Drive Clutch Holder 9314177 11. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Cover the tank inlet and remove the fuel tank lower steering coupler and remove it from the chassis. Disconnect the shift linkage from the shift lever. Remove the 4 screws that retain the pump neck assembly to the main gearcase. Be sure they are placed between the battery terminal and cable s. Trip Meters 1 and 2 Select N or P gear position.
Belt Removal 2877408 Position the vehicle on a level surface and place the transmission in Park. Remove the upper and lower headlight pods from the handlebar bracket see Chapter 9. Using Removal Tool Nut C a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Remove the seat and side panels see Chapter 9. Install adapter reducer Item 9. Never substitute or mix oil brands. This is truly the future of service manuals.
Inspect the bearing for wear. Polaris Switch Cylinder offers a number of service kits to rebuild this style of master cylinder. Remove the 3 bolts retaining the input cover. Chain Pitch: Distance between chain link pins No. Bearing Installation Visually inspect bearing for moisture, dirt, or corrosion. Check valve face for runout, pitting, and burnt spots.
Drive mechanical seal out from stator side of cover. Spin the bearing, if the bearing does not spin smoothly, replace it. Refer to the Polaris Electronic Parts Catalog. Be sure to note the number and thickness of these washers. Be sure machine is secure before beginning this service procedure.
Transmission Lubrication The plastic skid plate can be removed for better access to the drain plug. Washer Snap Ring Detent Plug 20. Carefully align pin of balance shaft with slot in gear. Washing the vehicle with a high-pressure With the engine still idling, top off the radiator with Polaris washer could damage the radiator fins and Premium Antifreeze. Clean sealing surfaces of the cylinder head and valve cover. If the internal fuel pump Slide the boot back far enough to expose the inline cable filters require service, the fuel pump and fuel tank must be adjuster sleeve and loosen the adjuster locknut. Remove the rear cab see Chapter 9.
Remove the high tension leads from the engine and remove the 2 nuts from each exhaust flange at the engine. If warp exceeds the service limit, replace the Wear eye protection when removing and installing cylinder head. Deflector Plate Retaining Screws: 7-10 ft. Inspect the armature plate for a consistent wear pattern. Fuel Pump - Located in the fuel tank as an assembly. Using a clean shop rag or towel, cover the fuel fill hose inlet to prevent dirt or debris from entering the fuel tank. Difference between measurements is Secure connecting rod lightly in a soft jawed vise.
Always consult the exploded views or each manual section for torque values of fasteners before using standard torque 9923067 - 2011 Sportsman 850 Service Manual © Copyright 2010 Polaris Sales Inc. Replace if feeler gauge through the pump outlet window and compare debris has entered, or if oil pressure was outside of specified to specification. Replace crankshaft if any journal is scratched or pitted. Access the drain plug from the rear right-hand Maintenance Chart. When installing the headlight into the lower pod, be sure Remove to install the O-rings prior to installing the headlight. Chain Pitch: Distance between chain link pins No. Set the intake and exhaust valve lash to specification.
Install the drive shaft axle through the backside of the bearing carrier. Regular fluid level inspections should be performed as well. Be sure machine is secure before beginning this service procedure. Turn puller barrel to increase tension on sheave if needed. All segments will light up for 1 second at start-up.