Replacement......2729
    PROP SHAFT - FRONT......2731
      Removal and Installation......2731
    U-JOINT......2731
      Disassembly......2731
      Assembly......2732
    DRIVE AXLE EXPLODED VIEWS......2734
      Drive Shafts and Propshaft......2734
    FRONT GEARCASE - CENTRALIZED HILLIARD......2735
      Exploded View......2735
      Operation......2736
      Gearcase Removal......2736
      Disassembly / Inspection......2737
      Reassembly / Inspection......2741
      Setting Ring Gear Backlash......2742
      Front Gearcase Diagnosis......2743
      Gearcase Installation......2744
    FRONT GEARCASE - Active Descent Control......2745
      ADC Gearcase Exploded View......2745
      Operation......2746
      ADC Coil Testing......2747
      ADC Differential Hydraulic Circuit Bleeding......2747
      Disassembly / Inspection......2747
      ADC Gearcase Piston Replacement Procedure......2751
      Assembly......2753
    REAR HUB......2756
      Removal......2756
      Disassembly......2757
      Assembly......2758
      Installation......2758
    REAR DRIVE (CV) SHAFT SERVICE......2759
      Removal......2759
      Service......2760
      CV Boot Replacement......2761
      INSTALLATION......2762
      Drive Shaft and CV Joint Handling Tips......2762
  CH 8 - TRANSMISSION......2763
    TRANSMISSION - GENERAL......2764
      Mounting Exploded View......2764
      Torque Specifications......2765
      Special Tools......2765
      Lubrication......2765
      Gear Selector Removal......2765
      Transmission Removal......2765
      Transmission Installation......2767
      Troubleshooting Checklist......2768
    TRANSMISSION SERVICE......2769
      X2 - Touring Exploded View......2769
      500 Carbureted Exploded View......2771
      Transmission Disassembly......2773
      Transmission Assembly......2778
      Transmission Front Output Shaft Backlash Procedure and Reassembly......2779
  CH 9 - BRAKES......2785
    SPECIFICATIONS......2786
      Torque Table......2786
      Component Service Limits......2786
    BRAKE SYSTEM Exploded Views......2787
      X2, Touring System Component Exploded View......2787
      Sportsman System Component Exploded View......2788
    BRAKE CALIPER EXPLODED VIEWS......2789
      Sportsman and X2, Touring Front Caliper Assembly......2789
      X2, Touring Rear Caliper Assembly......2789
      Sportsman Rear Caliper Assembly......2790
    HYDRAULIC BRAKE SYSTEM......2790
      Operation Overview......2790
      Brake Noise Troubleshooting......2791
      Brake Bleeding / Fluid Change......2791
    FRONT MASTER CYLINDER......2793
      Removal......2793
      Installation......2793
    FRONT BRAKES......2794
      Pad Removal......2794
      Assembly......2795
      Brake Burnishing Procedure......2796
    FRONT BRAKE DISC......2796
      Inspection......2796
      Removal / Replacement......2797
    FRONT CALIPER......2798
      Removal......2798
      Inspection......2799
      Reassembly......2799
      Installation......2800
    REAR BRAKE PAD......2801
      X2, Touring Pad Removal......2801
      X2, Touring Pad Installation......2802
      Sportsman Rear Pad Removal......2803
      Sportsman Rear Pad Installation......2804
      Brake Burnishing Procedure......2804
    X2, TOURING REAR CALIPER......2805
      Removal......2805
      Inspection......2806
      Reassembly......2806
    Sportsman REAR CALIPER......2807
      Removal and Inspection......2807
      Assembly......2808
    REAR BRAKE DISC......2809
      Inspection......2809
    REAR MASTER CYLINDER......2810
      X2, Touring Exploded View......2810
      Overview......2811
      X2, Touring Rear Master Cylinder Removal and Installation......2811
      Sportsman Rear Master Cylinder Removal / Installation......2812
      Pedal Removal and Installation......2813
    TROUBLESHOOTING......2813
      Brakes Squeal......2813
      Poor Brake Performance......2813
      Lever Vibration......2813
      Caliper Overheats (Brakes Drag)......2813
      Brakes Lock......2813
  CH 10 - ELECTRICAL......2815
    GENERAL INFORMATION......2817
      Special Tools......2817
      Ignition System / Basic Electrical Components......2817
      Electrical Service Notes......2818
      Troubleshooting......2818
    POWER DISTRIBUTION MODULE (PDM)......2819
      Sportsman 500 Carbureted Overview......2819
    INSTRUMENT CLUSTER......2822
      Overview......2822
      Instrument Cluster Diagnostic Mode......2823
      Setting A New Service Interval......2825
      EFI Diagnostic Mode ......2826
      Speedometer Removal......2827
      Speedometer Installation......2827
    ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING......2828
      TEST 1 - No All Wheel Drive......2828
      TEST 2 - No Speedometer Display......2829
      TEST 3 - No Reverse Speed Limit......2829
      TEST 4 - No AWD Hub Safety Limit......2830
      TEST 5 - Reverse Speed Limiter Activated In Forward Gear......2831
      TEST 6 - Wheel Speed Sensor......2831
      TEST 7 - Fuel Gauge Display Not Working......2832
      TEST 8 - Shift Indicator Not Working......2832
    ACTIVE DESCENT CONTROL (ADC) COIL......2833
      Operation Overview - EFI Only......2833
      Diagnosing System Failures......2833
    ALL WHEEL DRIVE (AWD) COIL......2833
      Operation Overview......2833
      Diagnosing System Failures......2833
    COOLING SYSTEM COMPONENTS......2834
      Fan Control Circuit Operation......2834
      Fan Control Bypass Test......2834
      Fan Motor Current Draw Test......2834
      Coolant Temperature Sensor......2835
    GEAR POSITION INDICATOR SWITCH......2835
      Test Diagram......2835
    ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......2836
      Operation Overview......2836
      ETC Test......2836
    IGNITION SYSTEM......2837
      Overview......2837
      Components of Alternator and DC / CDI Ignition System......2838
      EFI Ignition System Testing Flow Chart......2839
      Crankshaft Position Sensor Gap......2840
      Ignition Troubleshooting......2840
      Ignition Output Test Using Gap Tester......2840
    CHARGING SYSTEM......2841
      Current Draw - Key Off......2841
      Break Even Test......2841
      Alternator Output Test......2842
      Charging System Testing Diagrams......2843
    RELAYS......2845
      Operation - EFI Models......2845
    FUSES/Circuit Breaker......2846
      Operation - EFI Models......2846
    DIFFERENTIAL SOLENOID......2846
      Overview - X2 and Touring......2846
      Testing......2846
      Replacement......2847
      Differential Solenoid Diagram - X2 and Touring......2847
    LIGHTING......2848
      High Beam Headlight Bulb Replacement......2848
      Headlight Housing Relacement......2848
      High Beam Headlight Adjustment ......2849
      Lower Headlamp Removal / Installation......2850
      Low Beam Headlight Adjustment......2851
      Headlamp Switch Test......2851
      Work Light / Differential Lockout Switch......2851
      Brake Light / Work Light Replacement......2852
      Brake Light Switch Test......2853
    SPEED SENSOR......2853
      Testing......2853
      Replacement......2853
    FUEL SENDER......2854
      Testing......2854
    ACCESSORY POWER......2854
      Wire Connections......2854
    STARTER SYSTEM ......2855
      Troubleshooting......2855
      VOLTAGE DROP TEST......2855
      Starter Lockout Troubleshooting- EFI Models......2856
      Starter Lockout Troubleshooting- Sportsman 500 Carbureted......2856
      Starter Lockout Diagram- EFI......2857
      Starter Lockout Diagram- Sportsman 500 Carbureted......2857
      Starter Motor Removal / Disassembly......2858
      Brush Inspection / Replacement......2858
      Armature Testing......2859
      Starter Reassembly......2860
      Starter Solenoid Bench Test......2860
      Starter Exploded View......2860
    STARTER DRIVE......2861
      Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement......2861
    STARTER SYSTEM TESTING FLOW CHART......2862
      Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing.......2862
    BASIC WINCH WIRING......2863
      Pre-wired Models......2863
    BATTERY......2864
      Battery Identification......2864
      Battery Activation......2864
      Terminal Preparation......2865
      Battery Removal......2865
      Battery Installation......2865
      Off Season Storage......2866
      Low Maintenance Battery Off-Season Storage......2866
      Battery Testing......2866
      Conventional Battery OCV - Open Circuit Voltage Test......2866
      Conventional Battery Specific Gravity Test......2867
      Battery Load Test......2867
      Charging Procedure......2867
      Low Maintenance Battery Check:......2868
      Low Maintenance Battery Charging......2868
      Low Maintenance Battery - OCV- Open Circuit Voltage Test......2869
      Low Maintenance Battery Load Test......2869
      Low Maintenance Battery Charging Procedure......2869
    TROUBLESHOOTING DIAGRAMS......2870
      All Wheel Drive - EFI......2870
      Fuel Pump and Ignition Coil - EFI......2870
      Reverse Override - EFI......2871
      Fan Control - EFI......2871
  CH 11 - X2/TOURING QUADRICYCLE......2873
    500 EFI X2 / TOURING QUADRICYCLE BRAKE SYSTEM......2874
      Overview......2874
      Exploded View......2875
    500 EFI X2 / TOURING QUADRICYCLE STEERING POST AND LOCK......2876
      Steering Assembly Exploded View......2876
    500 EFI QUADRICYCLE EMISSIONS SYSTEM......2877
      Overview......2877
    500 QUADRICYCLE ELECTRICAL......2878
      Turn / Hazard Signal Diagram......2878
  INDEX......2879
  WIRE DIAGRAMS......2885
Polaris  '08 Sportsman 500 Service Repair Manual......2893
  FOREWORD......2893
    FOREWORD......2893
    understanding manual safety labels and directions......2894
    TRADEMARKS......2894
  CHAPTER INDEX......2895
  CH 1 - GENERAL INFORMATION......2897
    MODEL NUMBER INFORMATION......2898
      Model Number......2898
      Engine Designation Numbers......2898
      Vehicle Identification Number (VIN)......2898
      Transmission I.d. Location......2898
      Engine And Machine Serial Numbers......2898
      Publications......2899
      Paint Codes......2899
      Replacement Keys......2899
    2008 SPORTSMAN 500......2900
      Model Number: A08MH50AX, AZ ......2900
    2008 SPORTSMAN 500 EFI......2902
      Model Number: A08MN50AF, AN, AQ, AS, AX......2902
    2008 SPORTSMAN X-2 500 EFI......2904
      Model Number: A08TN50AX, AZ / A08TN50EA ......2904
    2008 SPORTSMAN TOURING 500 EFI......2906
      Model Number: A08DN50AF, AS, AZ / A08DN50EA......2906
    MISC. NUMBERS/CHARTS......2908
      Standard Torque Specifications......2908
      SAE Tap Drill Sizes......2909
      Metric Tap Drill Sizes......2909
      Decimal Equivalents......2909
      Conversion Table......2910
      Glossary Of Terms......2911
  CH 2 - MAINTENANCE......2913
    MAINTENANCE......2915
      Periodic Maintenance Chart......2915
      Maintenance Chart Key......2915
      Periodic Maintenance Chart......2916
    LUBRICATION / FLUIDS......2919
      SPORTSMAN Component Locations......2919
      SPORTSMAN X2-Touring Component locations......2920
      Polaris Lubricants, Maintenance and Service Products......2921
      Polaris Lubricant Symbol Identification......2922
      Pre-ride / Daily Inspection......2922
      Lubrication Components......2923
      Front Gearcase Lubrication......2924
      Transmission Lubrication......2925
      ADC Differential Hydraulic Circuit Fluid Change......2926
    VEHICLE INSPECTION......2926
      Shift Link Rod Inspection......2926
      Throttle Inspection......2927
      Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment......2927
      Fuel System......2928
      Fuel Lines......2928
      Vent Lines......2928
      Fuel Filter......2929
      Choke (Enricher) Adjustment - (500 Carb)......2929
      Compression Test......2929
      Engine Mounts......2929
      Spark Plug......2930
      Active Descent Control (ADC) Reservoir Level......2930
      Battery Maintenance......2930
      Liquid Cooling System Overview......2931
      Coolant Strength / Type......2931
      Cooling System Hoses......2931
      Radiator/Grill Screen......2931
      Cooling System Pressure Test......2932
      Coolant Level Inspection......2932
      Radiator Coolant Level Inspection......2932
      Air Filter/Pre-Filter Service......2932
      Air Box Sediment Tube......2933
      Breather Filter Inspection......2934
      Breather Hose......2934
      Recoil Housing......2934
      Engine Oil Level......2935
      Oil and Filter Change ......2935
      Oil Pump Priming Procedure......2937
      Valve Clearance......2937
      Intake Valve Clearance Adjustment......2938
      Exhaust Valve Clearance Adjustment......2938
      Steering......2938
      Tie Rod End/Steering Inspection ......2939
      Camber and Caster......2939
      Wheel Alignment......2939
      Toe Alignment Adjustment......2940
      Exhaust Pipe......2940
      Brake System Inspection......2941
      Brake Pad Inspection......2942
      Hose/Fitting Inspection......2942
      Auxiliary Brake Testing......2942
      Auxiliary Brake Adjustment (Hydraulic) ......2943
      Suspension Spring Preload Adjustment......2943
      Front Suspension......2943
      CV Shaft Boot Inspection......2943
      Controls......2944
      Wheels......2944
      Wheel, Hub, And Spindle Torque Table......2944
      Wheel Removal Front or Rear......2944
      Wheel Installation......2945
      Tire Pressure......2945
      Tire Inspection......2945
      Frame, Nuts, Bolts, Fasteners......2945
      Storage Compartments......2946
      Winch Operation (If Equipped)......2946
      ATV Cleaning & Storage......2948
    SPORTSMAN 500 CARBURETED MAINTENENCE......2950
      Choke (Enricher) Adjustment......2950
      Pilot Screw......2950
      Pilot Screw Adjustment......2951
      Idle Speed Adjustment......2951
      Fuel Filter......2952
      Carburetor Draining......2952
      Maintenance Schedule......2953
      Maintenance Schedule......2954
  CH 3 - ENGINE......2955
    Specifications......2957
      Torque Specifications......2957
      Special Tools......2957
      Engine Fastener Torque Patterns......2957
      Engine Service Data......2958
      Engine Service Data......2959
    GENERAL ENGINE SERVICE......2960
      Piston Identification......2960
      Cooling System Specifications......2960
      Cooling System......2961
      Accessible Components......2962
      Engine Removal (TYPICAL)......2962
      Engine Installation Notes......2963
      Cylinder Hone Selection/ Honing Procedure......2963
      Honing To Oversize......2963
      Cleaning the Cylinder After Honing......2964
      Crankshaft Straightening......2964
      Engine Lubrication- EH 50PL......2965
      Oil Pressure Test - EH 50PL......2965
      Oil Pump Priming Procedure......2965
      Oil Flow - EH50PL......2965
      EH50PL Oil Flow Diagram......2966
      EH50PL Engine Exploded Views......2967
    ENGINE DISASSEMBLY......2968
      Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal......2968
      Cam Chain Tensioner Inspection......2968
      Rocker Arm/Shaft Inspection......2969
      Camshaft Removal......2970
      Automatic Compression Release Removal/ Inspection......2971
      Automatic Compression Release Installation......2972
      Camshaft Inspection......2972
      Cylinder Head Removal......2973
      Cylinder Head Exploded View, EH50PL......2974
      Cylinder Head Inspection......2975
      Cylinder Head Warp......2975
      Cylinder Head Disassembly......2975
      Valve Inspection......2976
      Combustion Chamber......2977
      Valve Seat Reconditioning......2977
      Cylinder Head Assembly......2980
      Valve Sealing Test......2980
      Valve Clearance Adjustment......2980
      Cylinder/Piston Removal and Inspection......2981
      Piston Removal......2982
      Cylinder Inspection......2982
      Piston-to-Cylinder Clearance......2983
      Piston/Rod Inspection......2983
      Piston Ring Installed Gap......2984
      Crankcase Disassembly......2984
      Starter Drive Removal/Inspection......2985
      Flywheel/Stator Removal/Inspection......2985
      Cam Chain/Tensioner Blade......2986
      One Way Valve Removal......2986
      Crankcase Separation......2987
      Oil Pump Removal/Inspection......2987
      Oil Pump Assembly......2988
      Counter Balancer Shaft Removal/Inspection......2988
      Crankshaft Removal/Inspection ......2989
      Crankcase Bearing Inspection ......2990
      Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)......2990
      Crankcase Inspection......2990
      Bearing Installation......2991
      End Play Inspection/Adjustment......2991
      Crankshaft End Play Adjustment......2991
      Counter Balancer Shaft End Play Adjustment......2992
      Oil Pump Shaft End Play Adjustment......2993
    ENGINE REASSEMBLY......2994
      Pump Shaft Oil Seal Installation......2994
      Crankshaft/Counter Balance/Oil Pump Installation......2994
      Crankcase Assembly......2995
      Water Pump Mechanical Seal Installation......2995
      Water Pump Mechanical Seal Removal - Engine Installed......2995
      One Way Valve Installation......2996
      Cam Chain Drive Sprocket Installation......2997
      Tensioner Blade Installation......2997
      Piston Ring Installation......2997
      Piston Installation......2998
      Cylinder Installation......2998
      Cylinder Head Installation......2999
      Cam Chain/Camshaft Installation......2999
      Camshaft Timing......3000
      CAMSHAFT TIMING......3002
      Cam Chain Tensioner Installation......3003
      Stator, Flywheel and Starter Drive Installation......3003
      Rocker Shaft/Rocker Arm Assembly Installation......3004
      Thermostat Installation......3004
      Oil Pipes......3004
    RECOIL......3005
      Recoil Disassembly/Inspection......3005
      Recoil Assembly......3006
    TROUBLESHOOTING......3007
      Spark Plug Fouling......3007
      Engine......3007
      Cooling System ......3008
    Electronic Fuel Injection 4.3 - 4.30......3009
    Carburetor (sportsman 500) 4.31 - 4.47......3009
  CH 4 - FUEL INJECTION......3011
    SPECIAL TOOLS......3012
      Part Numbers / Descriptions......3012
    EFI SERVICE NOTES......3014
      General Service Information......3014
    EFI SYSTEM EXPLODED VIEW......3015
    EFI SYSTEM ......3016
      Component Locations/Identification......3016
    FUEL TANK......3017
      Exploded View......3017
    ELECTRONIC FUEL INJECTION......3017
      General Information......3017
      EFI Operation Overview......3017
      Initial Priming / Starting Procedure......3018
    FUEL LINES......3018
      Quick Connect Removal/Installation......3018
    ELECTRONIC CONTROL UNIT (ECU)......3019
      Operation Overview......3019
      ECU Replacement......3019
      ECU Service......3019
    FUEL PUMP ASSEMBLY......3020
      Operation / Testing......3020
      FUEL PUMP TEST......3020
      Fuel Pump / Tank Assembly Replacement......3021
    FUEL PRESSURE REGULATOR......3022
      General Information......3022
    FUEL FILTER......3022
      General Information......3022
    FUEL INJECTOR......3023
      General Information......3023
    CRANKSHAFT POSITION SENSOR (CPS)......3024
      General Information......3024
    MANIFOLD AIR PRESSURE SENSOR (MAP)......3025
      Operation Overview......3025
      Map Sensor Test......3025
      Map Sensor Replacement......3025
    INTAKE AIR TEMPERATURE SENSOR (IAT)......3025
      Operation Overview......3025
      Intake Air Temperature Sensor Test......3025
      Intake Air Temperature Sensor Replacement......3025
    I DLE AIR CONTROL (IAC)......3026
      General Information......3026
    THROTTLE POSITION SENSOR (TPS)......3026
      Operation Overview......3026
      Throttle Position Sensor Test......3026
      Throttle Position Sensor Replacement......3027
      Throttle Position Sensor (Tps) Initialization......3028
    ENGINE TEMPERATURE SENSOR......3028
      General Information......3028
      Engine Temperature Sensor Test......3029
      Engine Temperature Sensor Replacement......3029
    FUEL SYSTEM TROUBLESHOOTING......3029
      FUEL STARVATION / LEAN MIXTURE......3029
    EFI DIAGNOSTICS USING ‘BLINK CODES’......3031
      Blink Codes - Operation......3031
    TROUBLESHOOTING DIAGRAMS......3032
      EFI CIRCUIT - Power On......3032
      EFI CIRCUIT - Crank Position Sensor......3032
      EFI CIRCUIT - Fuel Pump......3033
      EFI CIRCUIT - Ignition Coil......3033
      EFI CIRCUIT - Idle Air Control......3034
      EFI CIRCUIT - Throttle Position Sensor......3034
      EFI CIRCUIT - Manifold Absolute Pressure Sensor......3035
      EFI CIRCUIT - Engine Coolant Temperature......3035
      EFI CIRCUIT - Air Temperature Sensor......3036
      EFI CIRCUIT - Malfunction Indicator Light......3036
  CH 4 - CARBURETOR......3037
    General Information and Specifications......3038
      Special Tools......3038
      Carburetor Jetting......3038
      Mikuni Jet Part Numbers......3038
      Carburetor Specifications......3038
    Carburetion......3039
      BST 40 Carburetor Exploded View 1 of 2......3039
      BST 40 Carburetor Exploded View 2 of 2......3040
      CV Carburetor System Function......3041
      Carburetor Venting......3041
      Mikuni CV Carb Operation......3041
      Starter System (Choke or Enrichment)......3042
      Pilot (Idle and Slow) System ......3042
      Main System......3043
      Float System ......3043
      Pilot Screw......3044
      Air/Fuel Mixture Ratio......3044
      Jet Needle......3045
      Needle Jet......3045
      Throttle Opening vs. Fuel Flow......3045
      Carburetor Disassembly - Mikuni CV......3045
      Carburetor Cleaning......3046
      Carburetor Inspection......3047
      Carburetor Assembly......3047
      Float Height Adjustment......3048
      Needle and Seat Leakage Test......3048
      Fuel Level Test......3049
    Fuel Tank/Fuel Delivery System......3050
      Fuel System Exploded View......3050
    Fuel Pump......3051
      Fuel Pump Testing......3051
      Fuel Pump Disassembly......3051
      Fuel Pump Inspection and Reassembly......3052
      Fuel Filter Replacement......3052
    Fuel Gauge Sending unit......3052
      Sending Unit Removal......3052
      Testing......3053
      Sending Unit Installation......3053
    Troubleshooting......3053
      Fuel Starvation/Lean Mixture......3053
  CH 5 - BODY/STEERING/SUSPENSION......3055
    GENERAL INFORMATION......3056
      Torque Specifications......3056
      Special Tools ......3056
      Decal Replacement......3056
      Plastic Insert Removal / Installation......3057
    BODY......3058
      Side Panel Removal......3058
      Front Cover Removal / Installation......3058
      Foot Well Removal / Installation......3059
      X2-Touring Foot Well Removal / Installation......3059
      Front Storage Removal......3060
      Front Storage Installation......3062
      Sportsman Rear Rack Removal / Installation......3062
      Front Cab/Fender Removal/Installation......3063
      Sportsman Rear Cab / Fender Removal / Installation......3064
      X2-Touring Rear Quarter Panel Removal / Installation......3064
      Sportsman Rear Storage Removal / Installation......3065
      Radiator Screen Removal......3065
      Sportsman Body Assembly Exploded View......3066
      X2-Touring Body Assembly Exploded View......3067
      Touring Body/Rack Assembly Exploded View......3068
      Body / Rack Exploded Views......3069
      Touring Body/Seat Assembly Exploded View......3070
      Headlight Pod Exploded View......3071
    STEERING......3072
      Handlebar Block Installation Procedure......3072
      Steering / A-arm Exploded View......3073
      A-Arm Replacement......3074
      Ball Joint Replacement......3075
      Steering Post Removal......3076
      Steering Post Assembly......3076
    SUSPENSION......3076
      Front Strut Cartridge Replacement......3076
      Strut Assembly......3077
      Sportsman Rear Suspension Assembly......3078
      X2-Touring Rear Suspension Exploded View......3079
      X2-Touring Torsion Bar Exploded View......3080
    X2 CARGO BOX......3081
      Exploded View......3081
      Removal / Installation......3082
    X2 SEAT assembly......3084
      Exploded Views......3084
      X2 Seat Operation - Configuring Cargo Box For Passenger Riding......3085
      X2 Driver Seat Backrest Removal / Installation......3086
      X2 Passenger Seat Backrest Removal / Installation......3086
  CH 6 - CLUTCH SYSTEM......3089
    SPECIAL TOOLS AND SPECIFICATIONS......3090
      Special Tools......3090
      Service Note......3090
      Component Fastener Torques......3090
    PVT EXPLODED VIEWS......3091
      PVT Sealing And Ducting Components......3091
      Drive Clutch Exploded Views......3091
      Driven Clutch Exploded Views......3092
      Engine Braking System (EBS) Exploded View......3093
    PVT SYSTEM......3094
      PVT Operation Overview......3094
      Drive Clutch Operation......3094
      Driven Clutch Operation......3094
      EBS Clutch Operation......3095
      PVT Maintenance / Inspection......3095
      Drive Clutch Spring......3096
      Optional Shift Weights......3097
      PVT Drying......3098
      PVT Disassembly ......3098
      PVT Installation......3099
      Drive Belt Removal / Inspection......3100
      DRIVE BELT INSTALLATION......3101
      Clutch Alignment......3102
      Clutch Offset......3102
    EBS DRIVE CLUTCH SERVICE......3103
      Drive Clutch Disassembly......3103
      Spider Removal......3103
      Button To Tower Clearance Inspection......3105
      Shift Weight Inspection......3105
      Drive Clutch Inspection......3105
      Moveable Sheave Bushing Inspection......3106
      Drive Clutch Bushing Service......3106
      One-Way Clutch Inspection (Drive Clutch)......3108
      Drive Clutch Reassembly......3108
    EBS DRIVEN CLUTCH SERVICE......3110
      Driven Clutch Disassembly ......3110
      DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION......3112
      EBS DRIVEN CLUTCH REASSEMBLY......3113
    STANDARD DRIVE CLUTCH - 500 Carburetor......3116
      Drive Clutch Disassembly......3116
      Spider Removal......3117
      Button To Tower Clearance Inspection......3118
      Shift Weight Inspection......3118
      Sheave / Bushing Inspection......3119
      Drive Clutch Bushing Service......3119
      Drive Clutch Reassembly......3120
    STANDARD DRIVEN CLUTCH - 500 Carburetor......3122
      Exploded View......3122
      Clutch Disassembly / Inspection......3122
      Bushing Service......3123
      Moveable Sheave - Bushing Installation......3124
      Clutch Assembly......3125
    PVT TROUBLESHOOTING......3127
      Overheating......3127
      Problem, Cause and Remedy Chart......3128
  CH 7 - FINAL DRIVE......3131
    SPECIFICATIONS......3132
      Torque Table......3132
      Special Tools......3132
      Gearcase Fluid / Capacity......3132
    FRONT HUB......3132
      Disassembly......3132
      Assembly......3133
    FRONT DRIVE SHAFT (CV) SERVICE......3133
      Removal......3133
      Installation......3134
      Inspection......3135
      CV Joint/Boot Replacement......3135
    PROP SHAFT - FRONT......3137
      Removal and Installation......3137
    U-JOINT......3137
      Disassembly......3137
      Assembly......3138
    DRIVE AXLE EXPLODED VIEWS......3140
      Drive Shafts and Propshaft......3140
    FRONT GEARCASE - CENTRALIZED HILLIARD......3141
      Exploded View......3141
      Operation......3142
      Gearcase Removal......3142
      Disassembly / Inspection......3143
      Reassembly / Inspection......3147
      Setting Ring Gear Backlash......3148
      Front Gearcase Diagnosis......3149
      Gearcase Installation......3150
    FRONT GEARCASE - Active Descent Control......3151
      ADC Gearcase Exploded View......3151
      Operation......3152
      ADC Coil Testing......3153
      ADC Differential Hydraulic Circuit Bleeding......3153
      Disassembly / Inspection......3153
      ADC Gearcase Piston Replacement Procedure......3157
      Assembly......3159
    REAR HUB......3162
      Removal......3162
      Disassembly......3163
      Assembly......3164
      Installation......3164
    REAR DRIVE (CV) SHAFT SERVICE......3165
      Removal......3165
      Service......3166
      CV Boot Replacement......3167
      INSTALLATION......3168
      Drive Shaft and CV Joint Handling Tips......3168
  CH 8 - TRANSMISSION......3169
    TRANSMISSION - GENERAL......3170
      Mounting Exploded View......3170
      Torque Specifications......3171
      Special Tools......3171
      Lubrication......3171
      Gear Selector Removal......3171
      Transmission Removal......3171
      Transmission Installation......3173
      Troubleshooting Checklist......3174
    TRANSMISSION SERVICE......3175
      X2 - Touring Exploded View......3175
      500 Carbureted Exploded View......3177
      Transmission Disassembly......3179
      Transmission Assembly......3184
      Transmission Front Output Shaft Backlash Procedure and Reassembly......3185
  CH 9 - BRAKES......3191
    SPECIFICATIONS......3192
      Torque Table......3192
      Component Service Limits......3192
    BRAKE SYSTEM Exploded Views......3193
      X2, Touring System Component Exploded View......3193
      Sportsman System Component Exploded View......3194
    BRAKE CALIPER EXPLODED VIEWS......3195
      Sportsman and X2, Touring Front Caliper Assembly......3195
      X2, Touring Rear Caliper Assembly......3195
      Sportsman Rear Caliper Assembly......3196
    HYDRAULIC BRAKE SYSTEM......3196
      Operation Overview......3196
      Brake Noise Troubleshooting......3197
      Brake Bleeding / Fluid Change......3197
    FRONT MASTER CYLINDER......3199
      Removal......3199
      Installation......3199
    FRONT BRAKES......3200
      Pad Removal......3200
      Assembly......3201
      Brake Burnishing Procedure......3202
    FRONT BRAKE DISC......3202
      Inspection......3202
      Removal / Replacement......3203
    FRONT CALIPER......3204
      Removal......3204
      Inspection......3205
      Reassembly......3205
      Installation......3206
    REAR BRAKE PAD......3207
      X2, Touring Pad Removal......3207
      X2, Touring Pad Installation......3208
      Sportsman Rear Pad Removal......3209
      Sportsman Rear Pad Installation......3210
      Brake Burnishing Procedure......3210
    X2, TOURING REAR CALIPER......3211
      Removal......3211
      Inspection......3212
      Reassembly......3212
    Sportsman REAR CALIPER......3213
      Removal and Inspection......3213
      Assembly......3214
    REAR BRAKE DISC......3215
      Inspection......3215
    REAR MASTER CYLINDER......3216
      X2, Touring Exploded View......3216
      Overview......3217
      X2, Touring Rear Master Cylinder Removal and Installation......3217
      Sportsman Rear Master Cylinder Removal / Installation......3218
      Pedal Removal and Installation......3219
    TROUBLESHOOTING......3219
      Brakes Squeal......3219
      Poor Brake Performance......3219
      Lever Vibration......3219
      Caliper Overheats (Brakes Drag)......3219
      Brakes Lock......3219
  CH 10 - ELECTRICAL......3221
    GENERAL INFORMATION......3223
      Special Tools......3223
      Ignition System / Basic Electrical Components......3223
      Electrical Service Notes......3224
      Troubleshooting......3224
    POWER DISTRIBUTION MODULE (PDM)......3225
      Sportsman 500 Carbureted Overview......3225
    INSTRUMENT CLUSTER......3228
      Overview......3228
      Instrument Cluster Diagnostic Mode......3229
      Setting A New Service Interval......3231
      EFI Diagnostic Mode ......3232
      Speedometer Removal......3233
      Speedometer Installation......3233
    ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING......3234
      TEST 1 - No All Wheel Drive......3234
      TEST 2 - No Speedometer Display......3235
      TEST 3 - No Reverse Speed Limit......3235
      TEST 4 - No AWD Hub Safety Limit......3236
      TEST 5 - Reverse Speed Limiter Activated In Forward Gear......3237
      TEST 6 - Wheel Speed Sensor......3237
      TEST 7 - Fuel Gauge Display Not Working......3238
      TEST 8 - Shift Indicator Not Working......3238
    ACTIVE DESCENT CONTROL (ADC) COIL......3239
      Operation Overview - EFI Only......3239
      Diagnosing System Failures......3239
    ALL WHEEL DRIVE (AWD) COIL......3239
      Operation Overview......3239
      Diagnosing System Failures......3239
    COOLING SYSTEM COMPONENTS......3240
      Fan Control Circuit Operation......3240
      Fan Control Bypass Test......3240
      Fan Motor Current Draw Test......3240
      Coolant Temperature Sensor......3241
    GEAR POSITION INDICATOR SWITCH......3241
      Test Diagram......3241
    ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......3242
      Operation Overview......3242
      ETC Test......3242
    IGNITION SYSTEM......3243
      Overview......3243
      Components of Alternator and DC / CDI Ignition System......3244
      EFI Ignition System Testing Flow Chart......3245
      Crankshaft Position Sensor Gap......3246
      Ignition Troubleshooting......3246
      Ignition Output Test Using Gap Tester......3246
    CHARGING SYSTEM......3247
      Current Draw - Key Off......3247
      Break Even Test......3247
      Alternator Output Test......3248
      Charging System Testing Diagrams......3249
    RELAYS......3251
      Operation - EFI Models......3251
    FUSES/Circuit Breaker......3252
      Operation - EFI Models......3252
    DIFFERENTIAL SOLENOID......3252
      Overview - X2 and Touring......3252
      Testing......3252
      Replacement......3253
      Differential Solenoid Diagram - X2 and Touring......3253
    LIGHTING......3254
      High Beam Headlight Bulb Replacement......3254
      Headlight Housing Relacement......3254
      High Beam Headlight Adjustment ......3255
      Lower Headlamp Removal / Installation......3256
      Low Beam Headlight Adjustment......3257
      Headlamp Switch Test......3257
      Work Light / Differential Lockout Switch......3257
      Brake Light / Work Light Replacement......3258
      Brake Light Switch Test......3259
    SPEED SENSOR......3259
      Testing......3259
      Replacement......3259
    FUEL SENDER......3260
      Testing......3260
    ACCESSORY POWER......3260
      Wire Connections......3260
    STARTER SYSTEM ......3261
      Troubleshooting......3261
      VOLTAGE DROP TEST......3261
      Starter Lockout Troubleshooting- EFI Models......3262
      Starter Lockout Troubleshooting- Sportsman 500 Carbureted......3262
      Starter Lockout Diagram- EFI......3263
      Starter Lockout Diagram- Sportsman 500 Carbureted......3263
      Starter Motor Removal / Disassembly......3264
      Brush Inspection / Replacement......3264
      Armature Testing......3265
      Starter Reassembly......3266
      Starter Solenoid Bench Test......3266
      Starter Exploded View......3266
    STARTER DRIVE......3267
      Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement......3267
    STARTER SYSTEM TESTING FLOW CHART......3268
      Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing.......3268
    BASIC WINCH WIRING......3269
      Pre-wired Models......3269
    BATTERY......3270
      Battery Identification......3270
      Battery Activation......3270
      Terminal Preparation......3271
      Battery Removal......3271
      Battery Installation......3271
      Off Season Storage......3272
      Low Maintenance Battery Off-Season Storage......3272
      Battery Testing......3272
      Conventional Battery OCV - Open Circuit Voltage Test......3272
      Conventional Battery Specific Gravity Test......3273
      Battery Load Test......3273
      Charging Procedure......3273
      Low Maintenance Battery Check:......3274
      Low Maintenance Battery Charging......3274
      Low Maintenance Battery - OCV- Open Circuit Voltage Test......3275
      Low Maintenance Battery Load Test......3275
      Low Maintenance Battery Charging Procedure......3275
    TROUBLESHOOTING DIAGRAMS......3276
      All Wheel Drive - EFI......3276
      Fuel Pump and Ignition Coil - EFI......3276
      Reverse Override - EFI......3277
      Fan Control - EFI......3277
  CH 11 - X2/TOURING QUADRICYCLE......3279
    500 EFI X2 / TOURING QUADRICYCLE BRAKE SYSTEM......3280
      Overview......3280
      Exploded View......3281
    500 EFI X2 / TOURING QUADRICYCLE STEERING POST AND LOCK......3282
      Steering Assembly Exploded View......3282
    500 EFI QUADRICYCLE EMISSIONS SYSTEM......3283
      Overview......3283
    500 QUADRICYCLE ELECTRICAL......3284
      Turn / Hazard Signal Diagram......3284
  INDEX......3285
  WIRE DIAGRAMS......3291
Polaris  '09 Sportman 300, Sportman 400 H.O. Service Repair Manual......3299
  9921820_CH 01......3299
    TABLE OF CONTENTS......3299
      VEHICLE IDENTIFICATION......3300
        Model Identification......3300
        Engine Designation Number......3300
        Vehicle Identification Number (VIN)......3300
        Vehicle and Engine Serial Number Locations......3300
      SPECIFICATIONS......3301
        MODEL: 2009 SPORTSMAN 300......3301
        MODEL: 2009 SPORTSMAN 400 H.O......3301
        MODEL: 2009 SPORTSMAN 300......3302
        MODEL: 2009 SPORTSMAN 400 H.O......3303
      VEHICLE INFORMATION......3304
        Publication Numbers......3304
        Replacement Keys......3304
        Special Tools......3304
      MISC. SPECIFICATIONS AND CHARTS......3305
        Standard Torque Specifications......3305
        SAE Tap Drill Sizes......3306
        Metric Tap Drill Sizes......3306
        Decimal Equivalents......3306
        Conversion Table......3307
        Glossary Of Terms......3308
  9921820_CH 02......3309
    TABLE OF CONTENTS......3309
      PERIODIC MAINTENANCE CHART......3311
        Periodic Maintenance Overview......3311
        Break-In Period......3311
        Maintenance Chart Key......3311
        Maintenance Intervals......3312
        Grease Lubrication Points......3314
        Maintenance quick reference......3315
      LUBRICANTS / SERVICE PRODUCTS......3316
        Polaris Lubricants,Maintenance and Service Products......3316
      GENERAL VEHICLE INSPECTION AND MAINTENANCE......3318
        Pre-ride / Daily Inspection......3318
        Frame, Nuts, Bolts, Fasteners......3318
        Controls......3318
        Handlebar Component Locations......3318
      FUEL SYSTEM AND AIR INTAKE......3319
        Fuel System......3319
        Fuel Lines......3319
        Fuel Filter......3319
        Vent Lines......3319
        Throttle Operation......3320
        Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment......3320
        Choke (Enricher) Adjustment......3320
        Fuel Valve......3320
        Carburetor Draining......3321
        Pilot Screw Location......3321
        Pilot Screw and Idle Speed Adjustment......3322
        Main Air Filter Cleaning......3322
        Air Filter / Pre-Filter Service (300)......3322
        Air Filter / Pre-Filter Service (400 H.O.)......3323
        Air Box Sediment Tube......3324
      ENGINE......3325
        Engine Oil Level (Sportsman 300)......3325
        Engine Oil and Filter Change (Sportsman 300)......3325
        Engine Oil Level (Sportsman 400 H.O.)......3327
        Engine Oil and Filter Change (Sportsman 400 H.O.)......3327
        Oil Pump Priming Procedure (Sportsman 400 H.O.)......3329
        Engine Breather Hose......3329
        Engine Breather Filter (Sportsman 300)......3329
        Engine Breather Filter (Sportsman 400 H.O.)......3329
        Valve Clearance (Sportsman 300)......3330
        Valve Clearance (Sportsman 400 H.O.)......3331
        Recoil Housing......3332
        Compression and Leakdown Tests......3332
        Exhaust Silencer Cleaning......3333
        Engine Mount Fastener Torque ......3333
      TRANSMISSION / FRONT GEARCASE......3334
        Transmission Lubrication......3334
        Front Gearcase Lubrication......3335
      COOLING SYSTEM (400 H.O.)......3336
        Cooling System Overview......3336
        Coolant Level Inspection......3336
        Coolant Strength / Type......3336
        Cooling System Pressure Test......3337
        Cooling System Hoses......3337
        Radiator......3337
        Coolant Drain / Radiator Removal......3337
      CVT / FINAL DRIVE / WHEEL AND TIRE......3338
        CVT Drying......3338
        Drive Shaft Boot Inspection......3339
        Wheel and Hub Torque Table......3339
        Wheel Removal......3339
        Wheel Installation......3339
        Tire Pressure......3340
        Tire Inspection......3340
      ELECTRICAL AND IGNITION SYSTEM......3340
        Battery Maintenance......3340
        Battery Removal (Sportsman 300)......3341
        Battery Installation (Sportsman 300)......3341
        Battery Removal (Sportsman 400 H.O.)......3342
        Battery Installation (Sportsman 400 H.O.)......3342
        Spark Plug Service......3343
      STEERING AND SUSPENSION......3344
        Steering Inspection......3344
        Tie Rod End / Steering Inspection ......3344
        Camber and Caster......3344
        Toe Alignment......3344
        Toe Alignment Adjustment......3345
        Suspension Inspection......3346
        Suspension Spring Preload Adjustment......3346
      BRAKE SYSTEM......3346
        Brake Fluid Inspection......3346
        Brake Pad Inspection......3347
        Hose / Fitting Inspection......3347
        Brake Pedal Freeplay......3347
  9921820_CH 03......3349
    TABLE OF CONTENTS......3349
    300 ENGINE......3351
      TOOLS......3353
        Special Tools......3353
      TORQUE SPECIFICATIONS......3353
        Engine Torque Specifications......3353
        Torque Pattern (Cylinder Head)......3353
      GENERAL ENGINE SERVICE......3354
        Engine Exploded View......3354
        Engine Service Data......3355
        Engine Service Data......3356
        Oil Flow Diagram......3358
        Piston Identification......3359
        Piston Ring Identification......3359
        Accessible Components......3359
      ENGINE SERVICE......3360
        Engine Removal......3360
        Engine Lubrication......3362
        Oil Flow / Pressure Test......3362
        Engine Breather / Oil separator......3362
        Cam Chain Tensioner Removal......3363
        Cam Chain Tensioner Inspection......3363
        Rocker Arm / Rocker Arm Shaft Disassembly and Inspection......3364
        Camshaft Removal......3365
        Camshaft Inspection......3365
        Cylinder Head Removal......3366
        Cylinder Head Inspection......3366
        Cylinder Head Warp Inspection......3366
        Combustion Chamber Inspection......3367
        Cylinder Head Disassembly......3367
        Valve Inspection ......3367
        Valve Seat Reconditioning......3368
        Cylinder Head Assembly......3370
        Valve Sealing Test......3370
        Engine Bottom End Disassembly......3370
        Cam Chain Guide And Tensioner Blade......3371
        Piston Removal......3371
        Cylinder Inspection......3371
        Cylinder Hone Selection / Honing Procedure......3372
        Honing To Deglaze......3372
        Piston Inspection......3373
        Piston Ring Installed Gap......3374
        Flywheel Removal / Inspection......3374
        Starter Drive Removal / Inspection......3375
        Cam Chain Drive Sprocket Removal / Inspection......3375
        Oil Pump Inspection / Removal......3376
        Starting Clutch and Engine Braking Clutch Removal / Inspection......3376
        Starting Clutch Assembly......3377
        Starting Clutch Exploded View......3379
        Crankcase Disassembly ......3380
        Crankcase Separation......3380
        Crankshaft Removal......3380
        Crankshaft / Cam Chain / Sprocket Inspection......3380
        Crankcase Oil Passages & Pressure Relief Valve......3381
        Camshaft Chain......3381
        Balance Shaft Bearing Inspection......3382
        Crankcase Oil Pickup Strainer Inspection......3382
        Bearing / Seal Installation......3382
        End Play Inspection / Adjustment......3382
        Crankshaft End Play Adjustment......3383
        Balancer Shaft End Play Adjustment......3384
        Crankcase Reassembly......3385
        Cam Chain, Oil Pump, & Tensioner Blade Installation......3386
        Piston Ring Installation......3387
        Piston Installation......3387
        Cylinder Installation......3388
        Cylinder Head and Camshaft Installation......3388
        Camshaft Installation & Timing......3389
        Cam Chain Tensioner Installation......3390
        Rocker Arm Installation......3390
        Starter Drive Assembly......3391
        Engine Installation Notes......3391
      TROUBLESHOOTING......3392
        Spark Plug Fouling troubleshooting......3392
        Engine Troubleshooting......3392
    400 H.O. ENGINE......3395
      SPECIAL TOOLS......3397
      SPECIFICATIONS......3397
        Torque Specifications......3397
        Engine Service Data......3398
        Engine Service Data......3399
        Engine Fastener Torque Patterns......3400
      GENERAL ENGINE SERVICE......3400
        Accessible Components......3400
        Engine Removal......3401
        Crankshaft Straightening......3404
        Engine Lubrication - EH460PLE020......3405
        Oil Pressure Test - EH460PLE020......3405
        Oil Flow - EH460PLE020......3405
        EH460PLE020 Oil Flow Diagram......3406
        EH460PLE020 Engine Exploded View......3407
      COOLING SYSTEM......3408
        Cooling System Specifications......3408
        Cooling System Layout and Testing......3408
      ENGINE DISASSEMBLY......3410
        Cam Chain Tensioner / Rocker Arm / Camshaft Removal......3410
        Cam Chain Tensioner Inspection......3410
        Rocker Arm / Shaft Inspection......3411
        Camshaft Removal......3412
        Automatic Compression Release Removal / Inspection......3413
        Automatic Compression Release Installation......3413
        Camshaft Inspection......3414
        Cylinder Head Removal......3414
        Cylinder Head Exploded View, EH460PLE020......3415
        Cylinder Head Inspection......3416
        Cylinder Head Warpage......3416
        Cylinder Head Disassembly......3416
        Valve Inspection......3417
        Combustion Chamber......3417
        Valve Seat Reconditioning......3418
        Cylinder Head Assembly......3420
        Valve Sealing Test......3421
        Valve Clearance Adjustment......3421
        Cylinder / Piston Removal and Inspection......3421
        Piston Removal......3422
        Cylinder Inspection......3423
        Cylinder Hone Selection / Honing Procedure......3423
        Honing to Oversize......3424
        Cleaning the Cylinder After Honing......3424
        Piston-to-Cylinder Clearance......3424
        Piston / Rod Inspection......3425
        Piston Ring Installed Gap......3425
        Starting Clutch Removal / Inspection......3426
        Starting Clutch Assembly......3427
        Starting Clutch Exploded View......3429
        Crankcase Disassembly......3430
        Starter Drive Removal / Inspection......3430
        Flywheel and Stator Removal / Inspection......3430
        Cam Chain / Tensioner Blade......3431
        One Way Valve......3431
        Crankcase Separation......3432
        Oil Pump Removal / Inspection......3432
        Oil Pump Assembly......3433
        Counter Balancer Shaft Removal / Inspection......3433
        Crankshaft Removal / Inspection......3434
        Crankcase Bearing Inspection ......3434
        Oil Seal / Mechanical Seal Removal (Engine Disassembled)......3435
        Crankcase Inspection ......3435
        Bearing Installation......3435
        End Play Inspection / Adjustment......3435
        Crankshaft End Play Adjustment......3435
        Counter Balancer Shaft End Play Adjustment......3437
        Oil Pump Shaft End Play Adjustment......3437
      ENGINE REASSEMBLY......3438
        Pump Shaft Oil Seal Installation......3438
        Crankshaft / Counter Balance / Oil Pump Installation......3438
        Crankcase Assembly......3438
        Water Pump Mechanical Seal Installation......3438
        Water Pump Mechanical Seal Removal (Engine Installed)......3439
        One Way Valve Installation......3440
        Cam Chain Drive Sprocket Installation......3440
        Tensioner Blade Installation......3440
        Piston Ring Installation......3440
        Piston Installation......3441
        Cylinder Installation......3441
        Cylinder Head Installation......3442
        Cam Chain / Camshaft Installation......3443
        Camshaft Timing......3443
        Camshaft Timing Illustration......3444
        Cam Chain Tensioner Installation......3445
        Stator, Flywheel and Starter Drive Installation......3445
        Rocker Shaft / Rocker Arm Assembly Installation......3446
        Thermostat Installation......3446
        Oil Pipes......3446
        Engine Installation Notes......3446
        Oil Pump Priming Procedure......3447
      TROUBLESHOOTING......3448
        Engine......3448
        Spark Plug Fouling......3449
        Cooling Troubleshooting......3449
  9921820_CH 04......3451
    TABLE OF CONTENTS......3451
      CARBURETION INFORMATION......3452
        Special Tools......3452
        Carburetor Jetting......3452
        Mikuni Optional Jet Part Numbers......3452
      CV CARBURETION SYSTEM......3453
        Carburetor Venting Exploded View......3453
        Carburetor Venting......3453
        BST 34 Carburetor Exploded View (Upper Components)......3454
        BST 34 Carburetor Exploded View (Lower Components)......3455
        Carburetor Function......3456
        Mikuni CV Carb Operation......3456
        Starter System (Choke or Enrichment)......3457
        Pilot (Idle and Slow) System ......3458
        Main System......3458
        Float System ......3459
        Pilot Screw......3459
        Air/Fuel Mixture Ratio......3460
        Jet Needle......3460
        Needle Jet......3460
        Throttle Opening vs. Fuel Flow......3461
      CARBURETOR SERVICE - MIKUNI CV......3461
        Carburetor Disassembly......3461
        Carburetor Cleaning......3462
        Carburetor Inspection......3462
        Carburetor Assembly......3463
        Float Height Adjustment......3463
        Needle and Seat Leakage Test......3464
        Fuel Level test......3464
        Troubleshooting......3465
      FUEL TANK / FUEL DELIVERY SYSTEM......3466
        Fuel Tank / Fuel Delivery System......3466
  9921820_CH 05......3467
    TABLE OF CONTENTS......3467
      TORQUE SPECIFICATIONS......3468
      PLASTIC RETAINER INSERTS......3468
        Removal / Installation......3468
      BODY ASSEMBLY......3469
        Exploded View......3469
      SEAT / SIDE PANEL / TANK COVER......3470
        Removal / Installation......3470
      FRONT BUMPER / CAB / FOOTWELL......3470
        Front Bumper Removal / Installation......3470
        Front Cab Removal......3471
        Front Cab Installation......3471
        Footwell Removal / Installation......3471
      REAR RACK / REAR CAB......3472
        Rear Rack Removal / Installation......3472
        Rear Cab Removal / Installation......3472
      INSTRUMENT POD......3472
        Pod / Key Switch / Choke / Instrument Cluster Removal / Installation......3472
      STEERING......3473
        Steering Post Removal......3473
        Steering Post Installation......3474
        Handlebar Block Installation Procedure......3475
        Tie Rod / Tie Rod End Replacement......3475
      FRONT SUSPENSION / A-ARM......3476
        Exploded View......3476
        A-arm Removal......3476
        Ball Joint Replacement......3477
        A-arm Installation......3477
      FRONT STRUT......3478
        Exploded View......3478
        Front Strut Removal......3479
        Front Strut Installation......3479
      REAR CONTROL ARMS......3480
        Exploded View......3480
        Control Arm Removal / Installation......3481
      REAR TORSION BAR......3482
        Exploded View......3482
      REAR SHOCKS / SPRINGS......3483
        Exploded View......3483
        Shock Removal / Installation......3483
        Shock / Spring Replacement......3483
      DECAL REPLACEMENT......3483
  9921820_CH 06......3485
    TABLE OF CONTENTS......3485
      CVT SYSTEM......3486
        Torque Specifications......3486
        Clutch Roller Weights......3486
        Special Tools......3486
        CVT Operation Overview......3487
        Starting Clutch Operation......3487
        Drive Clutch Operation......3487
        Driven Clutch Operation......3487
        Engine Braking Clutch......3488
        CVT Maintenance / Inspection......3488
        CVT Drying......3488
        CVT Overheating / Diagnosis......3490
        CVT System Disassembly......3491
        Drive Belt Inspection......3492
        Drive Clutch Service......3492
        Driven Clutch Service......3494
        Starting Clutch Exploded View (Sportsman 300)......3496
        Starting Clutch Exploded View (Sportsman 400 H.O.)......3497
      TRANSMISSION......3498
        Torque Specifications......3498
        Shift Linkage Inspection......3498
        Gear Selector Removal......3498
        Transmission Removal......3498
        Transmission Disassembly ......3500
        Transmission Reassembly......3502
        Transmission Installation......3503
        Transmission Exploded View......3504
  9921820_CH 07......3505
    TABLE OF CONTENTS......3505
      GENERAL SPECIFICATIONS......3506
        Torque Specifications......3506
        Special Tools......3506
      FRONT BEARING CARRIER......3506
        Bearing Carrier Removal......3506
        Bearing Removal......3507
        Bearing Installation......3507
        Bearing Carrier Installation......3508
      PROPSHAFT SERVICE......3509
        Removal......3509
        Installation......3509
      PROPSHAFT U-JOINT SERVICE......3509
        Disassembly......3509
        Assembly......3510
      FRONT GEARCASE CENTRALIZED HILLIARD......3511
        All Wheel Drive Operation......3511
        Centralized Hilliard Exploded View......3512
        AWD Diagnosis......3513
        Gearcase Removal......3514
        Disassembly......3515
        Gearcase Reassembly......3518
        Installation......3520
      REAR BEARING CARRIER......3521
        Bearing Carrier Inspection......3521
        Bearing Carrier Removal......3521
        Bearing Removal......3522
        Bearing Installation......3522
        Bearing Carrier Installation......3522
      DRIVE SHAFT SERVICE......3523
        Front Drive Shaft Removal......3523
        Rear Drive Shaft Removal......3524
        Drive Shaft / CV Joint Handling Tips......3524
        Outer CV Joint / Boot Replacement......3524
        Inner Plunging Joint / Boot Replacement......3526
        Exploded View......3527
        Front Drive Shaft Installation......3527
        Rear Drive Shaft Installation......3528
  9921820_CH 08......3529
    TABLE OF CONTENTS......3529
      SPECIFICATIONS......3530
        General Brake Specifications......3530
        General Torque Specifications......3530
        Special Tools......3530
      BRAKE SYSTEM SERVICE NOTES......3531
      BRAKE NOISE TROUBLESHOOTING......3531
      HYDRAULIC BRAKE SYSTEM OPERATION......3532
      BRAKE SYSTEM EXPLODED VIEW......3532
      BRAKE CALIPER......3533
        Exploded View......3533
      HAND MASTER CYLINDER......3533
        Exploded View......3533
      BRAKE BLEEDING......3534
        Fluid Replacement......3534
        Bleeding Procedure......3534
      HAND MASTER CYLINDER......3536
        Removal......3536
        Disassembly......3536
        Installation......3536
      FOOT MASTER CYLINDER......3537
        Operation Overview......3537
      FOOT BRAKE PEDAL......3537
        Foot Pedal Removal / Installation......3537
        Foot Master Cylinder Removal / Installation......3537
      BRAKE PADS......3538
        Pad Removal......3538
        Pad Installation......3539
        Brake Burnishing Procedure......3539
      CALIPER SERVICE......3540
        Caliper Removal......3540
        Caliper Disassembly......3540
        Caliper Inspection......3541
        Caliper Reassembly......3541
        Caliper Installation......3542
      BRAKE DISC SERVICE......3542
        Disc Inspection......3542
        Disc Removal / Replacement......3543
      TROUBLESHOOTING......3544
        Brake Squeal......3544
  9921820_CH 09......3545
    TABLE OF CONTENTS......3545
      GENERAL INFORMATION......3547
        Special Tools......3547
        Electrical Service Notes......3547
        Component Locations......3547
      INSTRUMENT CLUSTER......3548
        Display Functions......3548
        AWD Control System......3549
        Instrument Cluster Overview......3550
        Rider Information Display......3550
        Display Modes......3551
        Instrument Cluster Removal......3551
      ALL WHEEL DRIVE COIL......3551
        Operation Overview......3551
        Diagnosing System Failures......3551
      SPEED SENSOR......3552
        Vehicle Speed Sensor......3552
      ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......3553
        Electronic Throttle Control (ETC) Switch......3553
      GEAR SELECTOR SWITCH......3553
        Switch Test......3553
      ETC / REVERSE RPM CONTROL......3554
        ETC / Reverse RPM Control System......3554
      FUSIBLE LINK / FUSES / CIRCUIT BREAKERS......3555
        Fusible Link......3555
        Fuse and Circuit Breaker Function......3555
      FAN MOTOR / COOLING SYSTEM THERMAL SWITCHES (400 H.O.)......3556
        Cooling System Electrical Break-Out Diagram......3556
        Fan Motor Circuit Operation......3557
        Fan Motor Circuit Bypass Test......3557
        Fan Switch (Thermal Switch) Replacement......3557
        Engine Temperature Switch Operation......3557
        Engine Temperature Switch Replacement......3557
      IGNITION SYSTEM......3558
        DC/CDI Ignition System Diagram......3558
        RPM Limit Modes......3559
        Ignition System Troubleshooting......3559
        Ignition Coil Testing (Sportsman 300)......3559
        Ignition Coil Testing (Sportsman 400 H.O.)......3559
        Cranking Output Tests Using Peak Reading Adaptor or Volt Ohm Meter......3560
        Ignition Timing......3560
        Ignition System Testing......3561
      LIGHTS......3562
        Headlight Adjustment......3562
        Headlight Lamp Replacement......3562
        Tail / Brake Light Bulb Replacement......3562
      CHARGING SYSTEM......3563
        Charging System Diagram......3563
        Charging System Testing Flow Chart......3564
        Current Draw - Key Off......3565
        Charging System “Break Even” Test......3565
        Charging System Alternator Tests......3566
      BATTERY SERVICE......3567
        Battery Identification......3567
      CONVENTIONAL BATTERY (SPORTSMAN 300)......3567
        Battery Activation......3567
        Battery Inspection......3568
        Battery Removal / Installation......3568
        Conventional Battery Testing......3568
        OCV - Open Circuit Voltage Test......3568
        Specific Gravity Test......3568
        Load Test......3569
        Battery Off Season Storage......3569
        Charging Procedure (Conventional)......3569
      LOW MAINTENANCE BATTERY (SPORTSMAN 400 H.O.)......3570
        General Battery Information......3570
        Battery Removal / Installation......3570
        Battery Testing......3570
        OCV - Open Circuit Voltage Test......3570
        Load Test......3570
        Battery Off Season Storage......3571
        Charging Procedure (Low Maintenance) ......3571
      STARTER SYSTEM......3572
        Starter / Starter Lockout System Diagram......3572
        Troubleshooting......3573
        Voltage Drop Testing......3573
        Starter Motor Removal / Disassembly ......3573
        Brush Inspection / Replacement......3574
        Armature Testing......3575
        Starter Reassembly / Installation......3576
        Starter Drive......3577
        Starter Solenoid Bench Test......3577
        Starter Solenoid Operation......3577
        Starter Motor Exploded View......3578
      STARTER SYSTEM TESTING FLOW CHART......3579
        Condition: Starter motor fails to turn over the engine......3579
  9921820_WIRE DIAGRAM......3581
    Sportsman 300......3581
    Sportsman 400 H.O......3587
Polaris  '09 Sportman XP 850, XP850 EPS Service Repair Manual......3591
  GENERAL INFORMATION......3591
    VEHICLE IDENTIFICATION......3592
      Model Identification......3592
      Engine Designation Number......3592
      Vehicle Identification Number (VIN)......3592
      Vehicle and Engine Serial Number Locations......3592
    VEHICLE INFORMATION......3593
      Publication Numbers......3593
      Replacement Keys......3593
      Special Tools......3593
    SPECIFICATIONS......3594
      MODEL: 2009 SPORTSMAN XP 850......3594
      MODEL: 2009 SPORTSMAN XP 850 EPS......3594
      2009 SPORTSMAN XP 850 / XP 850 EPS......3595
    MISC. SPECIFICATIONS AND CHARTS......3596
      Conversion Table......3596
      Standard Torque Specifications......3597
      SAE Tap / Drill Sizes......3598
      Metric Tap / Drill Sizes......3598
      Decimal Equivalents......3598
      Glossary of Terms......3599
  MAINTENANCE......3601
    PERIODIC MAINTENANCE CHART......3602
      Periodic Maintenance Overview......3602
      Break-In Period......3602
      Maintenance Chart Key......3602
      Maintenance Intervals......3603
      Grease Lubrication Points......3605
      Maintenance Quick Reference......3606
      Maintenance Quick Reference, Continued.......3607
    LUBRICANTS / SERVICE PRODUCTS......3608
      Polaris Lubricants,Maintenance and Service Products......3608
    GENERAL VEHICLE INSPECTION AND MAINTENANCE......3609
      Pre-ride / Daily Inspection......3609
      Frame, Nuts, Bolts, Fasteners......3609
      Controls......3609
    FUEL SYSTEM AND AIR INTAKE......3609
      Fuel System......3609
      Fuel Lines......3609
      Fuel Filters......3610
      Vent Line......3610
      Throttle Operation......3610
      Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment......3610
      Air Filter / Pre-Filter Service......3611
    ENGINE......3612
      Engine Oil Level......3612
      Engine Oil and Filter Change......3612
      Engine Breather Hose......3613
      Engine Breather Assembly......3613
      Valve Clearance Adjustment......3614
      Compression and Leakdown Tests......3615
      Exhaust Silencer Cleaning......3616
      Engine Mount Fastener Torque ......3616
    TRANSMISSION AND GEARCASES......3617
      Transmission Lubrication......3617
      Front Gearcase Lubrication......3618
      Front Gearcase ADC Fluid......3619
      Rear Gearcase Lubrication......3620
    COOLING SYSTEM......3621
      Cooling System Overview......3621
      Coolant Level Inspection......3621
      Cooling System Hoses......3622
      Coolant Strength / Type......3622
    PVT / FINAL DRIVE / WHEEL AND TIRE......3623
      PVT Drying......3623
      Drive Belt Removal......3623
      Drive Shaft Boot Inspection......3623
      Wheel and Hub Torque Table......3624
      Wheel Removal......3624
      Wheel Installation......3624
      Tire Pressure......3625
      Tire Inspection......3625
    ELECTRICAL AND IGNITION SYSTEM......3625
      Battery Maintenance......3625
      Battery Removal......3626
      Battery Installation......3626
      Spark Plug Service......3626
      Engine / Chassis Ground......3627
    STEERING......3628
      Steering Inspection......3628
      Power Steering Unit (EPS Models)......3628
      Tie Rod End / Steering Inspection ......3629
      Toe Alignment......3629
      Toe Alignment Adjustment......3630
    SUSPENSION......3630
      Suspension Inspection......3630
      Suspension Spring Pre-Load Adjustment......3630
    BRAKE SYSTEM......3631
      Brake Fluid Inspection......3631
      Brake Pad Inspection......3631
      Hose / Fitting Inspection......3631
      Auxiliary Brake Pedal......3632
    MAINTENANCE LOG......3633
  ELECTRONIC FUEL INJECTION......3635
    SPECIAL TOOLS......3636
      Part Numbers / Descriptions......3636
      Fuel Pressure Gauge Kit - PU-43506-A......3636
      Fuel Pressure Gauge Adaptor - PS-48762......3636
      Throttle Position Sensor Tester Kit - 2201519......3636
      Digital Wrench™ Diagnostic Software PU-47063......3637
      Digital Wrench™ SmartLink Module Kit - PU-47471......3637
      Digital Wrench™ - Diagnostic Connector......3637
      Digital Wrench™ - Download Website......3637
    FUEL TANK......3638
      Exploded View......3638
    FUEL LINE......3639
      Quick Connect Removal / Installation......3639
    EFI SERVICE NOTES......3639
    EFI SYSTEM LAYOUT......3640
      Exploded View......3640
    EFI COMPONENTS......3641
      Identification / Location......3641
    ELECTRONIC FUEL INJECTION......3643
      General Information......3643
      EFI Operation Overview......3643
      Initial Priming / Starting Procedure......3643
    ELECTRONIC CONTROL UNIT (ECU)......3644
      Operation Overview......3644
      ECU Service......3644
      ECU Removal / Replacement......3645
    FUEL PUMP......3645
      Operation......3645
      Fuel Sender Test......3646
      Fuel Pump Test......3646
      Fuel Pump / Fuel Tank Removal......3647
      Fuel Pump / Fuel Tank Installation......3648
    FUEL PRESSURE REGULATOR......3648
      Operation Overview......3648
    FUEL INJECTORS......3648
      Operation Overview......3648
      Fuel Injector Service......3648
      Fuel Injector Test......3649
      Fuel Injector Replacement......3649
    CRANKSHAFT POSITION SENSOR (CPS)......3650
      Operation Overview......3650
      CPS Test......3650
      CPS Replacement......3650
    TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)......3651
      Operation Overview......3651
      T-MAP Test......3651
      T-MAP Replacement......3651
    IDLE AIR CONTROL VALVE (IAC)......3651
      Operation Overview......3651
      IAC Test......3651
      IAC Replacement......3652
    THROTTLE POSITION SENSOR (TPS)......3653
      Operation Overview......3653
      TPS Resistance Tests......3653
      TPS Tester Kit......3653
      Checking TPS Reading......3654
      TPS Adjustment......3655
      TPS Replacement......3656
    ENGINE COOLANT TEMPERATURE SENSOR (ECT)......3656
      Operation Overview......3656
      ECT Sensor Test......3656
      ECT Sensor Replacement......3657
    IGNITION COIL......3657
      Operation Overview......3657
      Ignition Coil Tests......3657
      Ignition Coil and HT Lead Replacement......3658
    EFI DIAGNOSTICS......3659
      Instrument Cluster Trouble Code Display......3659
    FUEL SYSTEM TROUBLESHOOTING......3662
      Fuel Starvation / Lean Mixture......3662
      Rich Mixture......3662
      Poor Idle......3662
    EFI SYSTEM BREAK-OUT DIAGRAMS......3663
      Fuel Injector Circuit (PTO)......3664
      Fuel Injector Circuit (MAG)......3664
      Idle Air Control (IAC) Circuit......3665
      Crankshaft Position Sensor (CPS) Circuit......3665
      Fuel Pump / Fuel Level Sensor Circuit......3666
      Fuel Pump Circuit......3667
      Fuel Gauge Circuit......3667
      Engine Coolant Temperature Sensor (ECT) Circuit ......3668
      Throttle Position Sensor (TPS) Circuit......3668
      Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit......3669
      Diagnostic Connector Circuit......3669
      Diagnostic Connector Circuit (EPS Models)......3670
  COOLING SYSTEM......3671
    SPECIAL TOOLS......3672
    TORQUE SPECIFICATIONS......3672
    COOLING SYSTEM......3672
      Cooling System Layout and Testing......3672
      Cooling System Specifications......3673
      Cooling System Bleeding Procedure......3674
    RADIATOR......3674
      Radiator Cleaning......3674
      Coolant Drain / Radiator Removal......3674
    WATER PUMP SERVICE......3676
      Water Pump Impeller Removal......3676
      Water Pump Mechanical Seal Replacement......3677
      Water Pump Shaft & Bearing Replacement......3678
      Stator Cover Installation......3679
      Water Pump Assembly / Torque Specifications......3680
      Stator Cover Assembly Torque Specifications......3681
    THERMOSTAT......3682
      Removal (Engine Installed)......3682
      Installation......3682
    TROUBLESHOOTING......3682
      Cooling System......3682
  ENGINE......3683
    GENERAL INFORMATION - ENGINE......3685
      Special Tools......3685
      Engine Lubrication Specifications......3685
      Oil Pressure Test......3685
      Oil Flow Diagram......3686
      Engine Specifications - EH085OLE-011......3687
    ENGINE ASSEMBLY VIEWS AND TORQUE VALUES......3689
      Torque & Torque Sequence - Main Engine Components......3689
      Valve Cover / Breather Valve......3690
      Camshaft Carrier / Camshaft / Rocker Arm......3691
      Cylinder Head / Valve / IAFM......3692
      Valve & Spring Height Detail......3693
      Piston / Connecting Rod......3694
      Crankshaft......3695
      Crankcase......3696
      Crankcase - Upper......3697
      Balance Shaft / Balance Shaft Timing......3698
      Crankcase (Lower) With Oil Pump......3699
      Water Pump Coupler......3700
      Water Pump / Water Pump Coupler / Stator / Flywheel......3701
      Drive Coupler (Rear) / Starter Gear......3702
    ENGINE SERVICE......3703
      Accessible Engine Components......3703
      Top-End Service (Engine in Chassis)......3703
      Crankcase Cylinder Service Information......3703
      Engine Removal......3703
      Engine Installation Notes......3707
    ENGINE DISASSEMBLY AND INSPECTION......3708
      Valve Cover / Breather Valve......3708
      Rocker Carrier / Camshaft Removal......3708
      Rocker Arm / Rocker Arm Shaft Inspection......3709
      Camshaft / Camshaft Bore Inspection......3710
      Cylinder Head Removal ......3710
      Cylinder Head Cleaning......3710
      Cylinder Head Warp Inspection......3711
      Cylinder Head......3711
      Valve Inspection......3712
      Combustion Chamber......3713
      Valve Guide Removal / Installation......3713
      Valve Seat Reconditioning......3714
      Cylinder Head Assembly......3716
      Valve Sealing Test......3716
      Cylinder Head Installation......3717
      Camshaft / Carrier Assembly......3718
      Camshaft / Camshaft Carrier Installation......3718
      Camshaft Timing......3719
      Cam Chain Tensioner Installation......3720
      Camshaft Timing - Quick Reference......3721
      Crankcase Disassembly......3722
      Crankcase (Lower) / Oil Pump Disassembly......3723
      Crankcase Disassembly (Upper)......3725
      Piston / Connecting Rod Removal......3725
      Counterbalance Shaft Removal / Inspection......3726
      Counterbalance Split Gear Replacement......3726
      Crankshaft / Cam Chain Removal......3728
      Cam Chain / Sprocket Inspection......3728
      Crankcase Inspection (Lower)......3728
      Crankshaft Inspection......3728
      Connecting Rod Inspection......3729
      Connecting Rod Big End Bearing Selection......3730
      Piston / Piston Ring Inspection......3730
      Piston Ring Removal......3730
      Piston Ring Installed Gap......3731
      Piston Pin Bore Inspection......3731
      Cylinder Inspection......3731
      Piston-to-Cylinder Clearance......3732
      Honing - Important Information......3732
    ENGINE ASSEMBLY......3733
      Crankcase Preparation - Upper......3733
      Piston Ring Installation......3733
      Piston / Connecting Rod Assembly......3734
      Piston / Connecting Rod Installation......3734
      Crankshaft Installation......3735
      Oil Passage Tube......3735
      Crankcase Assembly - Upper ......3736
      Balance Shaft Installation......3737
      Balance Shaft Timing......3738
      Crankcase Preparation (Lower)......3739
      Crankcase Sealant and Torque Values......3740
      Crankcase Assembly......3741
    WATER PUMP......3741
      Water Pump Impeller Removal......3741
      Water Pump Mechanical Seal Replacement / Coupler Shaft & Bearing Replacement......3741
    TROUBLESHOOTING......3742
      Engine......3742
  TRANSMISSION......3745
    TRANSMISSION SPECIFICATIONS......3746
      Torque Specifications......3746
      Lubrication Specifications......3746
    SHIFT LINKAGE / GEAR SELECTOR......3746
      Shift Linkage Inspection......3746
      Gear Selector Removal......3746
    TRANSMISSION SERVICE......3747
      Transmission Removal......3747
      Transmission Disassembly ......3748
      Transmission Shaft Service......3752
      Transmission Assembly......3754
      Transmission Installation......3758
      Transmission Exploded View......3760
    TROUBLESHOOTING......3762
      Troubleshooting Checklist......3762
  CLUTCHING (PVT)......3763
    SPECIAL TOOLS AND SUPPLIES......3764
    TORQUE SPECIFICATIONS......3764
      PVT System Fastener Torques......3764
    PVT SYSTEM OVERVIEW......3764
      General Operation......3764
      Drive Clutch Operation......3764
      Shift Weights......3765
      Driven Clutch Operation......3765
      PVT Break-In (Drive Belt / Clutches)......3765
      Maintenance / Inspection......3765
      Overheating / Diagnosis......3766
    PVT SYSTEM SERVICE......3767
      PVT Sealing and Ducting Components......3767
      Disassembly......3768
      Assembly......3769
    DRIVE BELT......3771
      Belt Removal......3771
      Belt Inspection......3772
      Belt Installation......3772
      PVT Break-In (Drive Belt / Clutches)......3772
    DRIVE CLUTCH SERVICE......3773
      Spring Specifications......3773
      Exploded View......3774
      Clutch Disassembly......3774
      Spider Removal......3775
      Roller, Pin, and Thrust Washer Inspection......3776
      Button To Tower Clearance Inspection......3776
      Shift Weight Inspection......3776
      Bearing Inspection......3777
      Clutch Inspection......3777
      Moveable Sheave Bushing Inspection......3778
      Bushing Service......3779
      Clutch Assembly......3781
    DRIVEN CLUTCH SERVICE......3782
      Clutch Disassembly ......3782
      Bushing Service......3784
      Clutch Assembly......3786
      Exploded View......3789
    TROUBLESHOOTING......3790
  FINAL DRIVE......3793
    GENERAL SPECIFICATIONS......3794
      Torque Specifications......3794
      Special Tools......3794
    WHEELS......3794
      Removal......3794
      Installation......3794
    WHEEL HUBS......3795
      Front Hub Exploded View......3795
      Rear Hub Exploded View......3795
    FRONT BEARING CARRIER......3796
      Inspection / Removal......3796
      Bearing Replacement......3797
      Installation......3798
    FRONT DRIVE SHAFT......3799
      Removal......3799
      Installation......3800
    FRONT PROPSHAFT......3801
      Removal......3801
      Installation......3801
    PROPSHAFT U-JOINT SERVICE......3801
      Disassembly......3801
      Assembly......3802
    FRONT GEARCASE - CENTRALIZED HILLIARD......3803
      Exploded View......3803
      AWD Operation......3804
      ADC Operation......3805
      AWD Diagnosis......3806
      Gearcase Removal......3807
      Gearcase Disassembly / Inspection......3808
      Gearcase Assembly......3812
      Setting Ring Gear Backlash......3814
      Gearcase Installation......3815
      ADC System Fluid Bleeding......3817
    REAR BEARING CARRIER......3818
      Inspection / Removal......3818
      Bearing Replacement......3819
      Bushing Replacement......3820
      Installation......3820
    REAR DRIVE SHAFT......3822
      Removal......3822
      Installation......3823
    DRIVE SHAFT SERVICE......3824
      Drive Shaft / CV Joint Handling Tips......3824
      Outer CV Joint / Boot Replacement......3824
      Inner Plunging Joint / Boot Replacement......3826
      Drive Shaft Exploded View......3828
    REAR PROPSHAFT......3829
      Removal......3829
      Installation......3829
    REAR GEARCASE......3830
      Gearcase Removal......3830
      Gearcase Disassembly and Inspection......3832
      Gearcase Bearing and Seal Replacement......3833
      Gearcase Assembly......3834
      Gearcase Installation......3835
      Gearcase Exploded View......3836
  BODY / FRAME......3837
    TORQUE SPECIFICATIONS......3838
    DECAL REPLACEMENT......3838
    SPECIAL TOOLS......3838
      Plastic Push Rivet Removal......3838
      Multi-Function Pliers......3838
    SEAT AND SIDE PANELS......3839
      Removal / Installation......3839
    FRONT RACK......3839
      Removal / Installation......3839
    FRONT BUMPER......3840
      Removal / Installation......3840
    MUD GUARDS......3840
      Removal / Installation......3840
    FOOTWELLS......3840
      Removal / Installation......3840
    FRONT CAB......3841
      Removal......3841
      Installation......3841
    REAR RACK......3842
      Removal / Installation......3842
    REAR BUMPER COVERS......3842
      Removal / Installation......3842
    REAR CAB......3842
      Removal / Installation......3842
    HEADLIGHT POD......3843
      Disassembly / Removal......3843
      Assembly / Installation......3843
    MAIN FRAME......3844
      Frame Support Exploded View......3844
    CHASSIS......3845
      Body Plastic Removed View......3845
  STEERING / SUSPENSION......3847
    GENERAL SPECIFICATIONS......3848
      Torque Specifications......3848
    HANDLEBAR......3848
      Removal / Replacement......3848
      Installation......3849
    STEERING......3849
      Steering Post Removal......3849
      Steering Post Installation......3850
      Steering Exploded View......3851
    STEERING (EPS MODELS)......3852
      Upper Steering Post Removal......3852
      Upper Steering Post Installation......3852
      Power Steering Unit Removal......3853
      Power Steering Unit Installation......3854
      Steering Exploded View (EPS Models)......3856
    STEERING TIE ROD......3857
      Tie Rod / Tie Rod End Replacement......3857
    FRONT A-ARMS......3858
      Exploded View......3858
      Removal / Replacement......3859
    BALL JOINT SERVICE......3860
      Removal......3860
      Installation......3860
    REAR A-ARMS......3862
      Exploded View......3862
      Removal......3863
      Installation......3863
    REAR STABILIZER BAR......3864
      Exploded View......3864
      Linkage Removal / Installation......3865
      Stabilizer Bar Removal / Installation......3865
    SHOCKS / SPRINGS......3866
      Exploded View......3866
      Shock Removal / Installation......3866
      Shock / Spring Replacement......3866
  BRAKES......3867
    SPECIFICATIONS......3868
      General Brake Specifications......3868
      General Torque Specifications......3868
      Special Tools / Brake Fluid......3868
    BRAKE SYSTEM SERVICE NOTES......3869
    BRAKE NOISE TROUBLESHOOTING......3869
    HYDRAULIC BRAKE SYSTEM OPERATION......3870
    BRAKE SYSTEM EXPLODED VIEW......3870
      Brake Caliper Exploded View......3871
      Hand Master Cylinder Exploded View......3871
    BRAKE BLEEDING......3872
      Fluid Replacement......3872
      Bleeding Procedure......3872
    HAND BRAKE MASTER CYLINDER......3874
      Removal......3874
      Disassembly......3874
      Installation......3874
      Brake Switch Replacement......3874
    FOOT BRAKE MASTER CYLINDER......3875
      Operation Overview......3875
      Foot Master Cylinder Removal / Installation......3875
      Brake Pedal Removal / Installation......3875
    BRAKE PADS......3876
      Pad Removal......3876
      Pad Inspection......3876
      Pad Installation......3876
      Brake Burnishing Procedure......3877
    CALIPER SERVICE......3877
      Caliper Removal......3877
      Caliper Disassembly......3877
      Caliper Inspection......3878
      Caliper Reassembly......3879
      Caliper Installation......3879
    BRAKE DISC SERVICE......3880
      Disc Inspection......3880
      Disc Removal / Replacement......3880
    TROUBLESHOOTING......3882
      Brake Squeal......3882
  Wire_Diagrams......0
    SPORTSMAN XP 850 (PAGE 1 OF 2)......3883
    SPORTSMAN XP 850 (PAGE 2 OF 2)......3884
    AWD / ADC......3885
    BATTERY CHARGING......3886
    BATTERY PLUS......3887
    BRAKE LAMPS-START......3888
    CHASSIS POWER......3889
    COOLING FAN......3890
    ECM WAKE-UP......3891
    EFI......3892
    ENGINE CRANK......3893
    EPS......3894
    FUEL PUMP & LEVEL......3895
    GEAR SENSOR......3896
    GROUND SPEED SENSOR......3897
    KEY ON POWER......3898
    HEADLAMPS......3899
Polaris  '09 Sportsman 500 Service Repair Manual......3900
  9921790_CH_01......3900
    MODEL NUMBER INFORMATION 1.2 ......3900
      MODEL NUMBER INFORMATION......3901
        Model Number......3901
        Engine Designation Numbers......3901
        Vehicle Identification Number (VIN)......3901
        Transmission I.d. Location......3901
        Engine And Machine Serial Numbers......3901
        Publications......3902
        Paint Codes......3902
        Replacement Keys......3902
      2009 SPORTSMAN 500 H.O......3903
        Model Number: A09MH50AX, AZ ......3903
      2009 SPORTSMAN 500 EFI......3905
        Model Number: A09MN50AN, AX, ET (International)......3905
      2009 SPORTSMAN X2 500 EFI......3907
        Model Number: A09TN50AX, AZ / A08TN50EA ......3907
      2009 SPORTSMAN TOURING 500 EFI......3909
        Model Number: A09DN50AB, AZ / A09DN50EA......3909
      MISC. NUMBERS/CHARTS......3911
        Standard Torque Specifications......3911
        SAE Tap Drill Sizes......3912
        Metric Tap Drill Sizes......3912
        Decimal Equivalents......3912
        Conversion Table......3913
        Glossary Of Terms......3914
  9921790_CH_02......3916
    TABLE OF CONTENTS......3916
      MAINTENANCE......3918
        Periodic Maintenance Chart......3918
        Maintenance Chart Key......3918
        Periodic Maintenance Chart......3919
      LUBRICATION / FLUIDS......3922
        SPORTSMAN Component Locations......3922
        SPORTSMAN X2-Touring Component locations......3923
        Polaris Lubricants, Maintenance and Service Products......3924
        Polaris Lubricant Symbol Identification......3925
        Pre-ride / Daily Inspection......3925
        Lubrication Components......3926
        Front Gearcase Lubrication......3927
        Transmission Lubrication......3928
        ADC Differential Hydraulic Circuit Fluid Change......3929
      VEHICLE INSPECTION......3929
        Shift Link Rod Inspection......3929
        Throttle Inspection......3930
        Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment......3930
        Fuel System......3931
        Fuel Lines......3931
        Vent Lines......3931
        Fuel Filter......3932
        Choke (Enricher) Adjustment - (500 Carb)......3932
        Compression Test......3932
        Engine Mounts......3932
        Spark Plug......3933
        Active Descent Control (ADC) Reservoir Level......3933
        Battery Maintenance......3933
        Liquid Cooling System Overview......3934
        Coolant Strength / Type......3934
        Cooling System Hoses......3934
        Radiator/Grill Screen......3934
        Cooling System Pressure Test......3935
        Coolant Level Inspection......3935
        Radiator Coolant Level Inspection......3935
        Air Filter/Pre-Filter Service......3935
        Air Box Sediment Tube......3936
        Breather Filter Inspection......3937
        Breather Hose......3937
        Recoil Housing......3937
        Engine Oil Level......3938
        Oil and Filter Change ......3938
        Oil Pump Priming Procedure......3940
        Valve Clearance......3940
        Intake Valve Clearance Adjustment......3941
        Exhaust Valve Clearance Adjustment......3941
        Steering......3941
        Tie Rod End/Steering Inspection ......3942
        Camber and Caster......3942
        Wheel Alignment......3942
        Toe Alignment Adjustment......3943
        Exhaust Pipe......3943
        Brake System Inspection......3944
        Brake Pad Inspection......3945
        Hose/Fitting Inspection......3945
        Auxiliary Brake Testing......3945
        Auxiliary Brake Adjustment (Hydraulic) ......3946
        Suspension Spring Preload Adjustment......3946
        Front Suspension......3946
        CV Shaft Boot Inspection......3946
        Controls......3947
        Wheels......3947
        Wheel, Hub, And Spindle Torque Table......3947
        Wheel Removal Front or Rear......3947
        Wheel Installation......3948
        Tire Pressure......3948
        Tire Inspection......3948
        Frame, Nuts, Bolts, Fasteners......3948
        Storage Compartments......3949
        Winch Operation (If Equipped)......3949
        ATV Cleaning & Storage......3951
      SPORTSMAN 500 CARBURETED MAINTENANCE......3953
        Choke (Enricher) Adjustment......3953
        Pilot Screw......3953
        Pilot Screw Adjustment......3954
        Idle Speed Adjustment......3954
        Fuel Filter......3955
        Carburetor Draining......3955
        Maintenance Schedule......3956
        Maintenance Schedule......3957
  9921790_CH_03......3958
    TABLE OF CONTENTS......3958
      SPECIFICATIONS......3960
        Torque Specifications......3960
        Special Tools......3960
        Engine Fastener Torque Patterns......3960
        Engine Service Data......3961
        Engine Service Data......3962
      GENERAL ENGINE SERVICE......3963
        Piston Identification......3963
        Cooling System Specifications......3963
        Cooling System......3964
        Accessible Components......3965
        Engine Removal (TYPICAL)......3965
        Engine Installation Notes......3966
        Cylinder Hone Selection/ Honing Procedure......3966
        Honing To Oversize......3966
        Cleaning the Cylinder After Honing......3967
        Crankshaft Straightening......3967
        Engine Lubrication- EH 50PL......3968
        Oil Pressure Test - EH 50PL......3968
        Oil Pump Priming Procedure......3968
        Oil Flow - EH50PL......3968
        EH50PL Oil Flow Diagram......3969
        EH50PL Engine Exploded Views......3970
      ENGINE DISASSEMBLY......3971
        Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal......3971
        Cam Chain Tensioner Inspection......3971
        Rocker Arm/Shaft Inspection......3972
        Camshaft Removal......3973
        Automatic Compression Release Removal/ Inspection......3974
        Automatic Compression Release Installation......3975
        Camshaft Inspection......3975
        Cylinder Head Removal......3976
        Cylinder Head Exploded View, EH50PL......3977
        Cylinder Head Inspection......3978
        Cylinder Head Warp......3978
        Cylinder Head Disassembly......3978
        Valve Inspection......3979
        Combustion Chamber......3980
        Valve Seat Reconditioning......3980
        Cylinder Head Assembly......3983
        Valve Sealing Test......3983
        Valve Clearance Adjustment......3983
        Cylinder/Piston Removal and Inspection......3984
        Piston Removal......3985
        Cylinder Inspection......3985
        Piston-to-Cylinder Clearance......3986
        Piston/Rod Inspection......3986
        Piston Ring Installed Gap......3987
        Crankcase Disassembly......3987
        Starter Drive Removal/Inspection......3988
        Flywheel/Stator Removal/Inspection......3988
        Cam Chain/Tensioner Blade......3989
        One Way Valve Removal......3989
        Crankcase Separation......3990
        Oil Pump Removal/Inspection......3990
        Oil Pump Assembly......3991
        Counter Balancer Shaft Removal/Inspection......3991
        Crankshaft Removal/Inspection ......3992
        Crankcase Bearing Inspection ......3993
        Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)......3993
        Crankcase Inspection......3993
        Bearing Installation......3994
        End Play Inspection/Adjustment......3994
        Crankshaft End Play Adjustment......3994
        Counter Balancer Shaft End Play Adjustment......3995
        Oil Pump Shaft End Play Adjustment......3996
      ENGINE REASSEMBLY......3997
        Pump Shaft Oil Seal Installation......3997
        Crankshaft/Counter Balance/Oil Pump Installation......3997
        Crankcase Assembly......3998
        Water Pump Mechanical Seal Installation......3998
        Water Pump Mechanical Seal Removal - Engine Installed......3998
        One Way Valve Installation......3999
        Cam Chain Drive Sprocket Installation......4000
        Tensioner Blade Installation......4000
        Piston Ring Installation......4000
        Piston Installation......4001
        Cylinder Installation......4001
        Cylinder Head Installation......4002
        Cam Chain/Camshaft Installation......4002
        Camshaft Timing......4003
        CAMSHAFT TIMING......4005
        Cam Chain Tensioner Installation......4006
        Stator, Flywheel and Starter Drive Installation......4006
        Rocker Shaft/Rocker Arm Assembly Installation......4007
        Thermostat Installation......4007
        Oil Pipes......4007
      RECOIL (Accessory)......4008
        Recoil Disassembly/Inspection......4008
        Recoil Assembly......4009
      TROUBLESHOOTING......4010
        Spark Plug Fouling......4010
        Engine......4010
        Cooling System ......4011
  9921790_CH_04......4012
    TABLE OF CONTENTS......4012
      SPECIAL TOOLS......4013
        Part Numbers / Descriptions......4013
      EFI SERVICE NOTES......4015
        General Service Information......4015
      EFI SYSTEM EXPLODED VIEW......4016
      EFI SYSTEM ......4017
        Component Locations/Identification......4017
      FUEL TANK......4018
        Exploded View......4018
      ELECTRONIC FUEL INJECTION......4018
        General Information......4018
        EFI Operation Overview......4018
        Initial Priming / Starting Procedure......4019
      FUEL LINES......4019
        Quick Connect Removal/Installation......4019
      ELECTRONIC CONTROL UNIT (ECU)......4020
        Operation Overview......4020
        ECU Replacement......4020
        ECU Service......4020
      FUEL PUMP ASSEMBLY......4021
        Operation / Testing......4021
        FUEL PUMP TEST......4021
        Fuel Pump / Tank Assembly Replacement......4022
      FUEL PRESSURE REGULATOR......4023
        General Information......4023
      FUEL FILTER......4023
        General Information......4023
      FUEL INJECTOR......4024
        General Information......4024
      CRANKSHAFT POSITION SENSOR (CPS)......4025
        General Information......4025
      MANIFOLD AIR PRESSURE SENSOR (MAP)......4026
        Operation Overview......4026
        Map Sensor Test......4026
        Map Sensor Replacement......4026
      INTAKE AIR TEMPERATURE SENSOR (IAT)......4026
        Operation Overview......4026
        Intake Air Temperature Sensor Test......4026
        Intake Air Temperature Sensor Replacement......4026
      I DLE AIR CONTROL (IAC)......4027
        General Information......4027
      THROTTLE POSITION SENSOR (TPS)......4027
        Operation Overview......4027
        Throttle Position Sensor Test......4027
        Throttle Position Sensor Replacement......4028
        Throttle Position Sensor Initialization......4029
      ENGINE TEMPERATURE SENSOR......4029
        General Information......4029
        Engine Temperature Sensor Test......4030
        Engine Temperature Sensor Replacement......4030
      FUEL SYSTEM TROUBLESHOOTING......4030
        FUEL STARVATION / LEAN MIXTURE......4030
      EFI DIAGNOSTICS USING ‘BLINK CODES’......4032
        Blink Codes - Operation......4032
      TROUBLESHOOTING DIAGRAMS......4033
        EFI CIRCUIT - Power On......4033
        EFI CIRCUIT - Crank Position Sensor......4033
        EFI CIRCUIT - Fuel Pump......4034
        EFI CIRCUIT - Ignition Coil......4034
        EFI CIRCUIT - Idle Air Control......4035
        EFI CIRCUIT - Throttle Position Sensor......4035
        EFI CIRCUIT - Manifold Absolute Pressure Sensor......4036
        EFI CIRCUIT - Engine Coolant Temperature......4036
        EFI CIRCUIT - Air Temperature Sensor......4037
        EFI CIRCUIT - Malfunction Indicator Light......4037
  9921790_CH_05......4038
    TABLE OF CONTENTS......4038
      GENERAL INFORMATION......4039
        Torque Specifications......4039
        Special Tools ......4039
        Decal Replacement......4039
        Plastic Insert Removal / Installation......4040
      BODY......4041
        Side Panel Removal......4041
        Front Cover Removal / Installation......4041
        Foot Well Removal / Installation......4042
        X2-Touring Foot Well Removal / Installation......4042
        Front Storage Removal......4043
        Front Storage Installation......4045
        Sportsman Rear Rack Removal / Installation......4045
        Front Cab/Fender Removal/Installation......4046
        Sportsman Rear Cab / Fender Removal / Installation......4047
        X2-Touring Rear Quarter Panel Removal / Installation......4047
        Sportsman Rear Storage Removal / Installation......4048
        Radiator Screen Removal......4048
        Sportsman Body Assembly Exploded View......4049
        X2-Touring Body Assembly Exploded View......4050
        Touring Body/Rack Assembly Exploded View......4051
        Body / Rack Exploded Views......4052
        Touring Body/Seat Assembly Exploded View......4053
        Headlight Pod Exploded View......4054
      STEERING......4055
        Handlebar Block Installation Procedure......4055
        Steering / A-arm Exploded View......4056
        A-Arm Replacement......4057
        Ball Joint Replacement......4058
        Steering Post Removal......4059
        Steering Post Assembly......4059
      SUSPENSION......4059
        Front Strut Cartridge Replacement......4059
        Strut Assembly......4060
        Sportsman Rear Suspension Assembly......4061
        X2-Touring Rear Suspension Exploded View......4062
        X2-Touring Torsion Bar Exploded View......4063
      X2 CARGO BOX......4064
        Exploded View......4064
        Removal / Installation......4065
      X2 SEAT assembly......4067
        Exploded Views......4067
        X2 Seat Operation - Configuring Cargo Box For Passenger Riding......4068
        X2 Driver Seat Backrest Removal / Installation......4069
        X2 Passenger Seat Backrest Removal / Installation......4069
  9921790_CH_06......4072
    TABLE OF CONTENTS......4072
      SPECIAL TOOLS AND SPECIFICATIONS......4073
        Special Tools......4073
        Service Note......4073
        Component Fastener Torques......4073
      PVT EXPLODED VIEWS......4074
        PVT Sealing And Ducting Components......4074
        Drive Clutch Exploded Views......4074
        Driven Clutch Exploded Views......4075
        Engine Braking System (EBS) Exploded View......4076
      PVT SYSTEM......4077
        PVT Operation Overview......4077
        Drive Clutch Operation......4077
        Driven Clutch Operation......4077
        EBS Clutch Operation......4078
        PVT Maintenance / Inspection......4078
        Drive Clutch Spring......4079
        Optional Shift Weights......4080
        PVT Drying......4081
        PVT Disassembly ......4081
        PVT Installation......4082
        Drive Belt Removal / Inspection......4083
        DRIVE BELT INSTALLATION......4084
        Clutch Alignment......4085
        Clutch Offset......4085
      EBS DRIVE CLUTCH SERVICE......4086
        Drive Clutch Disassembly......4086
        Spider Removal......4086
        Button To Tower Clearance Inspection......4088
        Shift Weight Inspection......4088
        Drive Clutch Inspection......4088
        Moveable Sheave Bushing Inspection......4089
        Drive Clutch Bushing Service......4089
        One-Way Clutch Inspection (Drive Clutch)......4091
        Drive Clutch Reassembly......4091
      EBS DRIVEN CLUTCH SERVICE......4093
        Driven Clutch Disassembly ......4093
        DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION......4095
        EBS DRIVEN CLUTCH REASSEMBLY......4096
      STANDARD DRIVE CLUTCH - 500 Carburetor......4099
        Drive Clutch Disassembly......4099
        Spider Removal......4100
        Button To Tower Clearance Inspection......4101
        Shift Weight Inspection......4101
        Sheave / Bushing Inspection......4102
        Drive Clutch Bushing Service......4102
        Drive Clutch Reassembly......4103
      STANDARD DRIVEN CLUTCH - 500 Carburetor......4105
        Exploded View......4105
        Clutch Disassembly / Inspection......4105
        Bushing Service......4106
        Moveable Sheave - Bushing Installation......4107
        Clutch Assembly......4108
      PVT TROUBLESHOOTING......4110
        Overheating......4110
        Problem, Cause and Remedy Chart......4111
  9921790_CH_07......4114
    TABLE OF CONTENTS......4114
      SPECIFICATIONS......4115
        Torque Table......4115
        Special Tools......4115
        Gearcase Fluid / Capacity......4115
      FRONT HUB......4115
        Disassembly......4115
        Assembly......4116
      FRONT DRIVE SHAFT (CV) SERVICE......4116
        Removal......4116
        Installation......4117
        Inspection......4118
        CV Joint/Boot Replacement......4118
      PROP SHAFT - FRONT......4120
        Removal and Installation......4120
      U-JOINT......4120
        Disassembly......4120
        Assembly......4121
      DRIVE AXLE EXPLODED VIEWS......4123
        Drive Shafts and Propshaft......4123
      FRONT GEARCASE - CENTRALIZED HILLIARD......4124
        Exploded View......4124
        Operation......4125
        Gearcase Removal......4125
        Disassembly / Inspection......4126
        Reassembly / Inspection......4130
        Setting Ring Gear Backlash......4131
        Front Gearcase Diagnosis......4132
        Gearcase Installation......4133
      FRONT GEARCASE - Active Descent Control......4134
        ADC Gearcase Exploded View......4134
        Operation......4135
        ADC Coil Testing......4136
        ADC Differential Hydraulic Circuit Bleeding......4136
        Disassembly / Inspection......4136
        ADC Gearcase Piston Replacement Procedure......4140
        Assembly......4142
      REAR HUB......4145
        Removal......4145
        Disassembly......4146
        Assembly......4147
        Installation......4147
      REAR DRIVE (CV) SHAFT SERVICE......4148
        Removal......4148
        Service......4149
        CV Boot Replacement......4150
        INSTALLATION......4151
        Drive Shaft and CV Joint Handling Tips......4151
  9921790_CH_08r01......4152
    TABLE OF CONTENTS......4152
      TRANSMISSION - GENERAL......4153
        Mounting Exploded View......4153
        Torque Specifications......4154
        Special Tools......4154
        Lubrication......4154
        Gear Selector Removal......4154
        Transmission Removal......4154
        Transmission Installation......4156
        Troubleshooting Checklist......4157
      TRANSMISSION SERVICE......4158
        X2 - Touring Exploded View......4158
        500 Carbureted Exploded View......4160
        Transmission Disassembly......4162
        Transmission Assembly......4167
        Transmission Output Shaft Backlash Procedure and Gearcase Reassembly - Standard Sportsman......4168
        Transmission Output Shaft Disassembly - Sportsman X2/Touring......4173
        Transmission Output Shaft Backlash Procedure and Gearcase Reassembly - Sportsman X2/Touring......4174
  9921790_CH_09......4180
    TABLE OF CONTENTS......4180
      SPECIFICATIONS......4181
        Torque Table......4181
        Component Service Limits......4181
      BRAKE SYSTEM EXPLODED VIEWS......4182
        X2, Touring System Component Exploded View......4182
        Sportsman System Component Exploded View......4183
      BRAKE CALIPER EXPLODED VIEWS......4184
        Sportsman and X2, Touring Front Caliper Assembly......4184
        X2, Touring Rear Caliper Assembly......4184
        Sportsman Rear Caliper Assembly......4185
      HYDRAULIC BRAKE SYSTEM......4185
        Operation Overview......4185
        Brake Noise Troubleshooting......4186
        Brake Bleeding / Fluid Change......4186
      FRONT MASTER CYLINDER......4188
        Removal......4188
        Installation......4188
      FRONT BRAKES......4189
        Pad Removal......4189
        Assembly......4190
        Brake Burnishing Procedure......4191
      FRONT BRAKE DISC......4191
        Inspection......4191
        Removal / Replacement......4192
      FRONT CALIPER......4193
        Removal......4193
        Inspection......4194
        Reassembly......4194
        Installation......4195
      REAR BRAKE PAD......4196
        X2, Touring Pad Removal......4196
        X2, Touring Pad Installation......4197
        Sportsman Rear Pad Removal......4198
        Sportsman Rear Pad Installation......4199
        Brake Burnishing Procedure......4199
      X2, TOURING REAR CALIPER......4200
        Removal......4200
        Inspection......4201
        Reassembly......4201
      SPORTSMAN REAR CALIPER......4202
        Removal and Inspection......4202
        Assembly......4203
      REAR BRAKE DISC......4204
        Inspection......4204
      REAR MASTER CYLINDER......4205
        X2, Touring Exploded View......4205
        Overview......4206
        X2, Touring Rear Master Cylinder Removal and Installation......4206
        Sportsman Rear Master Cylinder Removal / Installation......4207
        Pedal Removal and Installation......4208
      TROUBLESHOOTING......4208
        Brakes Squeal......4208
        Poor Brake Performance......4208
        Lever Vibration......4208
        Caliper Overheats (Brakes Drag)......4208
        Brakes Lock......4208
  9921790_CH 10......4210
    TABLE OF CONTENTS......4210
      GENERAL INFORMATION......4212
        Special Tools......4212
        Ignition System / Basic Electrical Components......4212
        Electrical Service Notes......4213
        Troubleshooting......4213
      INSTRUMENT CLUSTER......4214
        Overview......4214
        Instrument Cluster Diagnostic Mode......4215
        Setting A New Service Interval......4217
        EFI Diagnostic Mode ......4218
        Speedometer Removal......4219
        Speedometer Installation......4219
      ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING......4220
        TEST 1 - No All Wheel Drive......4220
        TEST 2 - No Speedometer Display......4221
        TEST 3 - No Reverse Speed Limit......4221
        TEST 4 - No AWD Hub Safety Limit......4222
        TEST 5 - Reverse Speed Limiter Activated In Forward Gear......4223
        TEST 6 - Wheel Speed Sensor......4223
        TEST 7 - Fuel Gauge Display Not Working......4224
        TEST 8 - Shift Indicator Not Working......4224
      ACTIVE DESCENT CONTROL (ADC) COIL......4225
        Operation Overview - EFI Only......4225
        Diagnosing System Failures......4225
      ALL WHEEL DRIVE (AWD) COIL......4225
        Operation Overview......4225
        Diagnosing System Failures......4225
      COOLING SYSTEM COMPONENTS......4226
        Fan Control Circuit Operation......4226
        Fan Control Bypass Test - EFI ......4226
        Fan Control Bypass Test - H.O. ......4226
        Fan Motor Current Draw Test......4226
        Coolant Temperature Sensor - EFI......4227
        Coolant Temperature Fan Switch - H.O......4227
      GEAR POSITION INDICATOR SWITCH......4228
        Test Diagram......4228
      ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......4228
        Operation Overview......4228
        ETC Test......4228
      IGNITION SYSTEM......4229
        Overview......4229
        Components of Alternator and DC / CDI Ignition System......4230
        EFI Ignition System Testing Flow Chart......4231
        Crankshaft Position Sensor Gap......4232
        Ignition Troubleshooting......4232
        Ignition Output Test Using Gap Tester......4232
      CHARGING SYSTEM......4233
        Current Draw - Key Off......4233
        Break Even Test......4233
        Alternator Output Test......4234
        Charging System Testing Diagrams......4235
      RELAYS......4237
        Operation......4237
      FUSES/Circuit Breaker......4238
        Operation......4238
      DIFFERENTIAL SOLENOID......4238
        Overview - X2 and Touring......4238
        Testing......4238
        Replacement......4239
        Differential Solenoid Diagram - X2 and Touring......4239
      LIGHTING......4240
        High Beam Headlight Bulb Replacement......4240
        Headlight Housing Relacement......4240
        High Beam Headlight Adjustment ......4241
        Lower Headlamp Removal / Installation......4242
        Low Beam Headlight Adjustment......4243
        Headlamp Switch Test......4243
        Work Light / Differential Lockout Switch......4243
        Brake Light / Work Light Replacement......4244
        Brake Light Switch Test......4245
      SPEED SENSOR......4245
        Testing......4245
        Replacement......4245
      FUEL SENDER......4246
        Testing......4246
      ACCESSORY POWER......4246
        Wire Connections......4246
      STARTER SYSTEM ......4247
        Troubleshooting......4247
        VOLTAGE DROP TEST......4247
        Starter Lockout Troubleshooting- EFI ......4248
        Starter Lockout Troubleshooting- H.O. ......4248
        Starter Lockout Diagram- EFI......4249
        Starter Lockout Diagram- H.O......4249
        Starter Motor Removal / Disassembly......4250
        Brush Inspection / Replacement......4250
        Armature Testing......4251
        Starter Reassembly......4252
        Starter Solenoid Bench Test......4252
        Starter Exploded View......4252
      STARTER DRIVE......4253
        Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement......4253
      STARTER SYSTEM TESTING FLOW CHART......4254
        Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing.......4254
      BASIC WINCH WIRING......4255
        Pre-Wired Models......4255
      BATTERY......4256
        Battery Identification......4256
        Battery Activation......4256
        Terminal Preparation......4257
        Battery Removal......4257
        Battery Installation......4257
        Off Season Storage......4258
        Low Maintenance Battery Off-Season Storage......4258
        Battery Testing......4258
        Conventional Battery OCV - Open Circuit Voltage Test......4258
        Conventional Battery Specific Gravity Test......4259
        Battery Load Test......4259
        Charging Procedure......4259
        Low Maintenance Battery Check:......4260
        Low Maintenance Battery Charging......4260
        Low Maintenance Battery - OCV- Open Circuit Voltage Test......4261
        Low Maintenance Battery Load Test......4261
        Low Maintenance Battery Charging Procedure......4261
      TROUBLESHOOTING DIAGRAMS......4262
        All Wheel Drive - EFI......4262
        Fuel Pump and Ignition Coil - EFI......4262
        Reverse Override - EFI......4263
        Fan Control - EFI......4263
  9921790_CH_11......4264
    TABLE OF CONTENTS......4264
      500 EFI X2 / TOURING QUADRICYCLE BRAKE SYSTEM......4265
        Overview......4265
        Exploded View......4266
      500 EFI X2 / TOURING QUADRICYCLE STEERING POST AND LOCK......4267
        Steering Assembly Exploded View......4267
      500 EFI QUADRICYCLE EMISSIONS SYSTEM......4268
        Overview......4268
      500 QUADRICYCLE ELECTRICAL......4269
        Turn / Hazard Signal Diagram......4269
  9921790_WIRE DIAGRAMS......4270
Polaris  '09 Sportsman 6x6 800 EFI Big Boss Service Repair Manual......4286
  9922030_CH_01.pdf......4286
    TABLE OF CONTENTS......4286
      MODEL INFORMATION......4287
        Model Number......4287
        Engine Designation Numbers......4287
        VIN Identification......4287
        TRANSMISSION I.D. LOCATION......4287
        Engine and Machine Serial Numbers......4287
        PUBLICATIONS......4288
        PAINT CODES......4288
        REPLACEMENT KEYS......4288
      2009 SPORTSMAN 6x6 800 EFI Specifications......4289
        MODEL NUMBER: A09CL76AA......4289
      MISC. NUMBERS/CHARTS......4291
        Standard Torque Specifications......4291
        SPECIAL TOOLS......4291
        SAE Tap Drill Sizes......4292
        Metric Tap Drill Sizes......4292
        Decimal Equivalents......4292
        Conversion Table......4293
        Glossary Of Terms......4294
  9922030_CH_02......4296
    TABLE OF CONTENTS......4296
      MAINTENANCE......4298
        Overview......4298
        Periodic Maintenance Chart......4299
      LUBRICATION / FLUIDS......4302
        Polaris Lubricants, Maintenance and Service Products......4302
        Polaris Lubricant Symbol Identification......4303
        Pre-Ride / Daily Inspection......4303
        Lubrication / Grease Points......4304
        Front Gearcase Lubrication......4305
        Middle Gearcase Lubrication......4306
        Rear Gearcase Lubrication......4307
        Transmission Lubrication ......4308
        ADC Differential Hydraulic Circuit Fluid Change......4309
      VEHICLE INSPECTION......4309
        Shift Link Rod Inspection......4309
        Throttle Inspection......4310
        Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment......4310
        Fuel System......4311
        Vent Lines......4311
        Compression Test......4311
        Engine Mounts......4312
        Spark Plug ......4312
        Active Descent Control (ADC) Reservoir Level......4312
        Battery Maintenance......4313
        Cooling System......4313
        Coolant Strength / Type......4314
        Cooling Hoses......4314
        Radiator......4314
        Cooling System Pressure Test......4314
        Reservoir Level Inspection......4314
        Radiator Coolant Level......4315
        Air Filter Service......4315
        Air Box Sediment Tube......4316
        Engine Breather Hose......4316
        PVT Inspection / Drying Procedure......4317
        Engine Ground......4317
        Engine Oil Level......4317
        Oil/filter Change......4318
        Steering Inspection......4319
        Tie Rod / Steering......4319
        Camber/Caster......4319
        Wheel Alignment......4320
        Toe Alignment......4320
        Exhaust Pipe......4321
        Brake System Inspection......4321
        Brake Pads......4322
        Brake Hose Inspection......4322
        Auxiliary (Rear) Brake Test......4322
        Auxiliary Brake Inspection......4323
        Suspension: Spring Preload Adjustment......4323
        Front Suspension......4323
        Rear Suspension......4323
        CV Shaft Boot Inspection......4323
        ATV Controls......4324
        Wheel Inspection......4324
        Wheel Removal: Front Or Rear......4324
        Wheel Installation......4324
        Tire Pressure......4325
        Tire Inspection......4325
        Frame, Nuts, Bolts, Fasteners......4325
        Front / Rear Storage Compartments......4325
        Winch Operation (If Equipped)......4326
        Cleaning And Storage Of ATV......4328
        Maintenance Schedule......4330
        Maintenance Schedule......4331
  9922030_CH_03......4334
    TABLE OF CONTENTS......4334
      SPECIFICATIONS......4335
        Crankcase Exploded Views......4335
        Engine Fastener Torque Patterns......4342
        Torque Specifications......4343
        800 EFI Engine Service Specifications......4344
        Special Tools......4346
      GENERAL ENGINE SERVICE......4347
        Accessible Components......4347
        Piston Identification......4347
        Cooling System Specifications......4347
        Cooling System Pressure Test......4348
        Four Stroke - Coolant Air Bleeding Procedure......4348
        Engine Removal (Typical)......4349
        Engine Installation Notes......4351
        Cylinder Hone Selection And Honing Procedure......4351
        Honing To Deglaze......4352
        Cleaning the Cylinder After Honing......4352
        Oil Flow Chart......4353
        Engine Lubrication Specifications......4353
        OIL PRESSURE TEST......4353
      ENGINE DISASSEMBLY AND INSPECTION......4354
        Cylinder Head Assembly Exploded View......4354
        Rocker Arms......4355
        Push Rods......4355
        Cylinder Head Removal ......4355
        Cylinder Head Inspection......4356
        Cylinder Head Warp......4356
        Valve Seal/Spring Service (On Engine)......4356
        Cylinder Head Disassembly......4357
        Valve Inspection......4358
        Combustion Chamber......4359
        Valve Seat Reconditioning......4359
        Cylinder Head Reassembly......4361
        Valve Sealing Test......4362
        Cylinder Removal......4362
        Valve Lifter Removal/Inspection......4362
        Piston Removal......4363
        Cylinder Inspection......4364
        Piston-To-Cylinder Clearance......4365
        Piston/rod Inspection......4365
        Piston Ring Installed Gap......4366
        Starter Drive/Bendix Removal Inspection ......4366
        Flywheel / Stator Removal / Inspection......4367
        Engine Crankcase Disassembly / Inspection......4368
        Camshaft Inspection......4375
      ENGINE REASSEMBLY......4376
        CRANKCASE REASSEMBLY......4376
        Flywheel / Stator Installation......4387
        Cylinder Head Reassembly......4388
      TROUBLESHOOTING......4390
        Engine......4390
        Cooling System......4391
  9922030_CH_04......4392
    TABLE OF CONTENTS......4392
      GENERAL INFORMATION......4393
        Special Tools......4393
        Service Notes......4395
        EFI System Exploded View......4396
        EFI System Component Locations......4397
        Fuel Tank Assembly......4398
        Fuel Lines - Quick Connect......4398
      ELECTRONIC FUEL INJECTION......4399
        Principal Components......4399
        EFI Operation Overview......4399
        Initial Priming / Starting Procedure......4399
      ELECTRONIC CONTROL Unit (ECU)......4400
        Operation Overview......4400
        ECU Service......4400
        ECU Replacement......4400
      FUEL PUMP......4401
        Operation Overview......4401
        Fuel Pump Test......4401
        Fuel Pump / Tank Assembly Replacement......4402
      FUEL PRESSURE REGULATOR......4403
        Operation Overview......4403
        Fuel Pressure Regulator Test......4403
        Fuel Pressure Regulator Replacement......4403
      FUEL FILTER......4403
        General Information......4403
        Fuel Filter Service......4403
        Fuel Filter Replacement......4403
      FUEL INJECTORS......4404
        Operation Overview......4404
        Fuel Injector Service......4404
        Fuel Injector Replacement......4404
      CRANKSHAFT POSITION SENSOR (CPS)......4405
        Operation Overview......4405
        Crankshaft Position Sensor Test......4405
        Crankshaft Position Sensor (CPS) Replacement......4405
      TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)......4406
        Operation Overview......4406
        Temperature and Barometric Air Pressure Sensor Test......4406
        Temperature and Barometric Air Pressure Sensor Replacement......4406
      THROTTLE POSITION SENSOR (TPS)......4406
        Operation Overview......4406
        Throttle Position Sensor Test......4407
        Throttle Position Sensor Replacement......4408
        Throttle Position Sensor Adjustment......4408
      ENGINE TEMPERATURE SENSOR......4409
        Operation Overview......4409
        Engine Temperature Sensor Test......4409
        Engine Temperature Sensor Replacement......4409
      TROUBLESHOOTING......4410
        Diagnostics Using “Blink Codes”......4410
        EFI Troubleshooting......4411
        EFI CIRCUIT - Power On......4412
        EFI CIRCUIT - Crank Position Sensor......4412
        EFI CIRCUIT - Fuel Pump......4413
        EFI CIRCUIT - Throttle Position Sensor......4413
        EFI CIRCUIT - Temperature - Barometric Air Pressure Sensor......4414
        EFI CIRCUIT - Engine Temperature......4414
        EFI CIRCUIT - Malfunction Indicator Light......4415
  9922030_CH_05......4416
    GENERAL INFORMATION 5.2 ......4416
      GENERAL INFORMATION......4417
        Torque Specifications......4417
        Special Tools ......4417
        Decal Replacement......4417
        Plastic Insert Removal / Installation......4418
      BODY......4419
        Side Panel Removal......4419
        Front Cover Removal / Installation......4419
        Foot Well Removal / Installation......4420
        Front Storage Removal......4420
        Front Storage Installation......4422
        Front Fender Removal/Installation......4423
        Rear Fender Panel Removal / Installation......4424
        Radiator Screen Removal......4424
        Body Assembly Exploded View......4425
        Bumper / Storage / Rack Exploded View......4426
        Headlight Pod Exploded View......4427
      STEERING......4428
        Handlebar Block Installation Procedure......4428
        Steering / A-arm Exploded View......4429
        A-Arm Replacement......4430
        Ball Joint Replacement......4431
        Steering Post Removal......4432
        Steering Post Assembly......4432
      SUSPENSION......4432
        Front Strut Cartridge Replacement......4432
        Front Strut Assembly......4433
        Rear Torsion Bar Assembly......4434
        Rear / Middle Suspension Exploded View......4435
      CARGO BOX......4436
        Exploded View......4436
        Removal / Installation......4437
  9922030_CH_06......4438
    SPECIAL TOOLS AND SPECIFICATIONS 6.2 ......4438
      SPECIAL TOOLS AND SPECIFICATIONS......4439
        Special Tools......4439
        Component Fastener Torques......4439
      PVT EXPLODED VIEWS......4440
        PVT Sealing And Ducting Components......4440
        Drive Clutch Exploded Views (EBS vs. Non-EBS)......4440
        Driven Clutch Exploded Views......4441
        Engine Braking System (EBS) Exploded View......4442
      PVT SYSTEM......4443
        PVT Operation Overview......4443
        Drive Clutch Operation......4443
        Driven Clutch Operation......4443
        EBS Clutch Operation......4444
        PVT Maintenance / Inspection......4444
        Drive Clutch Spring......4445
        Optional Shift Weights......4446
        PVT Drying......4447
        PVT Disassembly ......4447
        PVT Installation......4448
        Drive Belt Removal / Inspection......4449
        DRIVE BELT INSTALLATION......4450
        Clutch Alignment......4451
        Clutch Offset......4451
      EBS DRIVE CLUTCH SERVICE......4452
        Drive Clutch Disassembly......4452
        Spider Removal......4452
        Button To Tower Clearance Inspection......4454
        Shift Weight Inspection......4454
        Drive Clutch Inspection......4454
        Moveable Sheave Bushing Inspection......4455
        Drive Clutch Bushing Service......4455
        One-Way Clutch Inspection (Drive Clutch)......4457
        Drive Clutch Reassembly......4457
      EBS DRIVEN CLUTCH SERVICE......4459
        Driven Clutch Disassembly ......4459
        DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION......4461
        EBS DRIVEN CLUTCH REASSEMBLY......4462
      PVT TROUBLESHOOTING......4466
        Overheating......4466
        Problem, Cause and Remedy Chart......4467
  9922030_CH_07......4470
    TABLE OF CONTENTS......4470
      SPECIFICATIONS......4471
        Torque Table......4471
        Special Tools......4471
        Gearcase Fluid / Capacity......4471
      FRONT HUB......4471
        Disassembly......4471
        Assembly......4472
      FRONT DRIVE SHAFT (CV) SERVICE......4472
        Removal......4472
        Installation......4473
        Inspection......4474
        CV Joint/Boot Replacement......4474
      PROP SHAFT - FRONT OR REAR......4476
        Removal and Installation......4476
      U-JOINT......4476
        Disassembly......4476
        Assembly......4477
      DRIVE AXLE EXPLODED VIEWS......4479
        Drive Shafts and Propshafts......4479
      FRONT GEARCASE - CENTRALIZED HILLIARD W/ Active descent control......4480
        Operation......4480
        ADC Gearcase Exploded View......4481
        ADC Operation......4482
        Front Gearcase Diagnosis......4483
        Gearcase Removal......4484
        Gearcase Installation......4485
        Coil Testing......4486
        ADC Differential Hydraulic Circuit Bleeding......4486
        Disassembly / Inspection......4486
        ADC Gearcase Piston Replacement Procedure......4490
        Assembly......4492
        Setting Ring Gear Backlash......4495
      MIDDLE GEARCASE......4496
        Removal......4496
        Disassembly and Inspection......4496
        Reassembly......4499
        Installation ......4500
        Middle Gearcase Exploded View......4501
      REAR HUB......4502
        Removal......4502
        Disassembly......4503
        Assembly......4504
        Installation......4504
      REAR DRIVE (CV) SHAFT......4505
        Removal......4505
        Service......4506
        CV Boot Replacement......4507
        INSTALLATION......4508
        Drive Shaft and CV Joint Handling Tips......4508
      REAR GEARCASE......4509
        Removal......4509
        Disassembly and Inspection......4509
        Reassembly......4510
        Installation ......4511
        Rear Gearcase Exploded View......4513
  9922030_CH_08......4514
    TABLE OF CONTENTS......4514
      TRANSMISSION EXPLODED VIEW......4515
        Sportsman Transmission ......4515
      SPECIFICATIONS......4517
        Torque Specifications......4517
        Lubricant / Capacity......4517
      TRANSMISSION SERVICE......4517
        Transmission Removal......4517
        Disassembly......4518
        Assembly......4523
        Transmission Installation......4528
        Troubleshooting......4529
  9922030_CH_09......4530
    TABLE OF CONTENTS......4530
      SPECIFICATIONS......4531
        Torque Table......4531
        Component Service Limits......4531
      BRAKE SYSTEM Exploded View......4532
        System Components......4532
      BRAKE CALIPER EXPLODED VIEWS......4533
        Front Caliper Assembly......4533
        Rear Caliper Assembly......4533
      HYDRAULIC BRAKE SYSTEM......4534
        Operation Overview......4534
        Brake Noise Troubleshooting......4534
        Brake Bleeding / Fluid Change......4535
      MASTER CYLINDER......4537
        Removal......4537
        Installation......4537
      FRONT BRAKE PADS......4538
        Removal and Inspection......4538
        Assembly......4539
        Brake Burnishing Procedure......4540
      FRONT BRAKE DISC......4540
        Inspection......4540
        Removal / Replacement......4541
      FRONT CALIPER......4541
        Removal and Disassembly......4541
        Inspection......4542
        Reassembly......4543
        Installation......4543
      REAR BRAKE PADS......4544
        Removal......4544
        Installation......4545
        Brake Burnishing Procedure......4546
      REAR CALIPER......4546
        Removal and Inspection......4546
        Assembly......4548
      REAR BRAKE DISC......4549
        Inspection......4549
      TROUBLESHOOTING......4549
        Brakes Squeal......4549
        Poor Brake Performance......4549
        Lever Vibration......4549
        Caliper Overheats (Brakes Drag)......4549
        Brakes Lock......4549
  9922030_CH_10......4550
    TABLE OF CONTENTS......4550
      INSTRUMENT CLUSTER ......4552
        Overview......4552
        Instrument Cluster Diagnostic Mode......4553
        Setting A New Service Interval......4555
        EFI Diagnostic Mode......4556
        Speedometer Removal......4557
        Speedometer Installation......4558
      SPEEDOMETER TROUBLESHOOTING......4559
        Test 1 - No All Wheel Drive......4559
        TEST 2 - No Display / TEST 3 - No Reverse Speed Limit......4560
        TEST 4 - No AWD Hub Safety Limiter......4561
        TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor ......4562
        TEST 7 - No Fuel Gauge / TEST 8 - Transmission Switch......4563
      ACTIVE DESCENT CONTROL (ADC) COIL......4564
        Operation Overview......4564
        Diagnosing System Failures......4564
      ALL WHEEL DRIVE (AWD) COIL......4564
        Operation Overview......4564
        Diagnosing System Failures......4564
      COOLING SYSTEM COMPONENTS......4565
        Fan Control Circuit Operation / Testing......4565
        Fan Control Circuit Bypass Test......4565
        Coolant Temperature Sensor......4565
        Fan Motor Current Draw......4566
      GEAR POSITION INDICATOR SWITCH......4566
        Test Diagram......4566
      ELECTRONIC THROTTLE CONTROL (ETC) SWITCH......4567
        ETC Switch Operation......4567
        ETC Operation Test......4567
      IGNITION SYSTEM......4568
        Flywheel Identification......4568
        EFI - DC/CDI Ignition Overview......4568
        Alternator/Ignition Components - 800 EFI......4569
        Crankshaft Position Sensor Gap......4570
        Ignition System Troubleshooting......4570
      CHARGING SYSTEM......4570
        Current Draw - Key Off......4570
        Charging System “Break Even” Test......4571
        Alternator Output Test......4571
        Charging System Testing Flow Chart......4573
      RELAYS......4574
        Operation......4574
      FUSES/Circuit Breaker......4575
        Operation......4575
      LIGHTING......4575
        High Beam Headlight Bulb Replacement......4575
        Headlight Housing Replacement......4576
        High Beam Headlight Adjustment ......4577
        Lower Headlamp Removal / Installation......4577
        Low Beam Headlight Adjustment......4578
        Headlamp Switch Test......4578
        Brake Lamp/Tail Lamp Replacement......4579
        Brake Light Switch......4579
      FUEL SENDER......4580
        Testing......4580
      ACCESSORY POWER......4580
        Wire Connections......4580
      STARTER SYSTEM......4581
        Sportsman Starter Lockout Overview and Diagnostic......4581
        Troubleshooting......4582
        Voltage Drop Test......4582
        Starter Motor Removal / Disassembly ......4582
        BRUSH INSPECTION / REPLACEMENT......4583
        Armature Testing......4584
        Starter Reassembly / Installation......4585
        Starter Solenoid Bench Test......4585
        Starter Drive......4586
        Starter Exploded View......4587
      STARTER SYSTEM TESTING FLOW CHART......4588
        Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test......4588
      BASIC WINCH WIRING- PRE-WIRED MODELS......4589
      BATTERY......4590
        Battery Identification......4590
        Battery Activation (Conventional)......4590
        Battery Terminals/Bolts......4591
        Conventional Battery Inspection / Removal......4591
        Conventional Battery Installation......4591
        Conventional Battery Testing......4592
        Conventional Battery OCV - Open Circuit Voltage Test......4592
        Conventional Battery Specific Gravity Test......4592
        Battery Load Test......4593
        Off Season Storage......4593
        Charging Procedure......4593
        Low Maintenance Battery......4594
        Low Maintenance Battery Charging......4594
        Low Maintenance Battery Inspection / Removal......4595
        Low Maintenance Battery Installation......4595
        Low Maintenance Battery - OCV- Open Circuit Voltage Test......4596
        Low Maintenance Battery Load Test......4596
        Low Maintenance Battery Off-season Storage......4597
        Low Maintenance Battery Charging Procedure......4597
      TROUBLESHOOTING DIAGRAMS......4598
        Overview......4598
        All Wheel Drive - EFI......4598
        Charging Circuit - EFI......4598
        Cooling Fan - EFI......4599
        Fuel Pump - EFI......4599
        Gear Switch - EFI......4600
        Power Circuit - EFI......4600
        Reverse Override - EFI......4601
        Fan Control - EFI......4601
        Start Circuit - EFI......4602
        Start Enable - EFI......4602
  9922030_WIRE DIAGRAMS......4604
Polaris  '09 Sportsman 850_EFI_HD_EPS Service Repair Manual......4608
  GENERAL INFORMATION......4608
    VEHICLE IDENTIFICATION......4609
      Model Identification......4609
      Engine Designation Number......4609
      Vehicle Identification Number (VIN)......4609
      Vehicle and Engine Serial Number Locations......4609
    VEHICLE INFORMATION......4610
      Publication Numbers......4610
      Replacement Keys......4610
      Special Tools......4610
    SPECIFICATIONS......4611
      MODEL: 2009 SPORTSMAN XP 850......4611
      MODEL: 2009 SPORTSMAN XP 850 EPS......4611
      2009 SPORTSMAN XP 850 / XP 850 EPS......4612
    MISC. SPECIFICATIONS AND CHARTS......4613
      Conversion Table......4613
      Standard Torque Specifications......4614
      SAE Tap / Drill Sizes......4615
      Metric Tap / Drill Sizes......4615
      Decimal Equivalents......4615
      Glossary of Terms......4616
  MAINTENANCE......4618
    PERIODIC MAINTENANCE CHART......4619
      Periodic Maintenance Overview......4619
      Break-In Period......4619
      Maintenance Chart Key......4619
      Maintenance Intervals......4620
      Grease Lubrication Points......4622
      Maintenance Quick Reference......4623
      Maintenance Quick Reference, Continued.......4624
    LUBRICANTS / SERVICE PRODUCTS......4625
      Polaris Lubricants,Maintenance and Service Products......4625
    GENERAL VEHICLE INSPECTION AND MAINTENANCE......4626
      Pre-ride / Daily Inspection......4626
      Frame, Nuts, Bolts, Fasteners......4626
      Controls......4626
    FUEL SYSTEM AND AIR INTAKE......4626
      Fuel System......4626
      Fuel Lines......4626
      Fuel Filters......4627
      Vent Line......4627
      Throttle Operation......4627
      Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment......4627
      Air Filter / Pre-Filter Service......4628
    ENGINE......4629
      Engine Oil Level......4629
      Engine Oil and Filter Change......4629
      Engine Breather Hose......4630
      Engine Breather Assembly......4630
      Valve Clearance Adjustment......4631
      Compression and Leakdown Tests......4632
      Exhaust Silencer Cleaning......4633
      Engine Mount Fastener Torque ......4633
    TRANSMISSION AND GEARCASES......4634
      Transmission Lubrication......4634
      Front Gearcase Lubrication......4635
      Front Gearcase ADC Fluid......4636
      Rear Gearcase Lubrication......4637
    COOLING SYSTEM......4638
      Cooling System Overview......4638
      Coolant Level Inspection......4638
      Cooling System Hoses......4639
      Coolant Strength / Type......4639
    PVT / FINAL DRIVE / WHEEL AND TIRE......4640
      PVT Drying......4640
      Drive Belt Removal......4640
      Drive Shaft Boot Inspection......4640
      Wheel and Hub Torque Table......4641
      Wheel Removal......4641
      Wheel Installation......4641
      Tire Pressure......4642
      Tire Inspection......4642
    ELECTRICAL AND IGNITION SYSTEM......4642
      Battery Maintenance......4642
      Battery Removal......4643
      Battery Installation......4643
      Spark Plug Service......4643
      Engine / Chassis Ground......4644
    STEERING......4645
      Steering Inspection......4645
      Power Steering Unit (EPS Models)......4645
      Tie Rod End / Steering Inspection ......4646
      Toe Alignment......4646
      Toe Alignment Adjustment......4647
    SUSPENSION......4647
      Suspension Inspection......4647
      Suspension Spring Pre-Load Adjustment......4647
    BRAKE SYSTEM......4648
      Brake Fluid Inspection......4648
      Brake Pad Inspection......4648
      Hose / Fitting Inspection......4648
      Auxiliary Brake Pedal......4649
    MAINTENANCE LOG......4650
  ELECTRONIC FUEL INJECTION......4652
    SPECIAL TOOLS......4653
      Part Numbers / Descriptions......4653
      Fuel Pressure Gauge Kit - PU-43506-A......4653
      Fuel Pressure Gauge Adaptor - PS-48762......4653
      Throttle Position Sensor Tester Kit - 2201519......4653
      Digital Wrench™ Diagnostic Software PU-47063......4654
      Digital Wrench™ SmartLink Module Kit - PU-47471......4654
      Digital Wrench™ - Diagnostic Connector......4654
      Digital Wrench™ - Download Website......4654
    FUEL TANK......4655
      Exploded View......4655
    FUEL LINE......4656
      Quick Connect Removal / Installation......4656
    EFI SERVICE NOTES......4656
    EFI SYSTEM LAYOUT......4657
      Exploded View......4657
    EFI COMPONENTS......4658
      Identification / Location......4658
    ELECTRONIC FUEL INJECTION......4660
      General Information......4660
      EFI Operation Overview......4660
      Initial Priming / Starting Procedure......4660
    ELECTRONIC CONTROL UNIT (ECU)......4661
      Operation Overview......4661
      ECU Service......4661
      ECU Removal / Replacement......4662
    FUEL PUMP......4662
      Operation......4662
      Fuel Sender Test......4663
      Fuel Pump Test......4663
      Fuel Pump / Fuel Tank Removal......4664
      Fuel Pump / Fuel Tank Installation......4665
    FUEL PRESSURE REGULATOR......4665
      Operation Overview......4665
    FUEL INJECTORS......4665
      Operation Overview......4665
      Fuel Injector Service......4665
      Fuel Injector Test......4666
      Fuel Injector Replacement......4666
    CRANKSHAFT POSITION SENSOR (CPS)......4667
      Operation Overview......4667
      CPS Test......4667
      CPS Replacement......4667
    TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)......4668
      Operation Overview......4668
      T-MAP Test......4668
      T-MAP Replacement......4668
    IDLE AIR CONTROL VALVE (IAC)......4668
      Operation Overview......4668
      IAC Test......4668
      IAC Replacement......4669
    THROTTLE POSITION SENSOR (TPS)......4670
      Operation Overview......4670
      TPS Resistance Tests......4670
      TPS Tester Kit......4670
      Checking TPS Reading......4671
      TPS Adjustment......4672
      TPS Replacement......4673
    ENGINE COOLANT TEMPERATURE SENSOR (ECT)......4673
      Operation Overview......4673
      ECT Sensor Test......4673
      ECT Sensor Replacement......4674
    IGNITION COIL......4674
      Operation Overview......4674
      Ignition Coil Tests......4674
      Ignition Coil and HT Lead Replacement......4675
    EFI DIAGNOSTICS......4676
      Instrument Cluster Trouble Code Display......4676
    FUEL SYSTEM TROUBLESHOOTING......4679
      Fuel Starvation / Lean Mixture......4679
      Rich Mixture......4679
      Poor Idle......4679
    EFI SYSTEM BREAK-OUT DIAGRAMS......4680
      Fuel Injector Circuit (PTO)......4681
      Fuel Injector Circuit (MAG)......4681
      Idle Air Control (IAC) Circuit......4682
      Crankshaft Position Sensor (CPS) Circuit......4682
      Fuel Pump / Fuel Level Sensor Circuit......4683
      Fuel Pump Circuit......4684
      Fuel Gauge Circuit......4684
      Engine Coolant Temperature Sensor (ECT) Circuit ......4685
      Throttle Position Sensor (TPS) Circuit......4685
      Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit......4686
      Diagnostic Connector Circuit......4686
      Diagnostic Connector Circuit (EPS Models)......4687
  COOLING SYSTEM......4688
    SPECIAL TOOLS......4689
    TORQUE SPECIFICATIONS......4689
    COOLING SYSTEM......4689
      Cooling System Layout and Testing......4689
      Cooling System Specifications......4690
      Cooling System Bleeding Procedure......4691
    RADIATOR......4691
      Radiator Cleaning......4691
      Coolant Drain / Radiator Removal......4691
    WATER PUMP SERVICE......4693
      Water Pump Impeller Removal......4693
      Water Pump Mechanical Seal Replacement......4694
      Water Pump Shaft & Bearing Replacement......4695
      Stator Cover Installation......4696
      Water Pump Assembly / Torque Specifications......4697
      Stator Cover Assembly Torque Specifications......4698
    THERMOSTAT......4699
      Removal (Engine Installed)......4699
      Installation......4699
    TROUBLESHOOTING......4699
      Cooling System......4699
  ENGINE......4700
    GENERAL INFORMATION - ENGINE......4702
      Special Tools......4702
      Engine Lubrication Specifications......4702
      Oil Pressure Test......4702
      Oil Flow Diagram......4703
      Engine Specifications - EH085OLE-011......4704
    ENGINE ASSEMBLY VIEWS AND TORQUE VALUES......4706
      Torque & Torque Sequence - Main Engine Components......4706
      Valve Cover / Breather Valve......4707
      Camshaft Carrier / Camshaft / Rocker Arm......4708
      Cylinder Head / Valve / IAFM......4709
      Valve & Spring Height Detail......4710
      Piston / Connecting Rod......4711
      Crankshaft......4712
      Crankcase......4713
      Crankcase - Upper......4714
      Balance Shaft / Balance Shaft Timing......4715
      Crankcase (Lower) With Oil Pump......4716
      Water Pump Coupler......4717
      Water Pump / Water Pump Coupler / Stator / Flywheel......4718
      Drive Coupler (Rear) / Starter Gear......4719
    ENGINE SERVICE......4720
      Accessible Engine Components......4720
      Top-End Service (Engine in Chassis)......4720
      Crankcase Cylinder Service Information......4720
      Engine Removal......4720
      Engine Installation Notes......4724
    ENGINE DISASSEMBLY AND INSPECTION......4725
      Valve Cover / Breather Valve......4725
      Rocker Carrier / Camshaft Removal......4725
      Rocker Arm / Rocker Arm Shaft Inspection......4726
      Camshaft / Camshaft Bore Inspection......4727
      Cylinder Head Removal ......4727
      Cylinder Head Cleaning......4727
      Cylinder Head Warp Inspection......4728
      Cylinder Head......4728
      Valve Inspection......4729
      Combustion Chamber......4730
      Valve Guide Removal / Installation......4730
      Valve Seat Reconditioning......4731
      Cylinder Head Assembly......4733
      Valve Sealing Test......4733
      Cylinder Head Installation......4734
      Camshaft / Carrier Assembly......4735
      Camshaft / Camshaft Carrier Installation......4735
      Camshaft Timing......4736
      Cam Chain Tensioner Installation......4737
      Camshaft Timing - Quick Reference......4738
      Crankcase Disassembly......4739
      Crankcase (Lower) / Oil Pump Disassembly......4740
      Crankcase Disassembly (Upper)......4742
      Piston / Connecting Rod Removal......4742
      Counterbalance Shaft Removal / Inspection......4743
      Counterbalance Split Gear Replacement......4743
      Crankshaft / Cam Chain Removal......4745
      Cam Chain / Sprocket Inspection......4745
      Crankcase Inspection (Lower)......4745
      Crankshaft Inspection......4745
      Connecting Rod Inspection......4746
      Connecting Rod Big End Bearing Selection......4747
      Piston / Piston Ring Inspection......4747
      Piston Ring Removal......4747
      Piston Ring Installed Gap......4748
      Piston Pin Bore Inspection......4748
      Cylinder Inspection......4748
      Piston-to-Cylinder Clearance......4749
      Honing - Important Information......4749
    ENGINE ASSEMBLY......4750
      Crankcase Preparation - Upper......4750
      Piston Ring Installation......4750
      Piston / Connecting Rod Assembly......4751
      Piston / Connecting Rod Installation......4751
      Crankshaft Installation......4752
      Oil Passage Tube......4752
      Crankcase Assembly - Upper ......4753
      Balance Shaft Installation......4754
      Balance Shaft Timing......4755
      Crankcase Preparation (Lower)......4756
      Crankcase Sealant and Torque Values......4757
      Crankcase Assembly......4758
    WATER PUMP......4758
      Water Pump Impeller Removal......4758
      Water Pump Mechanical Seal Replacement / Coupler Shaft & Bearing Replacement......4758
    TROUBLESHOOTING......4759
      Engine......4759
  TRANSMISSION......4762
    TRANSMISSION SPECIFICATIONS......4763
      Torque Specifications......4763
      Lubrication Specifications......4763
    SHIFT LINKAGE / GEAR SELECTOR......4763
      Shift Linkage Inspection......4763
      Gear Selector Removal......4763
    TRANSMISSION SERVICE......4764
      Transmission Removal......4764
      Transmission Disassembly ......4765
      Transmission Shaft Service......4769
      Transmission Assembly......4771
      Transmission Installation......4775
      Transmission Exploded View......4777
    TROUBLESHOOTING......4779
      Troubleshooting Checklist......4779
  CLUTCHING (PVT)......4780
    SPECIAL TOOLS AND SUPPLIES......4781
    TORQUE SPECIFICATIONS......4781
      PVT System Fastener Torques......4781
    PVT SYSTEM OVERVIEW......4781
      General Operation......4781
      Drive Clutch Operation......4781
      Shift Weights......4782
      Driven Clutch Operation......4782
      PVT Break-In (Drive Belt / Clutches)......4782
      Maintenance / Inspection......4782
      Overheating / Diagnosis......4783
    PVT SYSTEM SERVICE......4784
      PVT Sealing and Ducting Components......4784
      Disassembly......4785
      Assembly......4786
    DRIVE BELT......4788
      Belt Removal......4788
      Belt Inspection......4789
      Belt Installation......4789
      PVT Break-In (Drive Belt / Clutches)......4789
    DRIVE CLUTCH SERVICE......4790
      Spring Specifications......4790
      Exploded View......4791
      Clutch Disassembly......4791
      Spider Removal......4792
      Roller, Pin, and Thrust Washer Inspection......4793
      Button To Tower Clearance Inspection......4793
      Shift Weight Inspection......4793
      Bearing Inspection......4794
      Clutch Inspection......4794
      Moveable Sheave Bushing Inspection......4795
      Bushing Service......4796
      Clutch Assembly......4798
    DRIVEN CLUTCH SERVICE......4799
      Clutch Disassembly ......4799
      Bushing Service......4801
      Clutch Assembly......4803
      Exploded View......4806
    TROUBLESHOOTING......4807
  FINAL DRIVE......4810
    GENERAL SPECIFICATIONS......4811
      Torque Specifications......4811
      Special Tools......4811
    WHEELS......4811
      Removal......4811
      Installation......4811
    WHEEL HUBS......4812
      Front Hub Exploded View......4812
      Rear Hub Exploded View......4812
    FRONT BEARING CARRIER......4813
      Inspection / Removal......4813
      Bearing Replacement......4814
      Installation......4815
    FRONT DRIVE SHAFT......4816
      Removal......4816
      Installation......4817
    FRONT PROPSHAFT......4818
      Removal......4818
      Installation......4818
    PROPSHAFT U-JOINT SERVICE......4818
      Disassembly......4818
      Assembly......4819
    FRONT GEARCASE - CENTRALIZED HILLIARD......4820
      Exploded View......4820
      AWD Operation......4821
      ADC Operation......4822
      AWD Diagnosis......4823
      Gearcase Removal......4824
      Gearcase Disassembly / Inspection......4825
      Gearcase Assembly......4829
      Setting Ring Gear Backlash......4831
      Gearcase Installation......4832
      ADC System Fluid Bleeding......4834
    REAR BEARING CARRIER......4835
      Inspection / Removal......4835
      Bearing Replacement......4836
      Bushing Replacement......4837
      Installation......4837
    REAR DRIVE SHAFT......4839
      Removal......4839
      Installation......4840
    DRIVE SHAFT SERVICE......4841
      Drive Shaft / CV Joint Handling Tips......4841
      Outer CV Joint / Boot Replacement......4841
      Inner Plunging Joint / Boot Replacement......4843
      Drive Shaft Exploded View......4845
    REAR PROPSHAFT......4846
      Removal......4846
      Installation......4846
    REAR GEARCASE......4847
      Gearcase Removal......4847
      Gearcase Disassembly and Inspection......4849
      Gearcase Bearing and Seal Replacement......4850
      Gearcase Assembly......4851
      Gearcase Installation......4852
      Gearcase Exploded View......4853
  BODY / FRAME......4854
    TORQUE SPECIFICATIONS......4855
    DECAL REPLACEMENT......4855
    SPECIAL TOOLS......4855
      Plastic Push Rivet Removal......4855
      Multi-Function Pliers......4855
    SEAT AND SIDE PANELS......4856
      Removal / Installation......4856
    FRONT RACK......4856
      Removal / Installation......4856
    FRONT BUMPER......4857
      Removal / Installation......4857
    MUD GUARDS......4857
      Removal / Installation......4857
    FOOTWELLS......4857
      Removal / Installation......4857
    FRONT CAB......4858
      Removal......4858
      Installation......4858
    REAR RACK......4859
      Removal / Installation......4859
    REAR BUMPER COVERS......4859
      Removal / Installation......4859
    REAR CAB......4859
      Removal / Installation......4859
    HEADLIGHT POD......4860
      Disassembly / Removal......4860
      Assembly / Installation......4860
    MAIN FRAME......4861
      Frame Support Exploded View......4861
    CHASSIS......4862
      Body Plastic Removed View......4862
  STEERING / SUSPENSION......4864
    GENERAL SPECIFICATIONS......4865
      Torque Specifications......4865
    HANDLEBAR......4865
      Removal / Replacement......4865
      Installation......4866
    STEERING......4866
      Steering Post Removal......4866
      Steering Post Installation......4867
      Steering Exploded View......4868
    STEERING (EPS MODELS)......4869
      Upper Steering Post Removal......4869
      Upper Steering Post Installation......4869
      Power Steering Unit Removal......4870
      Power Steering Unit Installation......4871
      Steering Exploded View (EPS Models)......4873
    STEERING TIE ROD......4874
      Tie Rod / Tie Rod End Replacement......4874
    FRONT A-ARMS......4875
      Exploded View......4875
      Removal / Replacement......4876
    BALL JOINT SERVICE......4877
      Removal......4877
      Installation......4877
    REAR A-ARMS......4879
      Exploded View......4879
      Removal......4880
      Installation......4880
    REAR STABILIZER BAR......4881
      Exploded View......4881
      Linkage Removal / Installation......4882
      Stabilizer Bar Removal / Installation......4882
    SHOCKS / SPRINGS......4883
      Exploded View......4883
      Shock Removal / Installation......4883
      Shock / Spring Replacement......4883
  BRAKES......4884
    SPECIFICATIONS......4885
      General Brake Specifications......4885
      General Torque Specifications......4885
      Special Tools / Brake Fluid......4885
    BRAKE SYSTEM SERVICE NOTES......4886
    BRAKE NOISE TROUBLESHOOTING......4886
    HYDRAULIC BRAKE SYSTEM OPERATION......4887
    BRAKE SYSTEM EXPLODED VIEW......4887
      Brake Caliper Exploded View......4888
      Hand Master Cylinder Exploded View......4888
    BRAKE BLEEDING......4889
      Fluid Replacement......4889
      Bleeding Procedure......4889
    HAND BRAKE MASTER CYLINDER......4891
      Removal......4891
      Disassembly......4891
      Installation......4891
      Brake Switch Replacement......4891
    FOOT BRAKE MASTER CYLINDER......4892
      Operation Overview......4892
      Foot Master Cylinder Removal / Installation......4892
      Brake Pedal Removal / Installation......4892
    BRAKE PADS......4893
      Pad Removal......4893
      Pad Inspection......4893
      Pad Installation......4893
      Brake Burnishing Procedure......4894
    CALIPER SERVICE......4894
      Caliper Removal......4894
      Caliper Disassembly......4894
      Caliper Inspection......4895
      Caliper Reassembly......4896
      Caliper Installation......4896
    BRAKE DISC SERVICE......4897
      Disc Inspection......4897
      Disc Removal / Replacement......4897
    TROUBLESHOOTING......4899
      Brake Squeal......4899
  Wire_Diagrams......0
    SPORTSMAN XP 850 (PAGE 1 OF 2)......4900
    SPORTSMAN XP 850 (PAGE 2 OF 2)......4901
    AWD / ADC......4902
    BATTERY CHARGING......4903
    BATTERY PLUS......4904
    BRAKE LAMPS-START......4905
    CHASSIS POWER......4906
    COOLING FAN......4907
    ECM WAKE-UP......4908
    EFI......4909
    ENGINE CRANK......4910
    EPS......4911
    FUEL PUMP & LEVEL......4912
    GEAR SENSOR......4913
    GROUND SPEED SENSOR......4914
    KEY ON POWER......4915
    HEADLAMPS......4916
Polaris  '09 Sportsman XP 550_EPS Service Repair Manual......4917
  9921830_Chapter_01.pdf......4917
    GENERAL INFORMATION......4917
      VEHICLE IDENTIFICATION......4918
        Model Identification......4918
        Engine Designation Number......4918
        Vehicle Identification Number (VIN)......4918
        Vehicle and Engine Serial Number Locations......4918
      VEHICLE INFORMATION......4919
        Publication Numbers......4919
        Replacement Keys......4919
        Special Tools......4919
      SPECIFICATIONS......4920
        MODEL: 2009 SPORTSMAN XP 550......4920
        MODEL: 2009 SPORTSMAN XP 550 EPS......4920
        2009 SPORTSMAN XP 550 / XP 550 EPS......4921
      MISC. SPECIFICATIONS AND CHARTS......4922
        Conversion Table......4922
        Standard Torque Specifications......4923
        SAE Tap / Drill Sizes......4924
        Metric Tap / Drill Sizes......4924
        Decimal Equivalents......4924
        Glossary of Terms......4925
  9921830_Chapter_02......4927
    MAINTENANCE......4927
      PERIODIC MAINTENANCE CHART......4928
        Periodic Maintenance Overview......4928
        Break-In Period......4928
        Maintenance Chart Key......4928
        Maintenance Intervals......4929
        Grease Lubrication Points......4931
        Maintenance Quick Reference......4932
        Maintenance Quick Reference, Continued.......4933
      LUBRICANTS / SERVICE PRODUCTS......4934
        Polaris Lubricants,Maintenance and Service Products......4934
      GENERAL VEHICLE INSPECTION AND MAINTENANCE......4935
        Pre-ride / Daily Inspection......4935
        Frame, Nuts, Bolts, Fasteners......4935
        Controls......4935
      FUEL SYSTEM AND AIR INTAKE......4935
        Fuel System......4935
        Fuel Lines......4935
        Fuel Filters......4936
        Vent Line......4936
        Throttle Operation......4936
        Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment......4936
        Air Filter / Pre-Filter Service......4937
      ENGINE......4938
        Engine Oil Level......4938
        Engine Oil and Filter Change......4938
        Engine Breather Hoses......4939
        Compression and Leakdown Tests......4939
        Valve Clearance Adjustment......4940
        Exhaust Silencer Cleaning......4942
        Engine Mount Fastener Torque ......4942
      TRANSMISSION AND GEARCASES......4943
        Transmission Lubrication......4943
        Front Gearcase Lubrication......4944
        Front Gearcase ADC Fluid......4945
        Rear Gearcase Lubrication......4946
      COOLING SYSTEM......4947
        Cooling System Overview......4947
        Coolant Level Inspection......4947
        Cooling System Hoses......4948
        Coolant Strength / Type......4948
      PVT / FINAL DRIVE / WHEEL AND TIRE......4949
        PVT Drying......4949
        Drive Belt Removal......4949
        Drive Shaft Boot Inspection......4949
        Wheel and Hub Torque Table......4950
        Wheel Removal......4950
        Wheel Installation......4950
        Tire Pressure......4951
        Tire Inspection......4951
      ELECTRICAL AND IGNITION SYSTEM......4951
        Battery Maintenance......4951
        Battery Removal......4952
        Battery Installation......4952
        Spark Plug Service......4952
        Engine / Chassis Ground......4953
      STEERING......4954
        Steering Inspection......4954
        Power Steering Unit (EPS Models)......4954
        Tie Rod End / Steering Inspection ......4955
        Toe Alignment......4955
        Toe Alignment Adjustment......4956
      SUSPENSION......4956
        Suspension Inspection......4956
        Suspension Spring Pre-Load Adjustment......4956
      BRAKE SYSTEM......4957
        Brake Fluid Inspection......4957
        Brake Pad Inspection......4957
        Hose / Fitting Inspection......4957
        Auxiliary Brake Pedal......4958
      MAINTENANCE LOG......4959
  9921830_Chapter_03......4961
    ELECTRONIC FUEL INJECTION......4961
      SPECIAL TOOLS......4962
        Part Numbers / Descriptions......4962
        Fuel Pressure Gauge Kit - PU-43506-A......4962
        Fuel Pressure Gauge Adaptor - PV-48656......4962
        Throttle Position Sensor Tester Kit - 2201519......4962
        Digital Wrench™ Diagnostic Software PU-47063......4963
        Digital Wrench™ SmartLink Module Kit - PU-47471......4963
        Digital Wrench™ - Diagnostic Connector......4963
        Digital Wrench™ - Download Website......4963
      FUEL TANK......4964
        Exploded View......4964
      FUEL LINE......4965
        Quick Connect Removal / Installation......4965
      EFI SERVICE NOTES......4965
      EFI SYSTEM LAYOUT......4966
        Exploded View......4966
      EFI COMPONENTS......4967
        Identification / Location......4967
      ELECTRONIC FUEL INJECTION......4969
        General Information......4969
        EFI Operation Overview......4969
        Initial Priming / Starting Procedure......4969
      ELECTRONIC CONTROL UNIT (ECU)......4970
        Operation Overview......4970
        ECU Service......4970
        ECU Removal / Replacement......4971
      FUEL PUMP ASSEMBLY......4971
        Operation......4971
        Fuel Sender Test......4972
        Fuel Pump Test......4972
        Fuel Pump / Fuel Tank Removal......4973
        Fuel Pump / Fuel Tank Installation......4974
      FUEL PRESSURE REGULATOR......4974
        Operation Overview......4974
      FUEL INJECTOR......4974
        Operation Overview......4974
        Fuel Injector Service......4974
        Fuel Injector Test......4975
        Fuel Injector Replacement......4975
      CRANKSHAFT POSITION SENSOR (CPS)......4976
        Operation Overview......4976
        CPS Test......4976
        CPS Replacement......4976
      TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)......4977
        Operation Overview......4977
        T-MAP Sensor Test......4977
        T-MAP Sensor Replacement......4977
      IDLE AIR CONTROL (IAC)......4978
        Operation Overview......4978
        IAC Test......4978
        IAC Replacement......4978
      THROTTLE POSITION SENSOR (TPS)......4979
        Operation Overview......4979
        TPS Resistance Tests......4979
        TPS Tester Kit......4979
        Checking TPS Reading......4980
        TPS Adjustment......4981
        TPS Replacement......4982
      ENGINE COOLANT TEMPERATURE SENSOR (ECT)......4982
        Operation Overview......4982
        ECT Sensor Test......4982
        ECT Sensor Replacement......4982
      IGNITION COIL......4983
        Operation Overview......4983
        Ignition Coil Tests......4983
        Ignition Coil and HT Lead Replacement......4984
      FUEL SYSTEM TROUBLESHOOTING......4985
        Fuel Starvation / Lean Mixture......4985
        Rich Mixture......4985
        Poor Idle......4985
      EFI DIAGNOSTICS......4986
        Instrument Cluster Trouble Code Display......4986
      EFI SYSTEM BREAK-OUT DIAGRAMS......4988
        EFI Sensor Circuits......4988
        Fuel Injector Circuit......4989
        Crankshaft Position Sensor (CPS) Circuit......4989
        Fuel Pump / Fuel Level Sensor Circuit......4990
        Fuel Pump Circuit......4991
        Ignition Coil Circuit......4992
        Idle Air Control (IAC) Circuit......4992
        Throttle Position Sensor (TPS) Circuit......4993
        Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit......4993
        Engine Coolant Temperature Sensor (ECT) Circuit......4994
        Diagnostic Connector Circuit......4994
        Diagnostic Connector Circuit (EPS Models)......4995
  9921830_Chapter_04......4997
    COOLING SYSTEM......4997
      SPECIAL TOOLS......4998
      TORQUE SPECIFICATIONS......4998
      COOLING SYSTEM......4998
        Cooling System Layout and Testing......4998
        Cooling System Specifications......4999
        Cooling System Bleeding Procedure......5000
      RADIATOR......5000
        Radiator Cleaning......5000
        Coolant Drain / Radiator Removal......5000
      WATER PUMP SERVICE......5002
        Water Pump Mechanical Seal Removal ......5002
        Water Pump Shaft Oil Seal Removal / Installation......5003
        Water Pump Mechanical Seal Installation......5003
      THERMOSTAT......5004
        Removal (Engine Installed)......5004
        Removal (Engine Removed)......5004
        Installation......5005
      TROUBLESHOOTING......5005
        Cooling System......5005
  9921830_Chapter_05......5007
    ENGINE......5007
      SPECIAL TOOLS......5009
        Engine......5009
      SPECIFICATIONS......5009
        Torque Specifications......5009
        Engine Service Data......5010
        Engine Service Data......5011
        Engine Fastener Torque Patterns......5012
      GENERAL ENGINE SERVICE......5012
        Piston Identification......5012
        Accessible Engine Components......5013
        Top-End Service (Engine in Chassis)......5013
        Engine Removal......5013
        Engine Installation Notes......5016
        Engine Lubrication - ES55PLE......5016
        Oil Pressure Test - ES55PLE......5016
        Oil Flow Diagram - ES55PLE Engine......5017
        Exploded Views - ES55PLE Engine ......5018
      ENGINE DISASSEMBLY - TOP END......5019
        Cam Chain Tensioner / Cam Sprocket Removal......5019
        Camshaft Sprocket Inspection......5019
        Cam Chain Tensioner Inspection......5020
        Rocker Support Removal......5020
        Camshaft / Rocker Arm Inspection......5020
        Automatic Compression Release Inspection......5022
        Automatic Compression Release Installation......5022
        Cylinder Head Removal......5023
        Cylinder Head Inspection......5023
        Cylinder Head Warpage......5023
        Cylinder Head Disassembly......5024
        Valve Inspection......5025
        Combustion Chamber......5026
        Valve Seat Reconditioning......5026
        Cylinder Head Assembly......5028
        Valve Sealing Test......5029
        Cylinder Removal......5029
        Cylinder Inspection......5030
        Piston Removal......5030
        Piston-to-Cylinder Clearance......5031
        Piston / Rod Inspection......5031
        Piston Ring Installed Gap......5032
        Honing to Oversize......5033
        Cylinder Hone Selection / Honing Procedure......5033
        Cleaning the Cylinder After Honing......5033
      ENGINE DISASSEMBLY - LOWER END......5034
        Crankcase Disassembly......5034
        Drive Coupler Removal / Inspection......5034
        Drive Coupler Installation......5034
        Flywheel / Stator Housing Removal......5034
        Starter One-Way Clutch Inspection......5035
        Starter One-Way Clutch Installation......5036
        Flywheel Installation......5036
        Stator Removal......5037
        Stator / Stator Cover Installation......5037
        Cam Chain / Tensioner Blade......5038
        Oil Pump Removal......5038
        Oil Pump Assembly......5039
        Crankcase Separation......5039
        Balance Shaft Removal / Inspection......5040
        Crankshaft Removal......5041
        Crankshaft Inspection......5041
        Crankcase Bearing Inspection / Removal......5042
        Crankcase Inspection ......5042
        Bearing Installation......5042
        Water Pump Mechanical Seal Replacement......5042
        Water Pump Shaft Oil Seal Replacement......5042
      ENGINE ASSEMBLY - LOWER END......5043
        Crankcase Assembly - PTO Side......5043
        Balance Shaft Installation / Timing......5044
      ENGINE ASSEMBLY - TOP END......5046
        Piston Ring Installation......5046
        Piston Installation......5046
        Cylinder Installation......5047
        Camshaft Chain Installation......5048
        Cylinder Head Installation......5049
        Camshaft / Rocker Support Installation......5049
        Camshaft Timing......5050
        Cam Chain Tensioner Installation......5052
        Camshaft Timing Quick Reference......5053
        Valve Clearance Adjustment......5054
        Oil Delivery Pipe Installation......5054
        Thermostat Installation......5054
      TROUBLESHOOTING......5055
        Engine......5055
        Spark Plug Fouling......5056
  9921830_Chapter_06......5057
    TRANSMISSION......5057
      TRANSMISSION SPECIFICATIONS......5058
        Torque Specifications......5058
        Lubrication Specifications......5058
      SHIFT LINKAGE / GEAR SELECTOR......5058
        Shift Linkage Inspection......5058
        Gear Selector Removal......5058
      TRANSMISSION SERVICE......5059
        Transmission Removal......5059
        Transmission Disassembly ......5060
        Transmission Shaft Service......5064
        Transmission Assembly......5066
        Transmission Installation......5070
        Transmission Exploded View......5072
      TROUBLESHOOTING......5074
        Troubleshooting Checklist......5074
  9921830_Chapter_07......5075
    CLUTCHING (PVT)......5075
      SPECIAL TOOLS AND SUPPLIES......5076
      TORQUE SPECIFICATIONS......5076
        PVT System Fastener Torques......5076
      PVT SYSTEM OVERVIEW......5076
        General Operation......5076
        Drive Clutch Operation......5076
        Shift Weights......5077
        Driven Clutch Operation......5077
        PVT Break-In (Drive Belt / Clutches)......5077
        Maintenance / Inspection......5077
        Overheating / Diagnosis......5078
      PVT SYSTEM SERVICE......5079
        PVT Sealing and Ducting Components......5079
        Disassembly......5080
        Assembly......5081
      DRIVE BELT......5083
        Belt Removal......5083
        Belt Inspection......5084
        Belt Installation......5084
        PVT Break-In (Drive Belt / Clutches)......5084
      DRIVE CLUTCH SERVICE......5085
        Spring Specifications......5085
        Exploded View......5086
        Clutch Disassembly......5086
        Spider Removal......5087
        Roller, Pin, and Thrust Washer Inspection......5088
        Button To Tower Clearance Inspection......5088
        Shift Weight Inspection......5088
        Bearing Inspection......5089
        Clutch Inspection......5089
        Moveable Sheave Bushing Inspection......5090
        Bushing Service......5091
        Clutch Assembly......5093
      DRIVEN CLUTCH SERVICE......5094
        Clutch Disassembly ......5094
        Bushing Service......5096
        Clutch Assembly......5098
        Exploded View......5101
      TROUBLESHOOTING......5102
  9921830_Chapter_08......5105
    FINAL DRIVE......5105
      GENERAL SPECIFICATIONS......5106
        Torque Specifications......5106
        Special Tools......5106
      WHEELS......5106
        Removal......5106
        Installation......5106
      WHEEL HUBS......5107
        Front Hub Exploded View......5107
        Rear Hub Exploded View......5107
      FRONT BEARING CARRIER......5108
        Inspection / Removal......5108
        Bearing Replacement......5109
        Installation......5110
      FRONT DRIVE SHAFT......5111
        Removal......5111
        Installation......5112
      FRONT PROPSHAFT......5113
        Removal......5113
        Installation......5113
      PROPSHAFT U-JOINT SERVICE......5113
        Disassembly......5113
        Assembly......5114
      FRONT GEARCASE - CENTRALIZED HILLIARD......5115
        Exploded View......5115
        AWD Operation......5116
        ADC Operation......5117
        AWD Diagnosis......5118
        Gearcase Removal......5119
        Gearcase Disassembly / Inspection......5120
        Gearcase Assembly......5124
        Setting Ring Gear Backlash......5126
        Gearcase Installation......5127
        ADC System Fluid Bleeding......5129
      REAR BEARING CARRIER......5130
        Inspection / Removal......5130
        Bearing Replacement......5131
        Bushing Replacement......5132
        Installation......5132
      REAR DRIVE SHAFT......5134
        Removal......5134
        Installation......5135
      DRIVE SHAFT SERVICE......5136
        Drive Shaft / CV Joint Handling Tips......5136
        Outer CV Joint / Boot Replacement......5136
        Inner Plunging Joint / Boot Replacement......5138
        Drive Shaft Exploded View......5140
      REAR PROPSHAFT......5141
        Removal......5141
        Installation......5141
      REAR GEARCASE......5142
        Gearcase Removal......5142
        Gearcase Disassembly and Inspection......5144
        Gearcase Bearing and Seal Replacement......5145
        Gearcase Assembly......5146
        Gearcase Installation......5147
        Gearcase Exploded View......5148
  9921830_Chapter_09......5149
    BODY / FRAME......5149
      TORQUE SPECIFICATIONS......5150
      DECAL REPLACEMENT......5150
      SPECIAL TOOLS......5150
        Plastic Push Rivet Removal......5150
        Multi-Function Pliers......5150
      SEAT AND SIDE PANELS......5151
        Removal / Installation......5151
      FRONT RACK......5151
        Removal / Installation......5151
      FRONT BUMPER......5152
        Removal / Installation......5152
      MUD GUARDS......5152
        Removal / Installation......5152
      FOOTWELLS......5152
        Removal / Installation......5152
      FRONT CAB......5153
        Removal......5153
        Installation......5153
      REAR RACK......5154
        Removal / Installation......5154
      REAR BUMPER COVERS......5154
        Removal / Installation......5154
      REAR CAB......5154
        Removal / Installation......5154
      HEADLIGHT POD......5155
        Disassembly / Removal......5155
        Assembly / Installation......5155
      MAIN FRAME......5156
        Frame Support Exploded View......5156
  9921830_Chapter_10......5157
    STEERING / SUSPENSION......5157
      GENERAL SPECIFICATIONS......5158
        Torque Specifications......5158
      HANDLEBAR......5158
        Removal / Replacement......5158
        Installation......5159
      STEERING......5159
        Steering Post Removal......5159
        Steering Post Installation......5160
        Steering Exploded View......5161
      STEERING (EPS MODELS)......5162
        Upper Steering Post Removal......5162
        Upper Steering Post Installation......5162
        Power Steering Unit Removal......5163
        Power Steering Unit Installation......5164
        Steering Exploded View (EPS Models)......5166
      STEERING TIE ROD......5167
        Tie Rod / Tie Rod End Replacement......5167
      FRONT A-ARMS......5168
        Exploded View......5168
        Removal / Replacement......5169
      BALL JOINT SERVICE......5170
        Removal......5170
        Installation......5171
      REAR A-ARMS......5172
        Exploded View......5172
        Removal......5173
        Installation......5173
      REAR STABILIZER BAR......5174
        Exploded View......5174
        Linkage Removal / Installation......5175
        Stabilizer Bar Removal / Installation......5175
      SHOCKS / SPRINGS......5176
        Exploded View......5176
        Shock Removal / Installation......5176
        Shock / Spring Replacement......5176
  9921830_Chapter_11......5177
    BRAKES......5177
      SPECIFICATIONS......5178
        General Brake Specifications......5178
        General Torque Specifications......5178
        Special Tools / Brake Fluid......5178
      BRAKE SYSTEM SERVICE NOTES......5179
      BRAKE NOISE TROUBLESHOOTING......5179
      HYDRAULIC BRAKE SYSTEM OPERATION......5180
      BRAKE SYSTEM EXPLODED VIEW......5180
        Brake Caliper Exploded View......5181
        Hand Master Cylinder Exploded View......5181
      BRAKE BLEEDING......5182
        Fluid Replacement......5182
        Bleeding Procedure......5182
      HAND BRAKE MASTER CYLINDER......5184
        Removal......5184
        Disassembly......5184
        Installation......5184
        Brake Switch Replacement......5184
      FOOT BRAKE MASTER CYLINDER......5185
        Operation Overview......5185
        Foot Master Cylinder Removal / Installation......5185
        Brake Pedal Removal / Installation......5185
      BRAKE PADS......5186
        Pad Removal......5186
        Pad Inspection......5186
        Pad Installation......5186
        Brake Burnishing Procedure......5187
      CALIPER SERVICE......5187
        Caliper Removal......5187
        Caliper Disassembly......5187
        Caliper Inspection......5188
        Caliper Reassembly......5189
        Caliper Installation......5189
      BRAKE DISC SERVICE......5190
        Disc Inspection......5190
        Disc Removal / Replacement......5190
      TROUBLESHOOTING......5192
        Brake Squeal......5192
  9921830_Chapter_12......5193
    ELECTRICAL......5193
      General Information......5195
        Special Tools......5195
        Electrical Service Notes......5195
        Component Locations......5195
      Instrument Cluster......5196
        Overview......5196
        Rider Information Display......5197
        Speed Information......5198
        Information Display Area......5198
        Diagnostic Mode......5200
        Instrument Cluster Pinouts......5201
      Ignition Switch......5201
        Function Test......5201
      ADC / 4x4 / 2x4 Switch......5202
        Function Test......5202
      Off / Run LH Switch......5202
        Function Test......5202
      Reverse Override / Mode Button......5203
        Function Test......5203
      Head Lamp Switch......5203
        Function Test......5203
      Electronic Throttle Control (ETC) Switch......5204
        Electronic Throttle Control (ETC) Switch......5204
      Gear Selector Switch......5204
        Selector Switch Function Test......5204
        Resistor Module Function Test......5204
      Speed Sensor......5205
        Vehicle Speed Sensor......5205
      Brake Switch......5206
        Function Test......5206
      AWD / ADC Coils......5206
        Operation Overview......5206
        Diagnosing System Failures......5206
      Relays......5207
        Relay Overview......5207
        Chassis Relay......5207
        Fan Relay......5207
        EFI Relay......5207
        Bumper Lights Relay......5208
        ECU Relay......5208
        Power Steering Relay......5208
      Fuses......5209
        Protected Circuits......5209
      Fuse Box Layout......5209
      Lights......5210
        Headlight Adjustment......5210
        Bumper Lamp Adjustment......5210
        Headlight Replacement......5211
        Bumper Lamp Replacement......5211
        Tail / Brake Bulb Replacement......5211
      Charging System......5212
        Charging System Diagram......5212
        Charging System Testing......5212
        Current Draw - Key Off......5212
        Battery Charge Test......5212
        Stator / Alternator Tests......5213
        Stator / Alternator Replacement......5213
      Battery Service......5214
        Battery Specifications......5214
        General Battery Information......5214
        Battery Removal / Installation......5214
        Battery Off Season Storage......5214
        Battery Testing......5214
        OCV - Open Circuit Voltage Test......5215
        Load Test......5215
        Charging Procedure ......5215
      Starter Motor......5216
        Starter / Starter Lockout System Diagram......5216
        Troubleshooting......5216
        Voltage Drop Testing......5216
        Starter Motor Removal / Replacement......5216
        Starter Motor Disassembly......5217
        Brush Inspection / Replacement......5217
        Armature Testing......5218
        Starter Motor Reassembly......5219
        Starter Motor Installation......5219
        Starter Drive Service......5220
        Starter Solenoid Bench Test......5220
      Instrument Cluster Troubleshooting......5221
        Instrument Cluster - Key OFF / No Power......5221
        Instrument Cluster - Key ON / No Power......5222
        Instrument Cluster - No High Beam Indicator......5223
        Instrument Cluster - No / Incorrect Fuel Level......5224
        Instrument Cluster Circuit......5225
      Electronic Power Steering (EPS)......5226
        Electronic Power Steering (EPS) Circuits......5226
        EPS Operation......5226
        EPS 8-Way Wire Harness Connector......5227
        EPS Troubleshooting......5227
      Electrical Break Out Diagrams......5228
        Battery Charging Circuits......5228
        Constant Power Circuits......5230
        Key-On Power Circuits......5232
        Chassis Power Circuits......5233
        Head Lamp Circuits......5234
        Brake Lamp Circuits......5235
        Engine Start Command Circuits......5236
        ECM / IAC Power Circuits......5238
        ECM Wake-Up Command Circuits......5239
        AWD / ADC Circuits (Early Build Units)......5240
        AWD / ADC Circuits (Late Build Units)......5242
        AWD / ADC Function Tests (Late-Build)......5244
        Reverse Override Circuit......5245
        Radiator Fan Circuit......5246
        Gear Selector Switch Circuit......5248
        Ground Speed Sensor Circuit......5250
      Controller Area Network (CAN)......5252
        Overview......5252
        CAN Troubleshooting......5252
  9921830_Wire_Diagrams......5253
    SPORTSMAN XP 550 (PAGE 1 OF 2)......5253
    SPORTSMAN XP 550 (PAGE 2 OF 2)......5254
    AWD / ADC......5255
    BATTERY CHARGING......5256
    BATTERY PLUS......5257
    BRAKE LAMPS - START......5258
    CHASSIS POWER......5259
    COOLING FAN......5260
    ECM POWER......5261
    ECM WAKE-UP......5262
    EFI......5263
    ENGINE CRANK......5264
    FUEL PUMP & LEVEL......5265
    GEAR SENSOR......5266
    GROUND SPEED SENSOR......5267
    KEY ON POWER......5268
    HEADLAMPS......5269
    EPS......5270
  9921830_Wire_Diagrams_Intl......5271
    SPORTSMAN XP 550 INTL (PAGE 1 OF 2)......5271
    SPORTSMAN XP 550 INTL (PAGE 2 OF 2)......5272
    AWD / ADC......5273
    BATTERY CHARGING......5274
    BATTERY PLUS......5275
    BRAKE LAMPS - START......5276
    CHASSIS POWER......5277
    COOLING FAN......5278
    ECM POWER......5279
    ECM WAKE-UP......5280
    EFI......5281
    ENGINE CRANK......5282
    FUEL PUMP & LEVEL......5283
    GEAR SENSOR......5284
    GROUND SPEED SENSOR......5285
    KEY ON POWER......5286
    LIGHTS......5287
    HAZARD LIGHTS......5288
Polaris  '12- '13 Sportsman 850 Service Repair Manual......5289
  Chapter_01......5289
    CHAPTER 1 - GENERAL INFORMATION......5289
      VEHICLE IDENTIFICATION......5290
        Model Number Designation......5290
        Engine Designation Number......5290
        Vehicle Identification Number (VIN) Designation......5290
        Vehicle and Engine Serial Number Locations......5291
      VEHICLE INFORMATION......5292
        Publication Numbers......5292
        Replacement Keys......5293
        Special Tools......5293
      2012 SPECIFICATIONS......5294
        MODEL: 2012 SPORTSMAN XP 850 HO......5294
        MODEL: 2012 SPORTSMAN XP 850 HO EPS / INT’L......5294
        2012 SPORTSMAN XP 850 HO / EPS / INT’L......5295
        MODEL: 2012 SPORTSMAN TOURING 850 HO / INT’L......5296
        2012 SPORTSMAN TOURING 850 HO / INT’L......5297
      2013 SPECIFICATIONS......5298
        MODEL: 2013 SPORTSMAN XP 850 HO......5298
        MODEL: 2013 SPORTSMAN XP 850 HO EPS / INT’L......5298
        2013 SPORTSMAN XP 850 HO / EPS / INT’L......5299
        MODEL: 2013 SPORTSMAN TOURING 850 HO / INT’L......5300
        2013 SPORTSMAN TOURING 850 HO / INT’L......5301
      MISC. SPECIFICATIONS AND CHARTS......5302
        Conversion Table......5302
        Standard Bolt Torque Specification......5303
        Metric Bolt Torque Specification......5303
        SAE Tap / Drill Sizes......5304
        Metric Tap / Drill Sizes......5304
        Decimal Equivalents......5304
  Chapter_02......5305
    CHAPTER 2 - MAINTENANCE......5305
      PERIODIC MAINTENANCE CHART......5306
        Periodic Maintenance Overview......5306
        Break-In Period......5306
        Maintenance Chart Key......5306
        Maintenance Intervals......5307
        Grease Lubrication Points......5309
        Maintenance Quick Reference......5310
        Maintenance Quick Reference, continued.......5311
      LUBRICANTS / SERVICE PRODUCTS......5312
        Polaris Lubricants,Maintenance and Service Products......5312
      GENERAL VEHICLE INSPECTION AND MAINTENANCE......5313
        Pre-ride / Daily Inspection......5313
        Frame, Nuts, Bolts, Fasteners......5313
        Controls......5313
      FUEL SYSTEM AND AIR INTAKE......5314
        Fuel System......5314
        Fuel Lines......5314
        Fuel Filters......5314
        Vent Line......5314
        Throttle Operation......5315
        Throttle Release Switch (TRS) /Throttle Cable Adjustment......5315
        Air Filter / Pre-Filter Service......5316
      ENGINE......5317
        Engine Oil Level......5317
        Engine Oil and Filter Change......5317
        Engine Breather Hose......5318
        Valve Clearance Adjustment......5318
        Compression and Leakdown Tests......5321
        Exhaust Silencer Cleaning......5322
        Engine Mount Fastener Torque ......5322
      TRANSMISSION AND GEARCASES......5323
        Transmission Lubrication......5323
        Front Gearcase Lubrication......5324
        Front Gearcase ADC Fluid......5325
        Rear Gearcase Lubrication......5326
      COOLING SYSTEM......5327
        Cooling System Overview......5327
        Coolant Level Inspection......5327
        Cooling System Hoses......5328
        Coolant Strength / Type......5328
      PVT / FINAL DRIVE / WHEEL AND TIRE......5329
        PVT Drying......5329
        Drive Belt Removal......5329
        Drive Shaft Boot Inspection......5329
        Wheel and Hub Torque Table......5330
        Wheel Removal......5330
        Wheel Installation......5330
        Tire Pressure......5331
        Tire Inspection......5331
      ELECTRICAL AND IGNITION SYSTEM......5331
        Battery Maintenance......5331
        Battery Removal......5332
        Battery Installation......5332
        Extreme Use 30 AH Battery......5333
        Engine / Chassis Ground......5333
        Spark Plug Service......5333
      STEERING......5334
        Steering Inspection......5334
        Power Steering Unit (EPS Models)......5335
        Tie Rod End / Steering Inspection ......5335
        Toe Alignment......5335
        Toe Alignment Adjustment......5336
      SUSPENSION......5337
        Suspension Inspection......5337
        Suspension Spring Pre-Load Adjustment......5337
      BRAKE SYSTEM......5337
        Brake Fluid Inspection......5337
        Brake Pad Inspection......5338
        Hose / Fitting Inspection......5338
        Auxiliary Brake Pedal......5338
  Chapter_03......5339
    CHAPTER 3 - ELECTRONIC FUEL INJECTION......5339
      SPECIAL TOOLS......5340
        Part Numbers / Descriptions......5340
        Fuel Pressure Gauge Kit - PU-43506-A......5340
        Fuel Pressure Gauge Adaptor - PS-48762......5340
        Digital Wrench® - Diagnostic Connector......5340
        Digital Wrench® Diagnostic Software PU-47063-B......5341
        Digital Wrench® SmartLink Module Kit - PU-47471......5341
        Digital Wrench® - Download Website......5341
      FUEL TANK......5342
        Exploded View......5342
      FUEL LINE......5343
        Quick Connect Removal / Installation......5343
      EFI SERVICE NOTES......5343
      EFI SYSTEM LAYOUT......5344
        Exploded View......5344
      EFI COMPONENTS......5345
        Identification / Location......5345
      ELECTRONIC FUEL INJECTION......5347
        General Information......5347
        EFI Operation Overview......5347
        Initial Priming / Starting Procedure......5347
      ELECTRONIC CONTROL UNIT (ECU)......5348
        Operation Overview......5348
        ECU Service......5348
        ECU Removal / Replacement......5348
      FUEL PUMP ASSEMBLY......5349
        Operation Overview......5349
        Fuel Sender Test......5350
        Fuel Pump Test......5350
        Fuel Tank Removal......5351
        Fuel Pump Replacement......5352
        Fuel Tank Installation......5355
      FUEL PRESSURE REGULATOR......5355
        Operation Overview......5355
      FUEL INJECTORS......5356
        Operation Overview......5356
        Fuel Injector Service......5356
        Fuel Injector Test......5356
        Fuel Injector Replacement......5357
      CRANKSHAFT POSITION SENSOR (CPS)......5359
        Operation Overview......5359
        CPS Test......5359
        CPS Replacement......5361
      TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)......5362
        Operation Overview......5362
        T-MAP Test......5362
        T-MAP Replacement......5362
      IDLE AIR CONTROL VALVE (IAC)......5364
        Operation Overview......5364
        IAC Test......5364
        IAC Replacement......5364
      THROTTLE POSITION SENSOR (TPS)......5365
        Operation Overview......5365
        TPS Resistance Tests......5365
        TPS Replacement / Adjustment......5366
      ENGINE COOLANT TEMPERATURE SENSOR (ECT)......5368
        Operation Overview......5368
        ECT Sensor Test......5368
        ECT Sensor Replacement......5369
      IGNITION COIL......5369
        Operation Overview......5369
        Ignition Coil Tests......5369
        Ignition Coil and HT Lead Replacement......5370
      EFI DIAGNOSTICS......5372
        Instrument Cluster Trouble Code Display......5372
      DIGITAL WRENCH® OPERATION......5376
        Digital Wrench® Diagnostic Software Overview......5376
        Special Tools (also refer to page 3.2)......5376
        Diagnostic Software Version......5376
        ECU Replacement......5376
        Guided Diagnostic Available......5376
        Digital Wrench® Communication Errors......5377
        Digital Wrench® - Diagnostic Connector......5377
        Digital Wrench® Serial Number Location......5377
        Digital Wrench® Version and Update ID......5377
        Digital Wrench® Updates......5378
        Digital Wrench® Feature Map......5380
        Engine Controller Reprogramming (Reflash)......5381
      FUEL SYSTEM TROUBLESHOOTING......5384
        Fuel Starvation / Lean Mixture......5384
        Rich Mixture......5384
        Poor Idle......5384
  Chapter_04......5385
    CHAPTER 4 - COOLING SYSTEM......5385
      SPECIAL TOOLS......5386
      TORQUE SPECIFICATIONS......5386
      COOLING SYSTEM......5386
        Cooling System Layout and Testing......5386
        Cooling System Specifications......5387
        Cooling System Bleeding Procedure......5388
      RADIATOR......5388
        Radiator Cleaning......5388
        Coolant Drain / Radiator Service......5388
      WATER PUMP SERVICE......5391
        Water Pump Impeller Removal......5391
        Water Pump Mechanical Seal Replacement......5392
        Water Pump Shaft & Bearing Replacement......5394
        Stator Cover Installation (2012)......5395
        Stator Cover Installation (2013)......5395
        Water Pump Assembly / Torque Specifications......5396
        Stator Cover Assembly Torque Specifications......5397
      THERMOSTAT......5398
        Removal (Engine Installed)......5398
        Installation......5400
      TROUBLESHOOTING......5400
        Cooling System......5400
  Chapter_05......5401
    CHAPTER 5 - ENGINE......5401
      GENERAL INFORMATION - ENGINE......5403
        Special Tools......5403
        Engine Lubrication Specifications......5403
        Oil Pressure Test......5403
        Oil Flow Diagram......5404
        Engine Specifications - SPM850-13......5405
      ENGINE ASSEMBLY VIEWS AND TORQUE VALUES......5407
        Torque Specification and Torque Sequence - Main Engine Components......5407
        Valve Cover......5408
        Camshaft Carrier / Camshaft / Rocker Arm......5409
        Cylinder Head / Valves / Integrated Throttle Body......5410
        Valve and Spring Height Detail......5411
        Piston / Connecting Rod......5412
        Crankshaft......5413
        Crankcase......5414
        Crankcase - Upper......5415
        Balance Shaft / Balance Shaft Timing......5416
        Crankcase (Lower) With Oil Pump......5417
        Stator Cover / Flywheel / Water Pump Coupler......5418
        Water Pump / Water Pump Coupler / Stator......5419
        Drive Coupler (Rear) / Starter Gear......5420
      ENGINE SERVICE......5421
        Accessible Engine Components......5421
        Top-End Service (Engine in Chassis)......5421
        Engine Removal......5421
        Engine Installation Notes......5426
      ENGINE DISASSEMBLY / INSPECTION......5427
        Valve Cover Removal / Inspection......5427
        Rocker Carrier / Camshaft Removal......5427
        Rocker Arm / Rocker Arm Shaft Inspection......5428
        Camshaft / Camshaft Bore Inspection......5429
        Cylinder Head Removal ......5429
        Cylinder Head Cleaning......5429
        Cylinder Head Warp Inspection......5430
        Cylinder Head......5430
        Valve Inspection......5431
        Combustion Chamber......5432
        Valve Guide Removal / Installation......5432
        Valve Seat Reconditioning......5433
        Cylinder Head Assembly......5435
        Valve Sealing Test......5435
        Cylinder Head Installation......5436
        Camshaft / Carrier Assembly......5437
        Camshaft / Camshaft Carrier Installation......5437
        Camshaft Timing......5438
        Cam Chain Tensioner Installation......5439
        Camshaft Timing - Quick Reference......5440
        Crankcase Disassembly......5441
        Crankcase (Lower) / Oil Pump Disassembly......5443
        Crankcase Disassembly (Upper)......5445
        Piston / Connecting Rod Removal......5445
        Counterbalance Shaft Removal / Inspection......5446
        Crankshaft / Cam Chain Removal......5447
        Cam Chain / Sprocket Inspection......5447
        Crankcase Inspection (Lower)......5447
        Crankshaft Inspection......5447
        Connecting Rod Inspection......5448
        Connecting Rod Big End Bearing Selection......5449
        Piston / Piston Ring Inspection......5450
        Piston Ring Removal......5450
        Piston Ring Installed Gap......5450
        Piston Pin Bore Inspection......5450
        Cylinder Inspection......5451
        Piston-to-Cylinder Clearance......5452
      ENGINE ASSEMBLY......5452
        Crankcase Preparation - Upper......5452
        Piston Ring Installation......5452
        Piston / Connecting Rod Assembly......5453
        Piston / Connecting Rod Installation......5454
        Crankshaft Installation......5454
        Oil Passage Tube......5455
        Crankcase Assembly - Upper ......5456
        Balance Shaft Installation......5457
        Balance Shaft Timing......5458
        Crankcase Preparation (Lower)......5459
        Crankcase Sealant and Torque Values......5460
        Crankcase Assembly......5461
      WATER PUMP......5461
        Water Pump Impeller Removal......5461
        Water Pump Mechanical Seal Replacement / Coupler Shaft and Bearing Replacement......5461
      TROUBLESHOOTING......5462
        Engine......5462
  Chapter_06......5465
    CHAPTER 6 - TRANSMISSION......5465
      TRANSMISSION SPECIFICATIONS......5466
        Torque Specifications......5466
        Lubrication Specifications......5466
      SHIFT LINKAGE / GEAR SELECTOR......5466
        Shift Linkage Inspection......5466
        Gear Selector Removal......5466
      TRANSMISSION SERVICE......5467
        Transmission Removal......5467
        Transmission Disassembly ......5469
        Transmission Shaft Service......5472
        Transmission Assembly......5474
        Transmission Installation......5478
        Transmission Exploded View......5480
      TROUBLESHOOTING......5482
        Troubleshooting Checklist......5482
  Chapter_07......5483
    CHAPTER 7 - CLUTCHING (PVT)......5483
      SPECIAL TOOLS AND SUPPLIES......5484
      TORQUE SPECIFICATIONS......5484
        PVT System Fastener Torques......5484
      PVT SYSTEM OVERVIEW......5484
        General Operation......5484
        Drive Clutch Operation......5485
        Driven Clutch Operation......5485
        Shift Weights......5485
        PVT Break-In (Drive Belt / Clutches)......5485
        Maintenance / Inspection......5485
        Overheating / Diagnosis......5486
      PVT SYSTEM SERVICE......5487
        PVT Sealing and Ducting Components......5487
        PVT Disassembly (XP Models)......5488
        PVT Disassembly (TOURING Models)......5489
        PVT Assembly......5491
      DRIVE BELT......5493
        Belt Removal (XP Models)......5493
        Belt Removal (TOURING Models)......5493
        Belt Inspection......5494
        Belt Installation......5494
        PVT Break-In (Drive Belt / Clutches)......5495
      DRIVE CLUTCH SERVICE......5496
        Exploded View......5496
        Shift Weights......5496
        Clutch Disassembly......5497
        Bearing Inspection......5497
        Drive Clutch Spring Inspection......5498
        Shift Weight Inspection......5498
        Button To Tower Clearance Inspection......5499
        Spider Removal......5499
        Roller, Pin, and Thrust Washer Inspection......5500
        Clutch Inspection......5500
        Moveable Sheave Bushing Inspection......5501
        Bushing Service......5502
        Clutch Assembly......5504
      DRIVEN CLUTCH SERVICE......5505
        Clutch Disassembly ......5505
        Clutch Inspection......5507
        Clutch Assembly......5508
        Exploded View......5510
      TROUBLESHOOTING......5511
  Chapter_08......5513
    CHAPTER 8 - FINAL DRIVE......5513
      GENERAL SPECIFICATIONS......5514
        Torque Specifications......5514
        Special Tools......5514
      WHEELS......5514
        Removal......5514
        Installation......5514
      WHEEL HUBS......5515
        Front Hub Exploded View......5515
        Rear Hub Exploded View......5515
      FRONT BEARING CARRIER......5516
        Inspection / Removal......5516
        Bearing Replacement......5517
        Installation......5518
      FRONT DRIVE SHAFT......5520
        Removal......5520
        Installation......5521
      FRONT PROPSHAFT......5522
        Removal......5522
        Installation......5522
      PROPSHAFT U-JOINT SERVICE......5522
        Disassembly......5522
        Assembly......5523
      FRONT GEARCASE - CENTRALIZED HILLIARD......5524
        Exploded View......5524
        AWD Operation......5525
        ADC Operation......5526
        AWD Diagnosis......5527
        Gearcase Removal (Non-EPS Models)......5528
        Gearcase Removal (EPS Models)......5530
        Gearcase Disassembly / Inspection......5532
        Gearcase Assembly......5536
        Setting Ring Gear Backlash......5539
        Gearcase Installation (Non-EPS Models)......5540
        Gearcase Installation (EPS Models)......5542
        ADC System Fluid Bleeding......5544
      REAR BEARING CARRIER......5545
        Inspection / Removal......5545
        Bearing Replacement......5546
        Bushing Replacement......5547
        Installation......5547
      REAR DRIVE SHAFT......5549
        Removal......5549
        Installation......5550
      DRIVE SHAFT SERVICE......5551
        Drive Shaft / CV Joint Handling Tips......5551
        Outer CV Joint / Boot Replacement......5551
        Inner Plunging Joint / Boot Replacement......5553
        Drive Shaft Exploded View......5555
      REAR PROPSHAFT......5556
        Removal......5556
        Installation......5556
      REAR GEARCASE......5557
        Gearcase Removal (XP Models)......5557
        Gearcase Removal (TOURING Models)......5559
        Gearcase Disassembly and Inspection......5561
        Gearcase Bearing and Seal Replacement......5562
        Gearcase Assembly......5564
        Gearcase Exploded View......5565
        Gearcase Installation (XP Models)......5566
        Gearcase Installation (TOURING Models)......5568
  Chapter_09......5569
    CHAPTER 9 - BODY / FRAME......5569
      TORQUE SPECIFICATIONS......5570
      DECAL REPLACEMENT......5570
      SPECIAL TOOLS......5570
        Plastic Push Rivet Removal......5570
        Multi-Function Pliers......5570
      HEADLIGHT POD......5571
        Disassembly / Removal......5571
        Assembly / Installation......5571
      SEAT AND SIDE PANELS......5572
        Removal / Installation (XP)......5572
        Removal / Installation (TOURING)......5572
      FRONT RACK / STORAGE BOX......5573
        Removal / Installation......5573
      FRONT BUMPER......5573
        Removal / Installation......5573
      MUD GUARDS......5574
        Removal / Installation......5574
      FOOTWELLS......5574
        Removal / Installation......5574
      FRONT CAB......5575
        Removal......5575
        Installation......5575
      REAR RACK......5576
        Removal / Installation (XP Models)......5576
        Removal / Installation (TOURING Models)......5576
      REAR CAB......5577
        Removal / Installation (XP Models)......5577
        Removal / Installation (TOURING Models)......5577
      REAR BUMPER COVERS (XP)......5578
        Removal / Installation......5578
      PASSENGER SEAT (TOURING)......5578
        Seat Removal / Installation......5578
        Seat Suspension Removal or Adjustment......5578
        Passenger Seat Exploded View......5579
      MAIN FRAME (XP)......5580
        Frame Support Exploded View......5580
      MAIN FRAME (TOURING)......5581
        Frame Support Exploded View......5581
  Chapter_10......5583
    CHAPTER 10 - STEERING / SUSPENSION......5583
      GENERAL SPECIFICATIONS......5584
        Torque Specifications......5584
      HANDLEBAR......5584
        Removal / Replacement......5584
        Installation......5585
      STEERING (NON-EPS MODELS)......5585
        Steering Post Removal......5585
        Steering Post Installation......5586
        Steering Exploded View (Non-EPS Models)......5587
      STEERING (EPS MODELS)......5588
        Upper Steering Post Removal......5588
        Upper Steering Post Installation......5588
        EPS Unit Removal......5589
        EPS Unit Installation......5590
        Steering Exploded View (EPS Models)......5592
      STEERING TIE ROD......5593
        Tie Rod / Tie Rod End Replacement......5593
      FRONT A-ARMS......5594
        Exploded View......5594
        Removal / Replacement......5595
      BALL JOINT SERVICE......5596
        Service Preparation......5596
        Ball Joint Removal......5597
        Ball Joint Installation......5597
      REAR A-ARMS......5599
        Exploded View......5599
        Removal......5600
        Installation......5601
      REAR STABILIZER BAR......5602
        Exploded View......5602
        Linkage Removal / Installation......5603
        Stabilizer Bar Removal / Installation......5603
      SHOCKS / SPRINGS......5604
        Exploded View......5604
        Shock Removal / Installation......5604
        Shock / Spring Replacement......5604
  Chapter_11......5605
    CHAPTER 11 - BRAKES......5605
      SPECIFICATIONS......5606
        General Brake Specifications......5606
        General Torque Specifications......5606
        Special Tools / Brake Fluid......5606
      BRAKE SYSTEM SERVICE NOTES......5607
      BRAKE NOISE TROUBLESHOOTING......5607
      HYDRAULIC BRAKE SYSTEM OPERATION......5608
      BRAKE SYSTEM EXPLODED VIEW......5608
        XP 850 / XP 850 EPS / 850 TOURING Models......5608
        850 INT’L Models......5609
        Brake Caliper Exploded View......5610
        Hand Master Cylinder Exploded View......5610
      INTERNATIONAL BRAKE SYSTEM OPERATION......5611
        Hand Master Cylinder Hydraulic Operation ......5611
        Foot Master Cylinder Hydraulic Operation......5611
      BRAKE BLEEDING......5612
        Fluid Replacement......5612
        Bleeding Procedure......5612
      HAND BRAKE MASTER CYLINDER......5614
        Removal......5614
        Disassembly......5614
        Installation......5615
        Brake Switch Replacement......5615
      FOOT BRAKE MASTER CYLINDER......5616
        Operation Overview......5616
        Foot Master Cylinder Removal / Installation......5616
        Brake Pedal Removal / Installation......5617
      BRAKE PADS......5618
        Pad Removal......5618
        Pad Inspection......5618
        Pad Installation......5618
        Brake Burnishing Procedure......5619
      CALIPER SERVICE......5619
        Caliper Removal......5619
        Caliper Disassembly......5619
        Caliper Inspection......5620
        Caliper Assembly......5621
        Caliper Installation......5621
      BRAKE DISC SERVICE......5622
        Disc Inspection......5622
        Disc Removal / Replacement......5622
      TROUBLESHOOTING......5624
        Brake Squeal......5624
  Chapter_12......5625
    CHAPTER 12 - ELECTRICAL......5625
      GENERAL INFORMATION......5627
        Special Tools......5627
        Electrical Service Notes......5627
        Component Locations......5627
      INSTRUMENT CLUSTER (XP EPS MODELS)......5628
        Overview......5628
        Rider Information Display......5629
        Speed Information......5630
        Information Display Area......5630
        Diagnostic Mode......5632
        Instrument Cluster Pinouts......5633
      INSTRUMENT CLUSTER (XP / TOURING MODELS)......5634
        Overview......5634
        Rider Information Display......5635
        Information Display Area......5636
        Diagnostic Mode......5638
        Instrument Cluster Pinouts......5639
      BRAKE SWITCH......5639
        Function Test......5639
      IGNITION SWITCH......5639
        Function Test......5639
        Function Test (INT’L)......5639
      ADC / 4x4 / 2x4 / SWITCH......5640
        Function Test......5640
      OFF / RUN LH SWITCH......5640
        Function Test......5640
      REVERSE OVERRIDE / MODE BUTTON......5641
        Function Test......5641
      HEAD LAMP SWITCH......5641
        Function Test......5641
      THROTTLE RELEASE SWITCH (TRS)......5642
        Throttle Release Switch (TRS)......5642
      GEAR SELECTOR SWITCH......5642
        Selector Switch Function Test......5642
        Resistor Module Function Test......5642
      SPEED SENSOR......5643
        Vehicle Speed Sensor......5643
      AWD / ADC COILS......5644
        Operation Overview......5644
        Diagnosing System Failures......5644
        AWD / ADC Function Tests......5644
      RELAYS......5645
        Relay Overview......5645
        Chassis Relay......5645
        Fan Relay......5645
        EFI Relay......5645
        Bumper Lights Relay......5646
        Start Solenoid Relay......5646
        Power Steering Relay (EPS Models)......5646
      FUSES......5647
        Protected Circuits......5647
      FUSE BOX LAYOUT......5647
      LIGHTS......5648
        Headlight Adjustment......5648
        Bumper Lamp Adjustment......5648
        Headlight Replacement......5649
        Bumper Lamp Replacement......5649
        Tail / Brake Bulb Replacement......5649
      CHARGING SYSTEM......5650
        Charging System Diagram......5650
        Voltage Rectifier / Regulator (600 Watt)......5650
        Current Draw - Key Off......5650
        Battery Charge Test......5650
        Stator / Alternator Tests......5651
        Stator / Alternator Removal......5652
        Stator / Alternator Installation......5653
      BATTERY SERVICE......5654
        Battery Specifications......5654
        General Battery Information......5654
        Battery Removal / Installation......5654
        Battery Off Season Storage......5654
        Battery Testing......5654
        OCV - Open Circuit Voltage Test......5655
        Load Test......5655
        Battery Conductance Analyzer......5655
        Extreme Use 30 AH Battery......5655
        Charging Procedure ......5655
      STARTER MOTOR......5656
        Starter / Starter Lockout System Diagram......5656
        Troubleshooting......5656
        Voltage Drop Testing......5656
        Starter Motor Removal / Replacement......5657
      INSTRUMENT CLUSTER TROUBLESHOOTING......5658
        Instrument Cluster - Key OFF / No Power......5658
        Instrument Cluster - Key ON / No Power......5659
        Instrument Cluster - No High Beam Indicator......5660
        Instrument Cluster - No / Incorrect Fuel Level......5661
      ELECTRONIC POWER STEERING (EPS)......5662
        EPS Operation......5662
        Proper EPS System Diagnosing......5662
        EPS Circuit......5662
        EPS Troubleshooting......5663
      CONTROLLER AREA NETWORK (CAN)......5664
        Overview......5664
        CAN Troubleshooting......5664
  2012_Wire_Diagrams......5665
    9923809_Wire_Diagrams 1......5665
    9923809_Wire_Diagrams 2......5666
    9923809_Wire_Diagrams 3......5667
    9923809_Wire_Diagrams 4......5668
    9923809_Wire_Diagrams 5......5669
    9923809_Wire_Diagrams 6......5670
    9923809_Wire_Diagrams 7......5671
    9923809_Wire_Diagrams 8......5672
    9923809_Wire_Diagrams 9......5673
    9923809_Wire_Diagrams 10......5674
  2013_Wire_Diagrams......5675
    page11......5675
    page12......5676
    page13......5677
    page14......5678
    page15......5679
    page16......5680
Polaris  '96- '03 Sportsman400-500, Xplorer500 Service Repair Manual......5681
  Introduction......5681
  Chapter 1 - General Information......5687
  Chapter 2 - Troubleshooting......5722
  Chapter 3 - Lubrication, Maintenance, & Tune-Up......5739
  Chapter 4 - Engine Top End......5780
  Chapter 5 - Engine Lower End......5823
  Chapter 6 - Fuel System......5861
  Chapter 7 - Cooling System......5884
  Chapter 8 - Clutch/Drive System......5899
  Chapter 9 - Transmission......5935
  Chapter 10 - Front Drive System......5976
  Chapter 11 - Electrical System......5989
  Chapter 12 - Front Suspension & Steering......6023
  Chapter 13 - Rear Suspension......6048
  Chapter 14 - Breaks......6068
  Chapter 15 - Body......6111
  Supplement......6123
  INDEX......6156
  WIRING DIAGRAMS......6162

Polaris Sportsman ATV Repair Service Manuals