Polaris 850-Hd-Eps 2009 Service Manual

2009 Polaris Sportsman 850 EFi/HD/EPS series

Some models may need supplemental manuals which have blue titles. Use

the base manual for everything not contained in the supplement if your

model or year requires a supplement.

If you bought this manual from any other seller, they are reselling my

work.

Please leave them negative feedback & email me at

Our goal is to be one of the BEST sellers on eBay and the internet by

providing you with the BEST customer service and the BEST manuals on the

market.

Thank you for choosing us.

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2009 SPORTSMAN XP 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

GENERAL: 2009 SPORTSMAN XP 850 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

DETAILED: 2009 SPORTSMAN XP 850 / XP 850 EPS. . . . . . . . . . . . . . . . . . . . . . . . . .1.5

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 .8

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

1.1

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

Y ear Designation

Engine Designation Number

EH085OLE.............................................................Twin Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start

V ehicle Identification Number (VIN)

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A Z N 8 5 A * 9 P 0 0 0 0 0 0

Vehicle Descriptor

A 0 9 Z N 8 5 A L

Basic Chassis

Designation

}

Engine Designation

}

Vehicle Identifier

Emissions & Model Option

}

Body Style

V e hicle and Engine Serial Number Locations

Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). The engine serial number can be found on top of the engine located on the valve cover (see Figure 1-2).

Figure 1-1

Engine

Powertrain

Emissions

Model

Year

Check Digit

Plant No

Figure 1-2

Individual Serial Number

* This could be either

a number or a letter

VIN

1.2

Engine Serial

Number

GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN

2009 SPORTSMAN XP 850

2009 SPORTSMAN XP 850 EPS

NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.

A09ZN85AL, AQ, AS, AT, AX, FL

A09ZX85AG, AL, AQ, AR, AS, AX, FS

9921854 9921857

9921976 9921977

Replacement Keys

Replacement keys can be made from the original key. T o identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary.

KEY COVER P/N 5533534

Key Series Number

Series # Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

Special Tools

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/

1.3

GENERAL INFORMATION

SPECIFICATIONS

MODEL: 2009 SPORTSMAN XP 850

MODEL NUMBER:. . . . . . . . . A09ZN85AL, AQ, AS, AT, AX, FL

ENGINE MODEL:. . . . . . . . . . EH085OLE

Category Dimension

Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 784 lbs. / 356 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Weight 150 lbs. / 68 kg

MODEL: 2009 SPORTSMAN XP 850 EPS

MODEL NUMBER:. . . . . . . . . A09ZX85AG, AL, AQ, AR, AS, AX, FS

ENGINE MODEL:. . . . . . . . . . EH085OLE

Category Dimension

Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 796 lbs. / 361 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Weight 150 lbs. / 68 kg

1.4

GENERAL INFORMATION

2009 SPORTSMAN XP 850 / XP 850 EPS

XP MODELS: A09ZN85AL,AQ,AS,AT,AX,FL XP EPS MODELS: A09ZX85AG,AL,AQ,AR,AS,AX,FS ENGINE MODEL: EH085OLE

Engine

Platform Domestic Twin Cylinder, 4-Cycle Engine Model Number EH085OLE011 Engine Displacement 850 cc Number of Cylinders 2 Bore & Stroke (mm) 87 x 71.5 mm Compression Ratio 11.0:1 Compression Pressure 210 - 250 psi Engine Idle Speed 1200 Cooling System / Cap. Liquid Cooled / 2 qt. (1.9 l) Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump Engine Oil Requirement PS-4 Plus / 2 qt. (1.9 l)

Exhaust System

Fuel System Type Throttle Body / Size Mikuni Dual Bore / 40 mm Fuel Delivery Fuel Pressure 43 psi Fuel Capacity Fuel Requirements 87 Octane (minimum)

Alternator Output 475 W @ 1200 RPM / Peak 575 W Voltage Regulator 3-Phase / 32 Amp

Head Lights Brake Light 12V / 27 Watts

Tail Light 12V / 7 Watts Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° ± 5° BTDC @ 1200 RPM Spark plug / Gap REA8MCL / .035 in. (.90 mm) Battery / Model / AH / CCA Deka / ETX30L / 30 AH / 365 Instrumentation Multifunction Instrument Cluster DC Outlet Standard Relays

(Located in Relay/Fuse Box)

Circuit Breaker Fan Motor: 20A Fuses

(Located in Relay/Fuse Box)

Stainless Steel Dual Header Pipe

w/ Dual Outlet Silencer

Fuel System

Bosch Multi-Port Sequential

Electronic Fuel Injection

Electronic Fuel Pump

XP EPS: 4.5 gal. (17 l)

Electrical

Pod: 12V / 50 Watts

Bumper: 12V / 50 Watts x 2

Chassis / Start Solenoid / Fan /

EFI / Bumper Lights

Lights: 20A / Drive: 20A /

Accessory: 20A / EFI: 20A /

Unswitched: 10A / EPS: 30A

± 50 RPM

(in tank)

XP: 5.25 gal. (20 l)

Drivetrain

Transmission Type

Transmission Fluid Type / Fluid Capacity

Front Gearcase Fluid Type / Fluid Capacity

Front Gearcase ADC Reservoir Fluid Type

Rear Gearcase Fluid Type / Fluid Capacity

Clutch Type PVT w/EBS Belt 3211123

Steering / Suspension

Toe Out 0-1/16 in. (0-.159 mm) Front Suspension Dual A-arm Front Travel 9.2 in. / 23.4 cm Rear Suspension Dual A-arm w/Rolled IRS Rear Travel 10.2 in. / 25.9 cm Shock Preload Adjustment

Front / Rear

Wheels / Brakes

Front Wheel Size / Bolt Pattern Tire Model / Size

Rear Wheel Size / Bolt Pattern Tire Model / Size

Tire Air Pressure

Brakes - Front & Rear Brake Fluid Polaris DOT 4 Brake Fluid

Automatic PVT

In-Line H-L-N-R-P

Synthetic Sportsman XP

Transmission Fluid /

32 oz. (946 ml)

Premium LT Demand Drive

Fluid / 9.3 oz. (275 ml)

Premium ADC

Front Drive Fluid

ATV Angle Drive Fluid /

7.1 oz. (210 ml)

Cam Adjustable

14 x 6 / 4-156

Carlisle T errathon / 26 x 8 - 14

14 x 8 / 4-156

Carlisle T errathon / 26 x 10 - 14

Front: 7 psi (48 kPa)

Rear: 5 psi (34.5 kPa)

Single Control

Hydraulic 4-Wheel Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1800

(0-6000)

1800-3700

(6000 - 12000)

Shift

Weight

24-63

5632215

24-60

5632216

Drive

Spring

Red / Wht

7043349

Red / Wht

7043349

Driven Spring

Red / Wht

3235621

Red / Wht

3235621

1.5

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

°C to °F:

9/5

(°C + 32) = °F °F to °C:

1.6

5/9

(°F - 32) = °C

GENERAL INFORMATION

Standard Torque Specifications

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

1.7

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.8

GENERAL INFORMATION

Glossary of Terms

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to

close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the

cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire

touching the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm²: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in²: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

mi.: Mi mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

le/miles.

1.9

GENERAL INFORMATION

NOTES

1.10

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2

MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

MAINTENANCE QUICK REFERENCE, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . .2.7

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 2.9

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

FUEL FILTERS / VENT LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

THROTTLE OPERATION / ETC SWITCH / THROTTLE CABLE ADJUSTMENT . . . . . 2.10

AIR FILTER / PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

ENGINE OIL LEVEL / OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

ENGINE BREATHER HOSE / BREATHER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .2.13

VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

COMPRESSION AND LEAKDOWN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

EXHAUST SILENCER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE MOUNT FASTENER TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

FRONT GEARCASE ADC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

COOLING SYSTEM HOSES / COOLANT STRENGTH / COOLANT TYPE . . . . . . . . .2.22

PVT / FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

PVT DRYING / DRIVE BELT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

WHEEL AND HUB TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

TIRE PRESSURE / TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

ENGINE / CHASSIS GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

POWER STEERING UNIT (EPS MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

TIE ROD END / STEERING INSPECTION / TOE ALIGNMENT . . . . . . . . . . . . . . . . . .2.29

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

SUSPENSION INSPECTION / SUSPENSION SPRING PRE-LOAD ADJUSTMENT . . 2.30

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

BRAKE FLUID / BRAKE PAD / HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . .2.31

AUXILIARY BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

2.1

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 per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• 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.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Pull only light loads.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 20 hours or one month.

• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.

= SEVERE USE ITEM: See information 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  could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

2.2

Maintenance Intervals

Maintenance Interval

Item

Hours Calendar

 Steering - Pre-Ride -

Front Suspension - Pre-Ride -



Rear Suspension - Pre-Ride -



Tires - Pre-Ride Brake Fluid Level - Pre-Ride -



Brake Lever Travel - Pre-Ride -



Brake System - Pre-Ride Wheels / Fasteners - Pre-Ride Frame Fasteners - Pre-Ride Engine Oil Level - Pre-Ride -



Air Filter, Pre-filter - Daily - Inspect;clean often

Coolant - Daily -

(whichever comes first)

Miles

(KM)

Inspect and make adjustments as needed. See Pre-Ride Checklist later in this chapter.

Check level daily, change coolant every two years

MAINTENANCE

Remarks

ADC Fluid - Daily - Check level daily, add as needed



Power Steering Unit



(if equipped) Head Lights / Tail Lights - Daily -



Air Filter (main element) - Weekly - Inspect; replace as needed



Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically



Battery 20 H Monthly 200 (320) Check terminals; clean; test Engine Oil Change



(Break-in Period)

Front Gearcase Fluid 25 H Monthly 250 (400) Inspect level



Rear Gearcase Fluid 25 H Monthly 250 (400) Inspect level



Transmission Fluid 25 H Monthly 250 (400) Inspect level



- Daily - Inspect daily, clean often Check operation; apply dielectric grease if

replacing

20 H 1 M -

Perform a break-in oil change at one mont h or 20 hours, whichever comes first

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.3

MAINTENANCE

Maintenance Interval

Item

Hours Calendar

General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.





Throttle Cable /

ETC Switch Throttle Body Intake

Duct Drive belt 50 H 6 M 500 (800) Inspect; replace as needed

Cooling System 50 H 6 M 500 (800) Radiator 50 H 6 M 500 (800) Inspect; clean external surfaces



Cooling Hoses 50 H 6 M 500 (800) Inspect for leaks



Engine Oil Change 100 H 6 M 1000 (1600)



Oil Filter Change 100 H 6 M 1000 (1600) Replace with oil change



50 H 6 M 500 (800)

50 H 6 M 500 (800) Inspect ducts for proper sealing / air leaks

(whichever comes first)

Miles

Remarks

(KM)

Inspect; adjust; lubricate; replace if necessary

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change at 20 hours or after one month of operation; change more frequently during cold weather operation

Front Gearcase Fluid - 12 M 1000 (1600) Change Fluid



Rear Gearcase Fluid - 12 M 1000 (1600) Change Fluid



Transmission Fluid - 12 M 1000 (1600) Change Fluid





Fuel System 100 H 12 M 1000 (1600)

Engine Mounts 100 H 12 M 1000 (1600) I nspect



Exhaust Pipe / Silencer 100 H 12 M 1000 (1600) Inspect



Sp ark Plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Wiring 100 H 12 M 1000 (1600)



Clutches



(Drive and Driven)

 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed  Brake Fluid 200 H 24 M 2000 (3200) Change every two ye ars  ADC Fluid 200 H 24 M 2000 (3200) Change every two years

Spark Arrestor (if applicable)



Valve Clearance 1000 H - 10000 (16000) Inspect; adjust

 Toe Adjustment - Inspect periodically; adjust as needed

Headlight Aim - Adjust as needed

100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

300 H 36 M 3000 (4800) Clean out; or remove clean out plug

Check for leaks at tank cap, fuel lines, fuel pump; replace lines every two years

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.4

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 a maximum of 3 pumps of grease at each of these areas.

Item Recommended Lube Method Frequency

Front Propshaft Yoke Front & Rear A-Arms Rear Bearing Carrier

Polaris Premium U-Joint Grease

Grease fittings (3 pumps maximum) every 500 miles (800 km).

Grease before long periods

of storage, and after pressure washing or submerging the ATV.

2.5

MAINTENANCE

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month or first 20 hours of operation, 100

Engine Oil Polaris PS-4 PLUS 2W-50

Performance Synthetic

Add oil to proper level on dipstick

hours thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation

2 Transmission

3 Engine Coolant Polaris 60/40 Coolant

* More often under severe use, such as operated in water or under severe loads.

Synthetic Sportsman XP Transmission Fluid

Add fluid until it is visible at the fill hole threads

Maintain coolant level in coolant reservoir bottle.

Check level every 25 hours; change fluid yearly

Check level daily, change coolant every 2 years

2.6

MAINTENANCE

Maintenance Quick Reference, Continued.....

III. # Item Lube Rec. Method Frequency*

Front Gearcase

ADC Reservoir

5 Front Gearcase

6 Rear Gearcase

7 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Polaris Premium ADC Front Drive Fluid

Polaris Premium LT Demand Drive Fluid

Polaris ATV Angle Drive Fluid (ADF)

Maintain fluid level in ADC Reservoir to indicated level

Add fluid until it is visible at the fill hole threads

Maintain fluid level in both master cylinder reservoirs to indicated levels

Check level every 25 hours; change fluid every two years

Check level every 25 hours; change fluid yearly or 1000 mi.

Check level every 25 hours; change fluid yearly

Check level during pre-ride inspection; change fluid every two years

2.7

MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants,Maintenance and Service Products

Part No. Description

Engine / Transmission Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2876244

2876245

2877606

2876251

2872277

2876160

2872276 2870465 Pump for Gallon Jug

2871534 60/40 Coolant (Quart) (12 count) 2871323 60/40 Coolant (Gallon) (6 count)

2871312 Grease Gun Kit 2871322

PS-4 PLUS 2W-50 Performance Synthetic 4-Cycle Engine Oil (Quart)

PS-4 PLUS 2W-50 Performance Synthetic 4-Cycle Engine Oil (Gallon)

Gearcase Lubricants

Synthetic Sportsman XP Transmission Fluid (Quart)

Premium LT Demand Drive Fluid (Quart) (12 count)

Premium Demand Drive Hub Fluid (2.5 Gallon) (2 count)

ATV Angle Drive Fluid (Quart) (12 count)

ATV Angle Drive Fluid (2.5 Gallon) (2 Count)

Coolant

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge) (24 Count)

Additives / Sealants / Thread Locking Agent s / Misc.

2870585 Loctite™ Primer N, Aerosol, 25 g 2871956

2871949

2871950

2871951

2871952

2871953

2871954

2870584

2870587

2871326 2870652 Fuel Stabilizer (16 oz.) (12 Count)

2872189 DOT 4 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count)

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

Loctite™ Thread Sealant 565 (50 ml.) (6 Count)

Loctite™ Threadlock 242 (50 ml.) (10 Count)

Loctite™ Threadlock 242 (6 ml.) (12 Count)

Loctite™ Threadlock 262 (50 ml.) (10 Count)

Loctite™ Threadlock 262 (6 ml.) (12 Count)

Loctite™ Threadlock 271 (6 ml.) (12 Count)

Loctite™ Threadlock 271 (36 ml.) (6 Count)

Loctite™ 680-Retaining Compound (10 ml.)

Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) (10 Count)

Premium Carbon Clean (12 oz.) (12 Count)

2871423 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 local Polaris dealer.

Premium All Season Grease (14 oz. cartridge) (10 Count)

2.8

MAINTENANCE

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check condition and tire pressure

• Fuel and oil - fill both to their proper level; do not overfill

• All brakes - check operation (includes auxiliary brake)

• Throttle - check for free operation

• Headlight / Taillight / Brakelight - check operation of all indicator lights and switches

• Engine stop switch (key switch) - check for proper function

• Wheels - check for loose wheel nuts

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or other fasteners

• Engine coolant - check for proper level at the recovery bottle

FUEL SYSTEM AND AIR INTAKE

Fuel System

WARNING

Gasoline is extremely flammable and explosive

under certain conditions.

• Always stop the engine and refuel outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately .

• If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time.

• Never drain the fuel when the engine is hot. Severe burns may result.

Frame, Nuts, Bolts, Fasteners

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

Controls

Check handlebar controls for proper operation, positioning and adjustment.

Fuel Lines

1. Check fuel lines for signs of wear, deterioration, damage, or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly and secured with cable ties where applicable.

CAUTION

Make sure lines are not kinked or pinched

3. Replace all fuel lines every two years.

2.9

MAINTENANCE

Fuel Filters

There are two fuel filters located within the fuel pump assembly. The fuel pump is non-serviceable. If the internal fuel pump filters require service, the fuel pump and fuel tank must be replaced as an assembly.

NOTE: See the “Electronic Parts Catalog” for more information. For all other information related to the EFI System, refer to Chapter 3.

Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment

NOTE: Sportsman XP requires a new adjustment procedure.

1. Slide the boot back far enough to expose the inline cab le adjuster sleeve and loosen the adjuster locknut.

2. Remove the (4) screws and cover from the RH control.

3. 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.

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 i dle 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.

4. 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 thrott le arm and throttle arm stop.

5. Reinstall the RH control cover and ensure the O-ring is properly in place. Securely tighten the (4) screws.

6. 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.

2.10

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.

• 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.

Cleaning:

4. Slip the pre-filter screen off of main element. Clean the prefilter 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 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.

2. Unscrew the two knobs retaining the airbox cover and open the 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.

12. Check the intake boot for cracks, deterioration, abrasion, or leaks. Replace as needed.

3. Remove the air filter assembly from the airbox.

2.11

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.

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.

2. Position the ATV on a level surface.

3. Stop engine and remove the dipstick. Wipe i t 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.

6. Maintain the oil level in the safe range. Do not overfill.

6. Place a drain pan beneath the engine crankcase.

7. Using a 6 mm Hex socket, remove the drain plug and allow the engine oil to drain completely.

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.

2.12

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 and torque to 12 ft. lbs. (16 Nm).

= T

Engine Drain Plug: 12 ft. lbs. (16 Nm)

10. Locate oil filter through access hole in the skid plate. Place shop towels beneath the oil filter. Using oil filter wrench (PV-43527) turn oil filter counterclockwise to remove it.

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 engine breather hose is routed properly and secured in place. CAUTION: Make sure line is not kinked or pinched.

Breather

Inspect

Airbox

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 filt er 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 and additional 1/2 turn.

= 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 1.75 qts. (1.66 L) of the recommended engine oil.

Recommended Engine Oil:

Engine Breather Assembly

The engine breather assembly is located on top of the valve cover. Inspect and service the breather components as required.

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.

2.13

MAINTENANCE

Valve Clearance Adjustment

1. Remove the seat and both upper side panels.

2. Disconnect the shift linkage from the shift lever.

3. Remove the (2) screws retaining the lower portion of the air box.

4. Remove the hose from the breaker valve located on top of the valve cover.

5. 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.

6. Remove the (4) bolts retaining the frame support. Pull the support forward and down to remove it from the vehicle.

7. Remove the (2) Torx-head screws retaining the upper portion of the air box to the front cab.

8. Carefully disconnect the ECU by pulling the tab out while pulling down on the connector.

9. Loosen the hose clamp retaining the intake boot to the intake plenum and remove the boot.

10. Lift up on the air box and turn it sideways to gain access to the valve cover bolts.

MAG & PTO ADJUSTMENT PROCEDURE

14. Turn the drive clutch counter-clockwise until the cam

sprocket is in the MAG (#1) Adjustment Position.

MAG (#1)

Adjustment Position

Timing Pin in Vertical Position

TDC #1 (MAG) Cylinder

11. Remove the spark plug wires and spark plugs.

12. Remove the (6) valve cover bolts and valve cover.

13. Remove PVT cover so the engine can be rotated (see “Drive Belt Removal” procedure within this chapter).

Timing Marks Lined Up With Top of Head

at MAG (#1) Adjustment Position

15. Set the MAG cylinder valve lash by placing the feeler gauge blade between the lash adjuster and valve as shown.

2.14

MAG (#1)

MAINTENANCE

16. Loosen the jam nut and turn the lash adjuster until the valve lash is correct.

17. Set the intake and exhaust valve lash to specification.

= In. / mm.

Intake Valve Clearance: .006 in. (.15 mm)

= In. / mm.

Exhaust Valve Clearance: .009 in. (.23 mm)

18. Hold adjuster and torque the jam nut using a torque wrench w/10 mm crow’s foot adaptor. Verify clearance is still correct after tightening the jam nut.

= T

Rocker Jam Nut: 71-89 in. lbs. (8-10 Nm)

19. Turn the drive clutch counter-clockwise to rotate the cam sprocket 225° to the PTO (#2) Adjustment Position.

21. Repeat steps 16-18.

22. Clean sealing surfaces of the cylinder head and valve cover.

23. Inspect the condition of the valve cover bolt rubber isolators. If rubber has become hardened or cracked, replace them.

24. Install a new valve cover seal and install the valve cover. Torque the cover bolts to specification.

= T

Valve Cover Bolts:

89 in. lbs. (10 Nm)

25. Install the upper right-hand frame support and torque the (4) mounting bolts to specification.

= T

Upper Right-Hand Frame Support Bolts:

36 ft. lbs. (49 Nm)

26. Reassemble vehicle by reversing this procedure. Start the engine to ensure proper valve adjustment was performed.

PTO (#2)

Adjustment Position

20. Set the PTO cylinder valve lash by placing the feeler gauge blade between the lash adjuster and valve as shown.

Timing Marks at PTO (#2)

Adjustment Position

PTO (#2)

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

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:

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).

1 ft.

6. If particles are still suspected to be in the silencer, drive the machine onto the incline so the front of the machine is 1 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.

1. Remove the clean out plug on the bottom of the 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.

Engine Mount Fastener Torque

Check engine mounting fasteners and ensure they are tight. Also inspect the condition of the rubber mounts. If rubber mounts are cracked or show signs of fatigue, replace them.

CAUTION

Wear protective gloves when covering the

exhaust outlets. Serious burns could result from

contact with exhaust components.

2.16

MAINTENANCE

TRANSMISSION AND GEARCASES

Transmission Lubrication

NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well.

The transmission fluid leve l should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Transmission Fluid 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 fluid level even with the bottom threads of the fill plug hole.

1. Position vehicle on a level surface.

Transmission Fluid 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 Fl uid Level Check”).

2. Place a drain pan under the transmission drain plug.

3. Remove the drain plug and allow fluid to drain complete ly.

2. Remove the fill plug and check the fluid level.

Fill Plug

10-14 ft. lbs.

(14-19 Nm)

Transmission fluid flush with the bottom of thread area.

3. If fluid level is not even with the b ottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

Drain Plug

10-14 ft. lbs. (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 fluid through the fill plug hole. Maintain the fluid level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

Fill Plug

10-14 ft. lbs.

(14-19 Nm)

Recommended Transmission Lubricant:

Synthetic Sportsman XP Transmission Fluid

(PN 2877606) (Quart)

Capacity: 32 oz. (946 ml)

7. Reinstall fill plug with a new O-ring and torque to specification.

= T

Drain/Fill Plug Torque:

10-14 ft. lbs. (14-19 Nm)

= T

Drain/Fill Plug Torque:

10-14 ft. lbs. (14-19 Nm)

8. Check for leaks. Dispose of used fluid properly.

2.17

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.

The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

• 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 fron t 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. Remove the fill plug and check the fluid level.

Fill Plug

8-10 ft. lbs. (11-14 Nm)

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”).

2. Place a drain pan under the front gearcase drain plug.

3. Remove the drain plug and allow fluid to drain completel y.

Drain Plug

8-10 ft. lbs.

(11-14 Nm)

4. Clean the drain plug magnetic surface.

Fill Plug

8-10 ft. lbs. (11-14 Nm)

Gearcase fluid flush with the bottom of thread area.

3. If fluid level is not even with the b ottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

= T

Drain / Fill Plug Torque:

8-10 ft. lbs. (11-14 Nm)

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 e ven with the bottom threads of the fill plug hole.

Recommended Front Gearcase Fluid:

Premium LT Demand Drive Fluid

(PN 2876251) (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. lbs. (11-14 Nm)

2.18

8. Check for leaks. Dispose of used fluid properly.

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.

The front gearcase ADC fluid level should be checked and changed in accordance with the maintenance schedule.

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.

5. Begin the bleeding process by filling reservoir to the “MAX” level with clean ADC Front Drive Fluid.

Recommended ADC Fluid:

Premium ADC Front Drive Fluid

(PN 2876144) (Quart)

6. Locate bleeder valves found on each side of the front gearcase and remove the protective caps.

Bleeder

Valve

Front

Gearcase

CapCap

Bleeder

Valve

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.

7. Attach a clean clear hose to one of the bleeder valves.

8. 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.

= T

Bleeder Valve Torque: 80 in. lbs. (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

+ 203 hidden pages