Polaris 2009 Sportsman XP 850 & XP 850 EPS ATV Service Manual (P/N 9921850)

This Polaris ATV service manual (P/N 9921850) covers the 2009 Sportsman XP 850 and Sportsman XP 850 EPS.

PDF Search and Wiring Diagram Detail

Text search, bookmarks, and diagram labels: Service chapter text is searchable, and bookmarks link to chapters, procedures, and individual wiring sheets. The photo cover has no searchable text. Text search is unreliable for small wiring labels, which are best read at higher zoom. Some entries in the dense wiring tables remain hard to distinguish.

The download is one printable English PDF with 311 pages. That total includes 309 pages of service content and wiring diagrams, a one-page photo cover, and a one-page parts catalog link sheet.

Engine Overhaul, PVT Service, and EFI Diagnostics

This selection of shop procedures covers the main repair and diagnostic areas. The manual also includes exhaust silencer cleaning and gear-selector linkage adjustment.

• Maintenance and cooling: Service intervals, lubrication points, fluid and filter changes, compression and leakdown testing, cooling-system pressure testing and bleeding, and water-pump service.

• Engine overhaul: In-chassis top-end service, engine removal, cylinder-head and valve work, cam timing, crankcase and oil-pump service, crankshaft bearing selection, and balance-shaft timing.

• EFI diagnostics: Instrument-cluster fault codes, Digital Wrench diagnostics, fuel-pump and injector tests, crankshaft and temperature sensor checks, idle-air control tests, and throttle-position sensor adjustment.

• Transmission and PVT: Gearbox removal and internal shaft inspection, drive-belt checks, and drive and driven clutch disassembly, bushing service, clearance checks, and reassembly.

• Final drive and AWD: Centralized Hilliard front gearcase and rear gearcase service, ring-gear backlash, bearings and seals, propshaft U-joints, CV joints and boots, and Active Descent Control bleeding.

• Steering, suspension, and brakes: EPS unit removal and installation, toe alignment, spring preload, A-arms and ball joints, brake bleeding, master cylinders, and caliper rebuilding.

• Wiring diagrams: An overall diagram across two pages and 15 circuit-specific sheets, including charging, engine cranking, EFI, EPS, AWD/ADC, fuel pump and level, cooling fan, and lighting.

The manual suits ATV technicians and experienced owners equipped for mechanical service and diagnostic testing. Polaris specifies a certified Master Service Dealer technician for PVT maintenance and repair, with factory-authorized tools for clutch disassembly and repair.

Engine and Cooling Service

The engine section distinguishes work that can be done in the chassis from jobs that require engine removal, such as crankshaft, piston, and oil-pump service. It identifies NiCaSil-plated and iron-lined cylinders so the technician can match replacement pistons to the crankcase. Cylinder-head and bottom-end inspection data are backed by assembly views, an oil-flow diagram, torque sequences, and sealant callouts.

Cooling procedures include radiator removal, thermostat service, and water-pump seal, shaft, and bearing replacement. Allow the pressurized cooling system to cool before opening it.

EFI and Power Steering Faults

The EFI section pairs fault codes with component tests and circuit diagrams for the Bosch system. It covers the crankshaft position sensor, T-MAP sensor, idle air control valve, throttle position sensor, coolant temperature sensor, and ignition coil. The ECU is sealed, and a replacement needs the correct calibration before startup. The fuel pump and tank are serviced as an assembly. Relieve EFI pressure before opening the fuel system.

The EPS procedures show how to index the steering unit during installation. Striking the steering post can damage the EPS unit, and the eight-way connector can fit in reverse and leave power steering inoperative.

Gearcases, Clutches, and Brake Inspection

Exploded views show the gearbox, gearcases, clutch assemblies, steering, and hydraulic brakes. The front gearcase procedure explains when factory-set ring-gear backlash needs to be reset after component replacement. The drive-clutch shaft and retaining bolt use left-hand threads. The chassis chapters cover hubs, bearing carriers, body panels, stabilizer linkage, and shocks, along with brake pad and disc inspection, burnishing, and brake-noise troubleshooting.

Tool references include the PU-43506-A fuel-pressure gauge with PS-48762 adapter, the 2201519 TPS tester, PU-47063 Digital Wrench software with PU-47471 SmartLink hardware, the PA-49318 crankshaft holding tool, and the PA-48595 drive-clutch puller. Support the ATV securely before working underneath it.

Electrical Service Coverage

The PDF contains Chapters 1–11 and the domestic wiring diagrams. The battery procedure refers to Chapter 12 for further electrical service. A copy with Chapter 12 is needed for the full starting, charging, and instrument-system service procedures.

Sample Compression, Valve Lash, and Sensor Specs

The engine test section lists cylinder compression at 210–250 psi at full throttle and notes that readings vary with cranking speed. The cylinder-head specifications list cold intake valve lash at 0.006 in.

For EFI diagnosis, the crankshaft position sensor test specifies 860 ohms ±10% at 68°F (20°C).