CHAPTER 2 MAINTENANCE - the Polaris International Extranet
Contents
1. 2 15 EXHAUST SILENCER CLEANING 2 16 ENGINE MOUNT FASTENER TORQUE 2 16 TRANSMISSION AND GEARCASES 2 17 TRANSMISSION LUBRICATION 2 2 17 FRONT GEARCASE LUBRICATION 2 18 FRONT GEARCASE ADC FLUID 0 0 000 000 0 eee eee 2 19 REAR GEARCASE LUBRICATION 2 20 COOLING SYSTEM ition matinee ck Gale eae ie ee RG eee SA 2 21 COOLANT LEVEL INSPECTION 2 21 COOLING SYSTEM HOSES COOLANT STRENGTH 2 22 PVT FINAL DRIVE WHEEL AND TIRE 6 582 ei ed Ore ee oes Gee ee 2 23 PVT DRYING DRIVE BELT REMOVAL DRIVE SHAFT BOOT INSPECTION 2 23 WHEEL AND HUB TORQUE TABLE 2 2 24 WHEEL REMOVAL INSTALLATION 2 2 24 TIRE PRESSURE INSPECTION 2 25 ELECTRICAL AND IGNITION SYSTEM asia Mee eS tk a 2 25 BATTERY MAINTENANCE 2 2 0 2 25 BATTERY REMOVAL INSTALLATION 0 2 26 ENGINE CHASSIS GROUND 2 27 SPARK PLUG SERVICE cue ce eh de AA ee ee a ea a a 2 27 STEERING oa rires en T AA nes G ES a to2. Test the strength of the coolant using an antifreeze hydrometer Antifreeze Hydrometer e A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection e Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system e Straight water or antifreeze may cause the system to freeze corrode or overheat Recommended Anti Freeze Coolant Polaris 60 40 Anti Freeze Coolant PN 2871534 Quart NOTE For further information on the engine cooling system refer to Chapter 4 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE PVT FINAL DRIVE WHEEL AND TIRE PVT Drying NOTE If operating the ATV through water be sure to check the PVT system components for water ingestion After operating in water the ATV should be checked immediately 1 Access the PVT drain plug on the bottom of the PVT cover using a long flat blade screwdriver between the frame and left hand lower control arm from the rear of the ATV 2 Remove the PVT drain plug and O ring PVT Cover Drain Plug 3 Allow the water to drain out completely 4 Reinstall the drain plug and O ring 5 Start the engine and shift into park 6 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutche
3. 2 Nm STEERING Steering Inspection The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must not be re used Always use new cotter pins ee Ph ca 77 Carriage Upper Post gt Bolt ee 1 Bushings Bracket y z SS BI BS 5 Apply asmall amount of anti seize compound to the spark Nuts plug threads PS Unit PE o 6 Install spark plugs and torque to specification 7 Make sure the high tension leads are retained by the airbox 8 Reinstall the shift linkage upper right hand side panel and seat 2 28 Nut TT Steering _ Post Cotter Pin Drive Brackets Jam Nut le Tie Rod Rod End e Washer E Jam Nut Nut Rod End Cotter Pin Replace any worn or damaged steering components Steering should move freely through entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Use only genuine Polaris parts WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer Only a qualified technician shoul
4. determining which tie rod s need adjustment CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment e Hold tie rod end to keep it from rotating e Loosen jam nuts at both ends of the tie rod e Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe out setting e Important When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly See illustration Hold Tie Rod End Parallel eu Correctly Incorrectly Tightened Jam Nut Tightened Jam Nut 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc MAINTENANCE SUSPENSION Suspension Inspection Compress and release the suspension Damping should be smooth throughout the range of travel e Check all suspension components and mounting fasteners for wear or damage e Inspect each shock body for leakage Suspension Spring Pre Load Adjustment The front and rear shock absorber springs are adjustable Rotate the adjuster cam either direction to increase or decrease spring tension Always adjust both sides equally 1 Elevate the front or rear of the vehicle to allow the suspension to ful
5. replacing E Air Filter main element Weekly Inspect replace as needed is Brake Pad Wear 10H Monthly 100 160 Inspect periodically Battery 20H Monthly 200 320 Check terminals clean test gt Engine Oil Change 20H iM g Perform a break in oil change at one month or E Break in Period 20 hours whichever comes first Front Gearcase Fluid 25H Monthly 250 400 Inspect level changa demand een exposed to extreme use gt Rear Gearcase Fluid 25H Monthly 250 400 Inspect level Transmission Fluid 25H Monthly 250 400 Inspect level gt Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services Service Note Under extreme use change demand drive fluid every 25 hours Extreme Use is defined as constant ADC operation on hilly or mountainous terrain or if ADC is the primary mode of AWD operation 2 3 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Maintenance Interval whichever comes first Item Miles Remarks i Hours Calendar KM General Lubrication 50H 3M 500 800 Lubricate all fittings pivots cables etc m Throttle Cable Inspect adjust lubricate replace if E ETC Switch oo om 200000 necessary E Le Booy Intake 50 H 6M 500 800 In
6. Method Frequency Change after 1st month or first 20 hours of operation 100 Engine Oil Polaris PS 4 Plus Add oil to proper level on hours thereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation Polaris AGL Plus 2 Transmission 2 Gearcase Lubricant Add fluid until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 3 Engine Coolant Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Check level daily change coolant every 2 years More often under severe use such as operated in water or under severe loads Engine Oil Check Fill 2 Transmission Check Fill Plug Rear RH wheel well SIDE VIEW Front RH wheel well Recovery Bottle a ee 3 Engine Coolant Radiator Cap TOP VIEW Under front rack storage box Rear Brake _ Fluid Res 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Maintenance Quick Reference Continued Ill Item Lube Rec Method Frequency 4 Front Gearcase Polaris Demand Drive Plus Maintain fluid level in ADC Check level daily change fluid ADC Reservoir Reservoir to indicated level every two years or 2000 miles 5 Front Gearcase Polaris Demand Drive Plis Add fluid until it is visible at Check level every 25 hours the fill hole threads change
7. Polaris Sales Inc MAINTENANCE e Check the fluid level of the auxiliary brake master cylinder reservoir Add fluid to the indicated level Auxiliary M C Reservoir To Auxiliary Master Cylinder Figure 2 31 e Use Polaris DOT 4 Brake Fluid PN 2872189 CAUTION DO NOT OVERFILL Excess brake fluid may cause brake drag Fill to the indicated fill line or specification e Check brake system for fluid leaks excessive travel or spongy feel e Check brake pads for wear damage or looseness e Check surface condition of the disc e Inspect thickness of brake pad friction material Brake Pad Inspection Inspect brake pad friction material for excessive wear Brake Pad Inspection Measure Thickness Service Limit 040 1 mm Hose Fitting Inspection Check brake system hoses and fittings for cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts 2 32 Auxiliary Brake Pedal The hydraulic auxiliary brake system requires no adjustment Frequently check the brake fluid level for the auxiliary brake system by viewing the level in the master cylinder reservoir located underneath the front rack assembly see Figure 2 31 e Check the effectiveness of the auxiliary brake by applying approximately 50 lbs 23 kg of downward force on the pedal If brake pedal requires an excessive amount of travel to operate inspect brake
8. filter Be sure the screen covers entire surface of main filter without folds creases or gaps NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling 10 Install air filter assembly into the airbox and position it correctly before closing the airbox cover NOTE Proper placement of the air filter is important to prevent air leaks 11 Close airbox cover and secure cover by tightening the retaining knobs or installing the rubber strap 12 Check the intake boot for cracks deterioration abrasion or leaks Replace as needed Retaining Knobs Washers Pre Filter Rubber Main Strap Filter Intake Cover Early Build Cover Late Build Screw Washer Breather Airbox Hose Clamp ee Intake Boot 2 11 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE ENGINE Engine Oil Level Polaris recommends the use of Polaris PS 4 Plus synthetic engine oil Always use PS 4 Plus engine oil Oil may need to be changed more frequently if Polaris engine oil is not used CAUTION Mixing brands or using a non recommended engine oil may cause serious engine damage Always use the recommended engine oil Never substitute or mix engine oil brands 1 Locate the engine oil dipstick on the left side of the ATV Oil Dipstick Fill Location 2 Position the ATV on a level surface 3 Stop engine
9. head and valve cover 21 Inspect the condition of the valve cover bolt rubber isolators If rubber has become hardened or cracked replace them 22 Install a new valve cover seal and install the valve cover Torque the cover bolts to specification Valve Cover Bolts 89 in Ibs 10 Nm 23 Install the upper right hand frame support and torque the 4 mounting bolts to specification E T Upper Right Hand Frame Support Bolts 36 ft Ibs 49 Nm 24 Reassemble vehicle by reversing this procedure Start the engine to ensure proper valve adjustment was performed Compression and Leakdown Tests NOTE This engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by worn or damaged exhaust cam lobes A cylinder leak down test is the best indication of engine condition Follow tester manufacturer s instructions to perform a cylinder leak down test Never use high pressure leakage testers as crankshaft seals may dislodge and leak Measured Cylinder Compression 210 250 psi full throttle Cylinder Leakage Service Limit 10 Inspect for cause if leakage exceeds 10 2 15 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sale
10. off with soap and water and looseness in any area change clothing Loose parts visually inspect vehicle for any damaged or loose nuts bolts or other fasteners Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in Engine coolant check for proper level at the recovery loss of consciousness or death in a short time bottle Never drain the fuel when the engine is hot Severe burns may result Ensure passenger seat mechanism functions properly if equipped Frame Nuts Bolts Fasteners Fuel Lines Periodically inspect the torque of all fasteners in accordance 1 Check fuel lines for signs of wear deterioration damage with the maintenance schedule Check that all cotter pins are in or leakage Replace if necessary lace Refer t ific fast t listed i h chapter Fr Se EN Hot ere sane E 2 Be sure fuel lines are routed properly and secured with Controls cable ties where applicable Check handlebar controls for proper operation positioning and adjustment CAUTION LH Control RH Control Make sure lines are not kinked or pinched Instrument Headlight Cluster 3 Replace all fuel lines every two years ADC AWD TURF Switch Override Button Engine Stop Switch Key Switch 2 9 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Fuel Filters The Sportsman 850 uses a serviceable high volume hi
11. the OFF position 2 Slide the boot back far enough to expose the inline cable adjuster sleeve and loosen the adjuster locknut 3 Remove the 4 screws and cover from the RH control With handlebars centered and wheels pointing forward slowly turn the adjuster sleeve counter clockwise out just until the gap is removed between the throttle arm and the throttle arm stop see illustration below NOTE While moving the adjuster sleeve flip the throttle lever slightly to remove slack in the cable RH Control Throttle Arm Contacts are closed at idle Inspect here when adjusting the gap between throttle arm and stop Throttle Arm Final adjustment should allow Stop for 079 118 2 3 mm gap 5 Turn the cable adjuster sleeve clockwise in 1 5 2 turns tighten locknut and reinstall boot After this adjustment there should be 079 118 2 3 mm gap between throttle arm and throttle arm stop Throttle Cable Adjuster Adjuster Sleeve 20 22 5 in lbs 2 3 2 5 Nm 6 Reinstall the RH control cover and ensure the O ring is properly in place Securely tighten the 4 screws 7 Place the vehicle in PARK and start the engine Turn the handlebars from full left to full right while listening for any change in engine speed If engine speed changes loosen the locknut and turn the adjuster sleeve clockwise in an additional 1 2 turn and repeat this step 9923067 2011 Sportsman 850 Se
12. the shift linkage from the shift lever Inspect the battery to chassis connection underneath the front cab between the rack support and fuel fill hose This connection 3 Remove the spark plug caps Clean plug area so no dirt and allows the chassis to provide a ground path debris can fall into engine when plugs are removed Inspect the chassis to engine connection on the front left side of 4 Using a 14 mm deep well socket with an extension remove the engine attached to the engine crankcase This connection the spark plug allows the engine to provide a ground path Spark Plug Inspection Installation 1 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 2 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 3 Measure gap with a wire gauge Refer to specifications in the following illustration for proper spark plug type and gap Adjust gap if necessary by carefully bending the side electrode Spark Plug Gap oon i Gap 035 0 90 mm 2 27 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE 4 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used Recommended Spark Plug Champion REA8MCX Spark Plug Torque 18 1 5 ft Ibs 24
13. MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART 44 24 44000 2 2 BREAK IN PERIOD MAINTENANCE CHART KEY 2 2 MAINTENANCE INTERVALS 2 2 2 3 GREASE LUBRICATION POINTS 2 5 MAINTENANCE QUICK REFERENCE 2 2 6 MAINTENANCE QUICK REFERENCE CONTINUED 2 7 LUBRICANTS SERVICE PRODUCTS 2 8 GENERAL VEHICLE INSPECTION AND MAINTENANCE 2 9 PRE RIDE DAILY INSPECTION 2 9 FRAME NUTS BOLTS FASTENERS CONTROLS 2 9 FUEL SYSTEM AND AIR INTAKE 0 00 eee 2 9 FUELLINES 5 56 tect Se ceca e Webbe bel as 2 9 FUEL FILTERS VENT LINE eee dle ed po her wich a datent 2 10 THROTTLE OPERATION 0000 ccoo atan ee a dau LE in guste do bee kala ep ee 2 10 ETC SWITCH THROTTLE CABLE ADJUSTMENT 2 10 AIR FILTER PRE FILTER SERVICE 2 11 ENGINES gsm ra be eae enabled a ato Sarees eels Bee 2 12 ENGINE OIL LEVEL OIL AND FILTER CHANGE 2 12 ENGINE BREATHER HOSE ASSEMBLY 2 13 VALVE CLEARANCE ADJUSTMENT 2 14 COMPRESSION AND LEAKDOWN TESTS
14. TION Overheating of engine could occur if air is not fully purged from system Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water Coolant Level Inspection The pressure cap and recovery bottle are located underneath the front rack as shown below Maintain the coolant level between the MIN and MAX levels indicated on the recovery bottle TOP VIEW Under front rack storage box With the engine at operating temperature the coolant level should be between the MAX and MIN marks on the coolant recovery bottle If not perform the following procedure 1 Position the vehicle on a level surface 2 View the coolant level in the recovery bottle The coolant level can be viewed from inside the front right wheel well Recovery Bottle As viewed from front right wheel well 3 If the coolant level is below the MIN line on the bottle remove the front rack assembly to access the radiator pressure cap and recovery bottle cap NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system A WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe bu
15. according to intervals 6 R a Gearc se Polaris ATV Angle Drive Add fluid until it is visible at Check level every 25 hours Fluid ADF the fill hole threads change fluid yearly Maintain fluid level in both Check level during pre ride 7 Brake Fluid Polaris DOT 4 Brake Fluid master cylinder reservoirs to inspection change fluid every indicated levels two years More often under severe use such as operated in water or under severe loads 4 ADC Reservoir see TOP VIEW on previous page ries 7 Brake Fluid GT ADC Res a Hand Brake Master Cylinder Reservoir 5 Front Gearcase y Check Fill Plu Front RH wheel well g Fluid Level Indicator 6 Rear Gearcase Rear RH wheel well Foot Brake Master Cylinder Reservoir see TOP VIEW on previous page Check Fill Plug 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE LUBRICANTS SERVICE PRODUCTS Additives Sealants Thread Locking Agents Misc Loctite Threadlock 242 Polaris Lubricants Maintenance and Service 2871950 6 ml 12 count Products l 2871326 ri Part No Description 12 oz 12 co Engine Transmission Lubricant 2870652 Fuel Stabilizer 16 oz 12 count 2870791 Fogging Oil 12 oz Aerosol 2872189 DOT 4 Brake Fluid 12 count ER PS 4 P
16. and remove the dipstick Wipe it dry with a clean cloth 4 Reinstall and tighten the dipstick NOTE The dipstick must be screwed in completely to ensure an accurate measurement 5 Remove the dipstick and check the oil level Maintain oil level in SAFE range Screw in completely to check level 6 Maintain the oil level in the safe range Do not overfill 2 12 Engine Oil and Filter Change Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart Always change the oil filter whenever changing the engine oil 1 Position the ATV on a level surface 2 Place the transmission in park 3 Start engine and allow it to run for two to three minutes until the engine is warm 4 Stop the engine 5 Clean the area around the drain plug BOTTOM VIEW Oil Drain Plug Access Hole Oil Filter Access Hole 6 Place a drain pan beneath the engine crankcase 7 Using a6 mm Hex socket remove the drain plug and allow the engine oil to drain completely Drain plug and washer WARNING Hot oil can cause serious burns to skin Do not allow hot oil to contact skin 8 Replace the sealing washer on the drain plug 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 9 Reinstall drain plug an
17. attery spacer on the frame Battery Spacer 2 Place the battery into the ATV on its side with the positive terminal towards the left side when facing the ATV as 3 Remove the nut retaining the hold down strap near the rear show portion of the battery and remove the strap d i Y Positive 3 Negative Cables Cables a 3 Coat the battery terminals and bolt threads with Dielectric 4 Disconnect the battery negative black cables first heave e ye followed by the positive red cables 4 Connect and tighten the positive red battery cables first followed by the negative black battery cables CAUTION A CAUTION To reduce the chance of sparks Whenever removing the battery disconnect the negative To reduce the chance of sparks Whenever black cables first installing the battery install the negative black cables last 5 Carefully lift the battery out of the ATV 5 Install the hold down strap cover and retaining nut 6 Verify cables are properly routed and fasteners are tight 7 Reinstall the front rack or storage box 2 26 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc MAINTENANCE Engine Chassis Ground Spark Plug Service Periodically inspect the electrical ground cable attachments 1 Remove the seat and upper right hand side panel Cables and connections should be tight and corrosion free 2 Disconnect
18. breather assembly is located on top of the valve cover Inspect and service the breather components as required Screw Compression Sleeve x l Breather Spring Cover Breather Bellows Filter Cartridge Outlet ES Breather Fet 2 13 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Valve Clearance Adjustment 1 2 3 10 11 12 13 2 14 Remove the seat and both upper side panels Disconnect the shift linkage from the shift lever Remove the 2 screws retaining the lower portion of the air box Remove the hose from the breaker valve located on top of the valve cover Remove the push rivets retaining the right hand portion of the rear cab to gain access to the bolts retaining the upper right hand frame support Remove the 4 bolts retaining the frame support Pull the support forward and down to remove it from the vehicle Remove the 2 Torx head screws retaining the upper portion of the air box to the front cab Carefully disconnect the ECU by pulling the tab out while pulling down on the connector Loosen the hose clamp retaining the intake boot to the intake plenum and remove the boot Lift up on the air box and turn it sideways to gain access to the valve cover bolts Remove the spark plug wires and spark plugs Remove the 6 valve cover bolts and valve cover Remove PVT cover so the engine can be rotated see D
19. components 2 16 5 If particles are still suspected to be in the silencer back the machine onto an incline so the rear of the machine is 1 ft 30 5 cm higher than the front Place the transmission in park and block the wheels Repeat steps 3 and 4 see WARNING 6 Ifparticles are still suspected to be in the silencer drive the machine onto the incline so the front of the machine is ft 30 5 cm higher than the rear Place the transmission in park and block the wheels Repeat Steps 3 and 4 see WARNING 7 Stop the engine and allow the silencer to cool Reinstall the clean out plug Engine Mount Fastener Torque Check engine mounting fasteners and ensure they are tight Also inspect the condition of the rubber mounts Ifrubber mounts are cracked or show signs of fatigue replace them Rubber Mounts 36 ft lbs 49 Nm 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc MAINTENANCE TRANSMISSION AND GEARCASES Transmission Lubrication NOTE It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart Regular lubricant level inspections should be performed as well The transmission lubricant level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the lubricant e Check vent hose to be sure it is routed properl
20. d area Clean the drain plug magnetic surface Reinstall drain plug with a new O ring and torque to specification Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole Recommended Rear Gearcase Lubricant ATV Angle Drive Fluid PN 2876160 XP TOURING Capacity 7 1 oz 210 ml X2 Differential Capacity 6 1 oz 180 ml Reinstall fill plug with a new O ring and torque to specification 7 Drain Fill Plug Torque 10 14 ft Ibs 14 19 Nm Check for leaks Dispose of used fluid properly 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE COOLING SYSTEM Cooling System Overview The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant level often during the break in period CAU
21. d replace worn or damaged steering parts Use only genuine Polaris replacement parts 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Power Steering Unit EPS Models The power steering unit can be accessed through the front right wheel well by removing the mud guard TE ji Frequently clean the areas around and on top of the power steering unit to allow for proper cooling Clean cooling fins of any mud or debris Power Steering Unit IMPORTANT Be sure to clean these areas thoroughly after riding through muddy conditions Tie Rod End Steering Inspection To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement e Repeat inspection for inner tie rod end on steering post e Replace any worn steering components Steering should move freely through entire range of travel without binding Steering Knuckle N Elevate front end of machine so front wheels are off the ground Check for any looseness in front hub wheel assembly by grasping the tire firmly at top and bottom first and then at front and rear Try to move the wheel and hub by pushing inward and pulling outward e If abnormal movement is detected inspect the hub and wheel assembly to determine the cause Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignme
22. d torque to 12 ft Ibs 16 Nm E T Engine Drain Plug 12 ft Ibs 16 Nm 10 Locate oil filter through access hole in the skid plate Place shop towels beneath the oil filter Using oil filter wrench PU 50105 turn oil filter counterclockwise to remove it 11 Use a clean dry towel to clean the filter sealing surface on the crankcase 12 Check to make sure the O ring on the new oil filter is in good condition Lubricate O ring on new filter with a film of fresh engine oil 13 Install new oil filter and turn by hand until filter gasket contacts the sealing surface then turn it an additional 1 2 turn e T Oil Filter Torque Turn by hand until filter gasket contacts sealing surface then turn an additional 1 2 turn 14 Remove dipstick and fill engine with 2 qts 1 9 1 of the recommended engine oil Recommended Engine Oil PS 4 Plus Synthetic 4 Cycle Engine Oil PN 2876244 Quart 15 Start the engine and allow it to idle for one to two minutes 16 Stop the engine and check for leaks 17 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 18 Dispose of used oil and filter properly Engine Breather Hose Be sure the engine breather hose is routed properly and secured in place CAUTION Make sure line is not kinked or pinched as r Engine Breather Assembly The engine
23. e the fill plug and check the fluid level Fill Plug 8 10 ft Ibs 11 14 Nm Gearcase fluid flush with the bottom of thread area 3 If fluid level is not even with the bottom threads add the recommended fluid as needed Do not overfill 4 Reinstall the fill plug and torque to specification E T Drain Fill Plug Torque 8 10 ft Ibs 11 14 Nm 2 18 Front Gearcase Fluid Change The drain plug is located on the bottom side of the front gearcase Access the drain plug through the access hole in the front skid plate 1 Remove the fill plug refer to Front Gearcase Fluid Level Check D Place a drain pan under the front gearcase drain plug 3 Remove the drain plug and allow fluid to drain completely Fill Plug 8 10 ft Ibs 11 14 Nm Drain Plug 8 10 ft Ibs 11 14 Nm 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O ring and torque to specification 6 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole Recommended Front Gearcase Fluid Polaris Demand Drive Plus PN 2877922 Quart Capacity 9 3 oz 275 ml 7 Reinstall fill plug with a new O ring and torque to specification T Drain Fill Plug Torque 8 10 ft Ibs 11 14 Nm 8 Check for leaks Dispose of used fluid properly 9923067 2011 Sportsman 850 Se
24. ed as well The rear gearcase fluid level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the fluid e Check vent hose to be sure it is routed properly and unobstructed Rear Gearcase Fluid Level Check The fill plug is located on the right side of the rear gearcase Maintain the fluid level even with the bottom threads of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug and check the fluid level Fill Plug 4 10 14 ft Ibs 14 19 Nm 0 W EN GS Gearcase fluid flush with the bottom of thread area 3 If fluid level is not even with the bottom threads add the recommended fluid as needed Do not overfill 4 Reinstall fill plug and torque to specification E T Drain Fill Plug Torque 10 14 ft Ibs 14 19 Nm Rear Gearcase Fluid Change The drain plug is located on the bottom right hand side of the rear gearcase Access the drain plug from the rear right hand side of the ATV 2 20 Remove the fill plug refer to Rear Gearcase Fluid Level Check Place a drain pan under the rear gearcase drain plug Remove the drain plug and allow the fluid to drain completely Fill Plug 10 14 ft Ibs Y 14 19 Nm N l O O xA V O TES i Drain Plug 10 14 ft Ibs 14 19 Nm Gearcase fluid flush with the bottom of threa
25. er hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 20 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components e Drive vehicle slowly at first while varying the throttle position Do not operate at sustained idle e Pull only light loads e Perform regular checks on fluid levels and other areas outlined on the daily pre ride inspection checklist e Change both the engine oil and filter after 20 hours or one month e See Owner s Manual for additional break in information Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance m CAUTION Due to the nature of these adjustments it is recommended this service be performed by an authorized Polaris dealer gt SEVERE USE ITEM See info
26. gh pressure fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator If the fuel pump filters require service the fuel pump must be replaced as an assembly D Fuel Pump Assembly Located in Fuel Tank 4 Ap o 5 5 124 h E 5 H 5 H ay Fine Filter o Preliminary Filter E NOTE Refer to Chapter 3 for fuel pump replacement and all other information related to the EFI System Vent Line 1 Check the vent line from the fuel tank for signs of wear deterioration damage or leakage Replace the line every two years 2 Verify vent line is routed properly and secured with an appropriate number of cable ties CAUTION Make sure lines are not kinked or pinched Throttle Operation Check for smooth throttle opening and closing in all handlebar positions Throttle lever operation should be smooth and lever must return freely without binding 1 Place the gear selector in neutral 2 Set parking brake 3 Start the engine and let it idle 4 Turn handlebars from full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition If cable is routed properly and in good condition no adjustment is required 5 Replace the throttle cable if worn kinked or damaged 2 10 Electronic Throttle Control Switch ETC Throttle Cable Adjustment 1 Turn the ignition key to
27. hange every two years Spark ArrESIOT 300 H 36 M 3000 4800 Clean out or remove clean out plug if applicable Valve Clearance 1000H 10000 16000 Inspect adjust Toe Adjustment Inspect periodically adjust as needed Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 2 4 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Grease Lubrication Points There are grease fittings on each upper and lower front and rear A arms each rear bearing carrier and on the front propshaft yoke Apply grease until all traces of water have been purged out at each of these areas Front amp Rear A Arms Rear Bearing Carrier Polaris Premium U Joint Grease miles 800 km Item Recommended Lube Method Frequency Front Propshaft Yoke Grease before long periods Grease fittings every 500 of storage and after thoroughly washing or submerging the ATV Grease Grease Front Propshaft eS ee O Rear Bearing Carrier Grease Grease N y Front A arms Rear A arms Grease 2 5 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc MAINTENANCE Maintenance Quick Reference Synthetic Engine Oil dipstick 11 4 Item Lube Rec
28. ive Plus Recommended ADC Fluid Polaris Demand Drive Plus PN 2877922 Quart 6 Locate bleeder valves found on each side of the front gearcase and remove the protective caps Bleeder Valve Bleeder Cap Valve 7 Attach a clean clear hose to one of the bleeder valves 00 Slowly loosen the valve counter clockwise and allow fluid and trapped air to flow from the fitting IMPORTANT Do not allow ADC fluid in reservoir to drop below the MIN fill line Close bleeder valve before the fluid level drops below the MIN fill line Refilling an empty reservoir will result in air pockets becoming trapped 9 Close the valve when clean bubble free fluid begins to flow from the valve 10 Repeat steps 7 9 on the remaining bleeder valve 11 Torque the bleeder valves to specification and reinstall the protective caps Bleeder Valve Torque 80 in Ibs 9 Nm 12 Fill reservoir to a level midway between MAX and MIN fill lines Verify no debris is found in reservoir fluid 13 Install the reservoir cap and diaphragm securely and wipe clean any fluid residue 2 19 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc MAINTENANCE Rear Gearcase Lubrication NOTE It is important to follow the rear gearcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be perform
29. l 2 8 Polaris dealer 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE GENERAL VEHICLE INSPECTION FUEL SYSTEM AND AIR INTAKE AND MAINTENANCE Pre ride Daily Inspection Perform the following pre ride inspection daily and when A WARNING servicing the vehicle at each scheduled maintenance Fuel System Tires check condition and tire pressure Gasoline is extremely flammable and explosive under certain conditions Fuel and oil fill both to proper level do not overfill All brakes check operation includes auxiliary brake Always stop the engine and refuel outdoors or in a well ventilated area Throttle check for free operation Headlight Taillight Brakelight check operation of Do not smoke or allow open flames or sparks in or near all indicator lights and switches the area where refueling is performed or where gasoline e Engine stop switch key switch check for proper is stored function Do not overfill the tank Do not fill the tank neck Wheels check for loose wheel nuts push and pull on the top of the wheel to feel for play in the suspension If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately Air cleaner element check for dirt or water clean or replace e If you spill gasoline on your skin or clothing e Steering check for free operation noting any unusual immediately wash it
30. les with the center of the tapered nuts Steel Wheel Aluminum Wheel IMPORTANT It is possible to torque the wheel nut on II a steel rim without the nut being centered in the hole HA NY Be sure to center the wheel nuts before applying E L a i torque to prevent wheel nuts from coming loose 5 Carefully lower the vehicle to the ground 6 Torque the wheel nuts and or hub nut to the proper torque specification listed in the Wheel and Hub Torque Table 45 ft Ibs 75 ft lbs CAUTION 61 Nm 102 Nm Improperly installed wheels could affect vehicle handling and tire wear On vehicles with tapered Wheel Removal rear wheel nuts make sure tapered end of nut goes into taper on wheel Be sure to properly 1 Position the vehicle on a level surface torque and install all wheel nuts 2 Stop the engine place the transmission in PARK and lock 7 If the hub nut was removed install a new cotter pin after the parking brake the hub nut has been tightened 3 Loosen the wheel nuts slightly If wheel hub removal is required remove the cotter key and loosen the hub nut slightly Hub Nut 4 Elevate the appropriate side of the vehicle by placing a Wheel Nuts suitable stand under the footrest frame 5 Remove the wheel nuts and remove the wheel 6 Ifhub removal is required remove the hub nut and washers Cotter Key 2 24 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polari
31. lus Synthetic 4 Cycle Engine Oil 2871557 Crankcase Sealant 3 Bond 1215 5 oz Quart 12 count 2871950 Loctite Threadlock 242 PS 4 Plus Synthetic 4 Cycle Engine Oil 6 ml 12 count 2876245 5 Gallon 4 count Premium Carbon Clean eet ieee 12 oz 12 count Gearcase Lubricants ie 02 PERF Demand Drive Plus 2870652 Fuel Stabilizer 16 oz 12 count Quart 2872189 DOT 4 Brake Fluid 12 count 2877923 Demand Drive Plus 2871557 Crankcase Sealant 3 Bond 1215 5 oz 2 5 Gallon NOTE The number count indicated by each part AGL Plus Gearcase Lubricant 2878068 1 Qt 12 Count number in the table above indicates the number of units that are shipped with each order 2878069 AGL Plus Gearcase Lubricant 1 Gal 4 Count AGL Plus Gearcase Lubricant 2878070 5 Gal 2 Count ATV Angle Drive Fluid 96169 Quart 12 count ATV Angle Drive Fluid FORTS 2 5 Gallon 2 count 2870465 Pump for Gallon Jug Coolant 2871534 60 40 Coolant Quart 12 count 2871323 60 40 Coolant Gallon 6 count Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season Grease Aar 3ag 3 oz cartridge 24 count Premium All Season Grease Ones 14 oz cartridge 10 count 2871460 Starter Drive Grease 12 count 2871515 Premium U Joint Lube 3 oz 24 count 2871551 Premium U Joint Lube 14 oz 10 count 2871329 Dielectric Grease Nyogel NOTE Each item can be purchased separately at your loca
32. ly extend CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before adjusting NOTE The tires should not be touching the ground 2 To adjust the suspension rotate the adjustment cam clockwise to increase spring tension or counter clockwise to decrease spring tension Highest amount of spring pre load Lowest amount of spring pre load Shock Pre Load Adjustment Operator weight and vehicle loading affect suspension spring pre load requirements Use Spanner Wrench PN 2877408 to adjust pre load as necessary to avoid bottoming of the shocks Shock Spanner Wrench PN 2877408 BRAKE SYSTEM Brake Fluid Inspection The following checks are recommended to keep the brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride e Keep fluid level in the hand master cylinder reservoir to the indicated level inside reservoir al Fluid Level Eye e Check the fluid level eye If it is clear it is an indication that fluid is needed or the brake pads may be worn which can reduce the fluid level e If required add brake fluid to 25 30 6 8 mm from the top of the reservoir 25 30 6 8 mm From the Top of Reservoir 2 31 9923067 2011 Sportsman 850 Service Manual O Copyright 2010
33. nal Drink large quantities of water or milk equipment size and type Follow with milk of magnesia beaten egg or The use of non standard size or type tires may vegetable oil Call physician immediately affect ATV handling Eyes Flush with water for 15 minutes and get Tire Tread Depth prompt medical attention ele replace tires when tread depth is worn to 1 8 3 mm or Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when Tread charging or using in an enclosed space Always Depth 1 8 3 mm shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN IMPORTANT Never attempt to open the battery If the seal is broken the battery will be ruined and will fail within a few weeks NOTE If battery voltage is below 12 6V fully charge the battery before putting into service Refer to the Charging Procedure provided in Chapter 12 for more information 2 25 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Battery Removal Battery Installation 1 Remove the front rack or storage box to access the battery IMPORTANT Using a new battery that is not fully charged can damage the battery resulting in a short battery life and can hinder performance Charge battery before installation see Chapter 12 2 Remove the 2 Torx screws retaining the front cover and remove the cover from the vehicle 1 Position the b
34. not overfill Recommended Transmission Lubricant AGL Plus Gearcase Lubricant PN 2878068 Quart Capacity 37 oz 1100 ml 7 Reinstall fill plug with a new O ring and torque to specification E T Drain Fill Plug Torque 10 14 ft Ibs 14 19 Nm 8 Check for leaks Dispose of used lubricant properly 2 17 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Front Gearcase Lubrication NOTE It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well SERVICE NOTE Under extreme use change fluid every 25 hours Extreme Use is defined as constant ADC operation on hilly or mountainous terrain or if ADC is the primary mode of AWD operation The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the fluid e Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located on the right side of the front gearcase Access the fill plug through the front right hand wheel well or through the front lower bumper Maintain the fluid level even with the bottom threads of the fill plug hole 1 Position vehicle on a level surface 2 Remov
35. nt is 0 1 8 0 3 mm toe out 1 Position the vehicle on a smooth level surface 2 Set handlebars in a straight ahead position and secure handlebars in this position NOTE The steering post frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 29 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE 3 Tie a length of string between two stands as shown in the following illustration Position the stands so the string is flush or parallel with the side of the rear tire NOTE If available you may use a long straight edge instead of a string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 0 1 16 O 1 5 mm more than the front measurement on each side of the vehicle to obtain the recommended 0 1 8 0 3 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle NOTE If you discover improper alignment refer to Toe Alignment Adjustment procedure A is cae A 3 Wheel Toe out Alignment 0 1 8 0 3 mm 2 30 Toe Alignment Adjustment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before
36. pads pedal linkage springs rear master cylinder and hoses for wear damage or leakage Replace components as needed 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician 20 Hours 1 Month Break In 2 33 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE NOTES 2 34 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc
37. rive Belt Removal procedure within this chapter MAG amp PTO ADJUSTMENT PROCEDURE 14 Turn the drive clutch counter clockwise until the cam sprocket is in the MAG 1 Adjustment Position MAG 1 Timing Pin in Vertical Position TDC 1 MAG Cylinder f NX Timing Marks Lined Up With Top of Head at MAG 1 Adjustment Position 15 Loosen the jam nut and turn the lash adjuster in until the rocker arm bearing lightly touches the valve Lash Adjuster le _ _ i 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE E In mm Intake Exhaust Valve Clearance 000 in 00 mm 16 Hold the lash adjuster and torque the jam nut using a torque wrench with a 10 mm crow s foot adaptor Torque the rocker jam nut to specification E T Rocker Jam Nut 71 89 in Ibs 8 10 Nm 17 After tightening the jam nut turn the rocker arm bearing with your fingers to ensure valve lash is not set too tight IMPORTANT If rocker arm bearing does not turn after setting the valve lash the adjustment is too tight and will need to be performed again see Step 15 18 Turn the drive clutch counter clockwise to rotate the cam sprocket 225 to the PTO 2 Adjustment Position PTO 2 Adjustment Position _ 7 Timing Marks at PTO 2 N je Adjustment Position 19 Repeat steps 15 17 20 Clean sealing surfaces of the cylinder
38. rmation provided above E Emission Control System Service California NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts WARNING Improperly performing the procedures marked M could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 2 2 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc MAINTENANCE Maintenance Intervals Maintenance Interval whichever comes first Item Miles Remarks i Hours Calendar KM m Steering Pre Ride Front Suspension Pre Ride gt Rear Suspension Pre Ride Tires x Pre Ride gt Brake Fluid Level x Pre Ride x gt Brake Lever Travel E Pre Ride Inspect and make adjustments as needed BraksiSvctem Pre Ride See Pre Ride Checklist later in this chapter Passenger Seat g Pre Ride i Mechanism Wheels Fasteners Pre Ride Frame Fasteners Pre Ride Engine Oil Level a Pre Ride i Air Filter Pre filter Daily Inspect clean often Coolant Daily _ Check level daily change coolant every two years gt ADC Fluid Daily Check level daily add as needed Power Steering Unit g gt if equipped Daily Inspect daily clean often Head Lights Tail Lights _ Daily _ Check operation apply dielectric grease if
39. rns The engine must be cool before removing the pressure cap 4 Remove the pressure cap Using a funnel add coolant to the top of the radiator filler neck 5 Reinstall the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly 6 Remove recovery bottle cap and add coolant using a funnel 7 Fill recovery bottle to MAX level with Polaris Premium 60 40 Anti Freeze Coolant or a 50 50 mixture of anti freeze coolant and distilled water as required for freeze protection in your area 8 Reinstall the recovery bottle cap 2 21 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE 9 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overheating 10 Add coolant as needed Maintain the coolant level between the MIN and MAX marks on the bottle 11 Reinstall the front rack assembly Cooling System Hoses 1 Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary Hose from Thermostat Recovery Bottle 2 Hose to Waterpump Clamp Radiator 2 Check tightness of all hose clamps CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp torque is 36 in lbs 4 Nm 2 22 Coolant Strength Type
40. rvice Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Air Filter Pre Filter Service It is advisable to replace the filter when it is dirty However in an emergency it is permissible to clean the main filter if you observe the following practices Never immerse the filter in water since dirt can be transferred to the clean air side of the filter e If compressed air is used never exceed a pressure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside It is recommended that the air filter and pre filter be replaced annually When riding in extremely dusty conditions replacement is required more often Removal 1 Remove the seat to access the airbox cover Airbox Cover 2 Unscrew the two knobs or remove the rubber strap retaining the airbox cover and open the cover Pre Filter Main Filter 3 Remove the air filter assembly from the airbox Cleaning 4 Slip the pre filter screen off of main element Clean the pre filter with hot soapy water 5 Rinse and dry thoroughly 6 Inspect pre filter screen for tears or damage 7 Inspect main filter and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 8 Inspect airbox cover seal for damage It should adhere tightly to the cover and seal all the way around Replace seal as needed 9 Reinstall pre filter screen over main
41. rvice Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Front Gearcase ADC Fluid NOTE It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well Front Gearcase ADC Fluid Level Check The ADC fluid reservoir is located underneath the front rack as shown below Maintain the fluid level between the MIN and MAX levels indicated on the reservoir 1 Disengage the anchors and remove front rack assembly 2 Check the fluid level of the ADC reservoir TOP VIEW Under front rack storage box ADC Fluid Reservoir 3 If fluid level is below the minimum mark on the reservoir remove the cap and add the recommended fluid 4 Reinstall the cap and front rack assembly Front Gearcase ADC Fluid Change 1 Position the vehicle on a level surface and allow the vehicle to sit for at least 30 minutes 2 Thoroughly clean the areas around the ADC reservoir and bleeder valves 3 Remove the reservoir cap and diaphragm assembly 4 Make sure the fluid inside the reservoir is free of debris If any debris is found use a clean shop towel or suction device to remove it from the reservoir NOTE Debris in the reservoir may result in inadequate bleeding and reduced performance of the system 5 Begin the bleeding process by filling reservoir to the MAX level with clean Polaris Demand Dr
42. s NOTE Do not hold the throttle wide open for more than 5 seconds 7 Allow the engine RPM to return to idle then shift into low gear 8 Test the PVT system for belt slippage If the belt slips repeat the process Drive Belt Removal Refer to Chapter 7 Clutching PVT for drive belt removal procedures Drive Shaft Boot Inspection Inspect the front and rear drive shaft boots for damage tears wear or leaking grease If the rubber boots exhibit any of these symptoms replace the boot s Refer to Chapter 8 for drive shaft boot replacement NOTE Remove the CV boot shield from the front lower A arms to inspect both front CV boots 2 23 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE Wheel and Hub Torque Table Wheel Installation ae ee 1 Verify the transmission is still in PARK and the parking Item Nut Type Specification brakeis locked Aluminum Wheels Tap red Nut 75 ft Ibs 102 Nm 2 Install the wheel hub washers and hub nut if previously Long removed Tapered Nut Slee Wheels Short 45 ft Ibs 61 Nm 3 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation Hub Retaining Nuts 5 80 ft Ibs 108 Nm arrows on the tire point toward forward rotation Front amp Rear 4 Install the wheel nuts and finger tighten them to align the center of the wheel ho
43. s Inc MAINTENANCE Exhaust Silencer Cleaning WARNING Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with exhaust components To reduce fire hazard make sure that there are no combustible materials in the area when purging the exhaust silencer Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the silencer Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide Do not go under the machine while it is inclined Set the hand brake and block the wheels to prevent roll back Failure to heed these warnings could result in serious personal injury or death The exhaust silencer must be periodically purged of accumulated carbon as follows 1 Remove the clean out plug on the bottom of the silencer O O S 7 E Clean Out Plug Exhaust Silencer 2 Place the transmission in park and start the engine 3 Purge accumulated carbon from the exhaust system by momentarily revving the engine several times 4 If some carbon is expelled cover the exhaust outlets and lightly tap on the silencer around the clean out plug with a rubber mallet while revving the engine several more times CAUTION Wear protective gloves when covering the exhaust outlets Serious burns could result from contact with exhaust
44. s Sales Inc MAINTENANCE Tire Pressure ELECTRICAL AND IGNITION SYSTEM Tire Pressure Inspection PSI Cold Battery Maintenance Front Rear Keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire 7 psi 48 kPa 5 psi 34 5 kPa brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean Tire Inspection shop towels Coat the terminals with dielectric grease or petroleum jelly WARNING A WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding and CALIFORNIA PROPOSITION 65 WARNING possible loss of control Batteries battery posts terminals and related accessories contain lead and lead compounds and Worn tires can cause an accident other chemicals known to the State of California to cause cancer and birth defects or other reproductive Always replace tires when the tread depth harm WASH HANDS AFTER HANDLING measures 1 8 3 cm or less A WARNING CAUTION Battery electrolyte is poisonous It contains sulfuric Maintain proper tire pressure acid Serious burns can result from contact with skin Refer to the warning tire pressure decal eyes or clothing Antidote applied to the vehicle Improper tire inflation may affect External Flush with water ATV maneuverability When replacing a tire always use original Inter
45. spect ducts for proper sealing air leaks Drive belt 50H 6M 500 800 Inspect replace as needed Cooling System 50H 6M 500 800 Inspect coolant strength seasonally pressure test system yearly Radiator 50 H 6M 500 800 Inspect clean external surfaces gt Cooling Hoses 50 H 6M 500 800 Inspect for leaks Perform a break in oil change at 20 hours or gt Engine Oil Change 100 H 6M 1000 1600 after one month of operation change more frequently during cold weather operation Oil Filter Change 100 H 6M 1000 1600 Replace with oil change gt Front Gearcase Fluid 100 H 12M 1000 1600 Change fluid also refer to 25 H interval gt Rear Gearcase Fluid 100 H 12M 1000 1600 Change fluid Transmission Fluid 100 H 12M 1000 1600 Change fluid Fuel System 100 H 12M 1000 1600 Cheek for leaks at tank cap fuel lines fuel E pump replace lines every two years Engine Mounts 100 H 12M 1000 1600 Inspect Exhaust Pipe Silencer 100 H 12M 1000 1600 Inspect E Spark Plug 100 H 12M 1000 1600 Inspect replace as needed Inspect for wear routing security apply gt Wiring 100 H 12M 1000 1600 dielectric grease to connectors subjected to water mud etc Clutches Drive and Driven 100 H 12M 1000 1600 Inspect clean replace worn parts Front Wheel Bearings 100 H 12M 1000 1600 Inspect replace as needed Brake Fluid 200 H 24M 2000 3200 Change every two years m ADC Fluid 200 H 24M 2000 3200 C
46. t wae 2 28 POWER STEERING UNIT EPS MODELS 2 29 TIE ROD END STEERING INSPECTION TOE ALIGNMENT 2 29 TOE ALIGNMENT ADJUSTMENT 2 2 30 SUSPENSION cosa mice psa Do AN SRR ae Ba Pee ele eh a ats 2 31 SUSPENSION INSPECTION SPRING PRE LOAD ADJUSTMENT 2 31 BRAKE SYSTEME sieve eae a wees Rom ties amie dae ate Da eles WO ei 2 31 BRAKE FLUID INSPECTION 2 31 BRAKE PAD HOSE FITTING INSPECTION 2 32 AUXILIARY BRAKE PEDAL oocccccccccccco eee 2 32 MAINTENANCE LOG onc said elit da tl Oe Sete tare eu 2 33 2 1 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Pure Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles p
47. y and unobstructed Transmission Lubricant Level Check The fill plug is located on the right hand side of the transmission Access the fill plug through the rear right hand wheel well Maintain the lubricant level even with the bottom threads of the fill plug hole 1 Position vehicle on a level surface 2 Remove the fill plug and check the lubricant level Fill Plug 10 14 ft Ibs 14 19 Nm Transmission fluid flush with the bottom of thread area 3 If lubricant level is not even with the bottom threads add the recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification E T Drain Fill Plug Torque 10 14 ft Ibs 14 19 Nm Transmission Lubricant Change Access the drain plug through the rear right hand wheel well The plastic skid plate can be removed for better access to the drain plug 1 Remove the fill plug refer to Transmission Lubricant Level Check 2 Place a drain pan under the transmission drain plug 3 Remove drain plug and allow lubricant to drain completely Fill Plug 10 14 ft Ibs 14 19 Nm Drain Plug 10 14 ft Ibs 14 19 Nm 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O ring and torque to specification 6 Add the recommended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission Do
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