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2018
Sportsman
850/1000
Service
Manual
FOREWORD
The
information
printed
within
this
publication
includes
the
latest
product
information
at
time
of
print.
This
Service
Manual
is
designed
primarily
for
use
by
certified
®
technicians
in
a
properly
equipped
shop
and
should
be
kept
available
for
reference.
All
references
to
left
and
right
side
of
the
vehicle
are
from
the
operator's
perspective
when
seated
in
a
normal
riding
position.
Some
procedures
outlined
in
this
manual
require
a
sound
knowledge
of
mechanical
theory,
tool
use,
and
shop
procedures
in
order
to
perform
the
work
safely
and
correctly.
Technicians
should
read
the
text
and
be
familiar
with
the
service
procedures
before
starting
any
repair.
Certain
procedures
require
the
use
of
special
tools.
Use
only
the
proper
tools
as
specified.
If
you
have
any
doubt
as
to
your
ability
to
perform
any
of
the
procedures
outlined
in
this
Service
Manual,
contact
an
authorized
dealer
for
service.
Publication
Printed
August
2017
(PN
9928503
R02)
Summary of Contents for Sportsman 850 Touring EPS
Page 4: ......
Page 6: ......
Page 72: ...2 40 NOTES MAINTENANCE ...
Page 78: ...3 6 OIL FLOW DIAGRAM ENGINE COOLING SYSTEM ...
Page 93: ...3 3 21 WATER PUMP ASSEMBLY TORQUE SPECIFICATIONS ENGINE COOLING SYSTEM ...
Page 94: ...3 22 STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS ENGINE COOLING SYSTEM ...
Page 100: ...3 28 VALVE COVER ENGINE COOLING SYSTEM ...
Page 101: ...3 3 29 CAMSHAFT CARRIER CAMSHAFT ROCKER ARM ENGINE COOLING SYSTEM ...
Page 102: ...3 30 CYLINDER HEAD VALVES INTEGRATED THROTTLE BODY ENGINE COOLING SYSTEM ...
Page 103: ...3 3 31 VALVE AND SPRING HEIGHT DETAIL SPM850 ENGINE COOLING SYSTEM ...
Page 104: ...3 32 VALVE AND SPRING HEIGHT DETAIL SPM1000 ENGINE COOLING SYSTEM ...
Page 105: ...3 3 33 PISTON CONNECTING ROD ENGINE COOLING SYSTEM ...
Page 106: ...3 34 CRANKSHAFT ENGINE COOLING SYSTEM ...
Page 107: ...3 3 35 CRANKCASE ENGINE COOLING SYSTEM ...
Page 108: ...3 36 CRANKCASE UPPER ENGINE COOLING SYSTEM ...
Page 109: ...3 3 37 BALANCE SHAFT BALANCE SHAFT TIMING ENGINE COOLING SYSTEM ...
Page 110: ...3 38 CRANKCASE LOWER WITH OIL PUMP ENGINE COOLING SYSTEM ...
Page 111: ...3 3 39 STATOR COVER FLYWHEEL WATER PUMP COUPLER ENGINE COOLING SYSTEM ...
Page 112: ...3 40 WATER PUMP WATER PUMP COUPLER STATOR ENGINE COOLING SYSTEM ...
Page 113: ...3 3 41 DRIVE COUPLER REAR STARTER GEAR ENGINE COOLING SYSTEM ...
Page 141: ...3 3 69 CRANKCASE ASSEMBLY UPPER ENGINE COOLING SYSTEM ...
Page 143: ...3 3 71 BALANCE SHAFT TIMING ENGINE COOLING SYSTEM ...
Page 145: ...3 3 73 CRANKCASE SEALANT AND TORQUE VALUES ENGINE COOLING SYSTEM ...
Page 154: ...3 82 NOTES ENGINE COOLING SYSTEM ...
Page 160: ...4 6 FUEL TANK FUEL TANK ASSEMBLY VIEW FUEL SYSTEM ...
Page 170: ...4 16 EFI SYSTEM LAYOUT EFI SYSTEM ASSEMBLY VIEW FUEL SYSTEM ...
Page 204: ...4 50 NOTES FUEL SYSTEM ...
Page 217: ...5 5 13 DRIVE CLUTCH SERVICE DRIVE CLUTCH EXPLODED VIEW ALL MODELS PVT SYSTEM ...
Page 245: ...6 6 11 Primary Shaft Rear Output Shaft Reverse Shaft Coupler Input Shaft TRANSMISSION ...
Page 246: ...6 12 Cam Shift Shaft Bellcrank Shift Shaft TRANSMISSION ...
Page 254: ...6 20 TRANSMISSION EXPLODED VIEW TRANSMISSION ...
Page 330: ...7 74 NOTES FINAL DRIVE ...
Page 338: ...8 8 STEERING EPS STEERING ASSEMBLY VIEW EPS MODELS STEERING SUSPENSION ...
Page 372: ...8 42 NOTES STEERING SUSPENSION ...
Page 377: ...9 9 5 BRAKE SYSTEM ASSEMBLY VIEWS SPORTSMAN SCRAMBLER 850 BRAKE SYSTEM BRAKE SYSTEM ...
Page 378: ...9 6 SPORTSMAN SCRAMBLER 1000 BRAKE SYSTEM BRAKE SYSTEM ...
Page 379: ...9 9 7 SPORTSMAN SCRAMBLER INTERNATIONAL BRAKE SYSTEM BRAKE CALIPER EXPLODED VIEW BRAKE SYSTEM ...
Page 381: ...9 9 9 BRAKE SYSTEM ...
Page 436: ...11 22 INSTERMENT CLUSTER TROUBLESHOOTING INSTRUMENT CLUSTER KEY OFF NO POWER ELECTRICAL ...
Page 437: ...11 11 23 INSTRUMENT CLUSTER KEY ON NO POWER ELECTRICAL ...
Page 438: ...11 24 INSTRUMENT CLUSTER NO HIGH BEAM INDICATOR ELECTRICAL ...
Page 439: ...11 11 25 INSTRUMENT CLUSTER NO INCORRECT FUEL LEVEL ELECTRICAL ...
Page 492: ...11 78 EPS TROUBLESHOOTING ELECTRICAL ...
Page 500: ...11 86 NOTES ELECTRICAL ...