2011 SPORTSMAN 850 Chapter 10
Contents
1. A CAUTION Locking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal NOTE Refer to exploded views throughout this chapter for more torque specifications component identification and location of components 10 2 HANDLEBAR Removal Replacement 1 Remove the upper and lower headlight pods from the handlebar bracket see Chapter 9 IMPORTANT Take note of all vent line wire harness and throttle cable routing for reassembly purposes 2 Remove the 4 fasteners retaining the handlebar bracket and block to the steering post 3 Remove the handlebar assembly from the steering post IMPORTANT Take care not to bend the throttle cable or brake line while the handlebar is removed 4 Ifreplacing the handlebar Remove the RH and LH controls Remove the hand grips Pry open the upper and lower handlebar blocks and remove them from the handlebar 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Installation 1 Locate the alignment pin on the bottom side of the upper block The pin should line up with the alignment hole in the lower block and should face the front 14 ft Ibs 19 Nm Alignment Hole Bracket Lea Xs a INE RE CENE pel Nuts 2 Position the handlebar properly and install the 4 bolts2. Ibs E 60 Nm PUT 10 seo goo eS 44 ft Ibs 9 60 Nm REF DESCRIPTION REF DESCRIPTION 1 Tie Rod Assembly 12 Upper Steering Bushing 2 Upper Steering Post 13 Carriage Bolt 3 Rod End RH 14 Nut 4 Jam Nut RH 15 Bolt 5 Tie Rod 16 Lower Steering Post 6 Jam Nut LH 17 Power Steering Assembly 7 Rod End LH 18 Power Steering Mount Plate 8 Washer 19 Front Drive Bracket LH 9 Cotter Pin 20 Front Drive Bracket RH 10 Nut 21 Bolt 11 Upper Steering Bracket 22 Pinch Bolt 10 10 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION STEERING TIE ROD If replacing just the tie rod end D loosen the jam nut E and remove the rod end Tie Rod Tie Rod End Replacement Use the following procedure to replace the tie rod assembly or tie rod ends 5 Install the new tie rod assembly C Install new rod end and torque jam nuts to specification 1 Elevate front of vehicle and safely support machine under 6 Install the rod ends and fasteners B in the proper the frame area orientation see illustration 7 Torque the tie rod end fasteners to specification and install CAUTION n w cotter ping Serious injury may result if machine tips or falls eS zT Be sure machine is secure before beginning this rvi r re Alw wear r ion service procedure ays wear eye protectio Tie Rod End Fastener 44 ft Ibs 60 Nm 2 Remove the 4 wheel nuts a
3. install a new retaining ring Ball Joint Upper A arm NEW Retaining Ring 3 Reinstall the A arm see FRONT A ARMS Removal Replacement 4 Repeat the ball joint service procedure for any additional A arm ball joint replacements 10 15 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc STEERING SUSPENSION REAR A ARMS Exploded View 13 45 ft Ibs b 61 Nm IN 14 45 ft Ibs NG f e Pa o Eu 9 40 ft Ibs 54 Nm 45 ft Ibs 61 Nm REF DESCRIPTION REF DESCRIPTION 1 Bolt 9 Bolt 2 Nut 10 Pivot Shaft Upper 3 Bushing LCA 11 Pivot Shaft Lower 4 Upper A arm 12 Bushing Lower 5 Grease Fitting 13 Pivot Tube 6 Pivot Shaft 14 Bushing UCA 7 Bolt 15 Bolt 8 Lower A arm 16 Bushing Upper 10 16 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Removal The following procedure details upper and lower A arm removal and replacement on one side of the vehicle 1 Elevate and safely support the rear of the vehicle and remove the rear wheel Upper A arm Removal 2 Remove the through bolt fastener attaching the upper A arm to the bearing carrier see Exploded View 3 Remove the through bolt fastener attaching the upper A arm to the frame and remove the A arm from the vehicle 4 Examine A arm and bearing carrier bushi
4. 3 Evenly tighten the pin side front bolts first Torque the 2 front bolts to specification ey T Handlebar Bolts 14 ft Ibs 19 Nm 4 Install the rear bolts and tighten evenly Torque the 2 rear bolts to specification NOTE There will be a slight gap on the backside of the handlebar blocks after installation 5 Ifhandlebar was replaced Install the hand grips Install the RH and LH controls 6 Reassemble the headlight pod see Chapter 9 NOTE Make sure to route all vent lines wire harness and throttle cable correctly into the lower headlight pod STEERING NON EPS MODELS Steering Post Removal 1 Remove the front rack and front cover see Chapter 9 2 Remove the upper and lower headlight pods from the handlebar bracket see Chapter 9 IMPORTANT Take note of all vent line wire harness and throttle cable routing for reassembly purposes 3 Remove the 4 fasteners retaining the handlebar bracket and block to the steering post 4 Carefully remove the handlebar assembly from the steering post and place it on the front cab IMPORTANT Take care not to bend the throttle cable or brake line while the handlebar is removed 5 Remove the cotter pin and nut from each tie rod end at the steering post frog 10 3 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION 6 Remove the 2 bolts retaining the lower s
5. Ring 2 Remove the retaining ring from the ball joint 3 A driver must be used for the removal of the ball joint Use the dimensions below to fabricate or locate the correct size driver to use in the following process Driver Dimensions 1 375 in 3 49 cm 1 75 in 4 45 cm Y Outside diameter of driver cannot be any larger than 1 75 in 4 45 cm Inside diameter cannot be any smaller than 1 375 in 3 49 cm Driver must be at least 3 in 7 62 cm tall 10 14 4 Use a press and correct size driver to remove the ball joint from the A arm Correct Driver Placement The driver must fit the inside diameter of the A arm end Upper A arm Shown NOTE The driver must fit the ball joint housing in the A arm This will allow the ball joint to be properly pressed out of the A arm without damaging the A arm Press out of the A arm in this direction Upper A arm Shown Place driver HERE to support A arm 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Installation 1 Place the A arm in the correct position for ball joint installation Face the A arm end flat on top of the driver Carefully drive the ball joint into place until the ball joint is properly seated Press into the A arm in this direction Place driver HERE to support A arm Upper A arm Shown 2 After the new ball joint is installed into the A arm
6. front wheel 2 Remove the lower shock fastener from the upper A arm 8 Ifnot replacing the A arm thoroughly clean the A arm and pivot shafts 9 Install new ball joint into A arm Refer to Ball Joint Replacement section 10 Insert new bushings and pivot shafts into the new A arm 11 Install new upper A arm assembly onto vehicle frame Torque new bolts to 40 ft Ibs 54 Nm 12 Insert upper A arm ball joint end into the bearing carrier Install new pinch bolt and fastener hardware Torque new pinch bolt to 17 ft Ibs 23 Nm 1 4 Turn 90 13 Attach shock to A arm with new fastener Torque lower shock bolt to 37 ft Ibs 50 Nm 3 Remove the upper ball joint pinch bolt from the front 14 Remove the lower ball joint pinch bolt from the front bearing carrier see Figure 10 2 bearing carrier see Figure 10 2 15 Using a soft face hammer tap on bearing carrier to loosen the lower A arm ball joint end while pushing downward on the lower A arm Completely remove the ball joint end from the bearing carrier 16 Remove the lower A arm through bolt fasteners and remove the lower A arm from the vehicle 17 Examine A arm bushings and pivot shafts see Exploded View Replace if worn and discard the hardware 18 Ifnot replacing the A arm thoroughly clean the A arm and pivot shafts 19 Install new ball joint into A arm Refer to Ball Joint Replacement section Bearing Carrie
7. key to the ON position and move the i handlebar from left to right several times to ensure the y power steering doesn t bind If binding occurs E Upper Steering Post Loosen the 4 mounting fasteners Move handlebars from left to right several times to position the power steering unit Torque the 4 mounting fasteners to specification and check the steering operation for binding again CAUTION Striking the steering post can permanently damage the EPS unit and cause a Power Steering Fault If no binding is present proceed if binding is still present repeat this procedure 13 Install both front mud guards upper side panels front cab if removed and right hand footwell see Chapter 9 14 Install the front cover and front rack or storage box see Chapter 9 10 9 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Steering Exploded View EPS Models 20 ft Ibs ax D IA 27 Nm y 7 Steering Lock S l E INT L Models cre 15 ft Ibs S e d 20 Nm Y 13 E e d e 22 14 ear 16 E 22 ft Ibs i A 30 Nm 30 ft Ibs 44 ft lbs 12 ft Ibs 41 Nm m 15 60 Nm 16 Nm 9 10 9 14 e 5 44 ft Ibs M L ps 60 Nm 16 Y 8 6 amp 3 4 1 Z 12 ft Ibs E 12 ft lbs 10 12 ft Ibs z 9 16 Nm j 246 Nm 16 Nm EC P g e e 6 ef 44 ft
8. Ibs 16 Nm BN Ue Nm 16 Nm 10 E 1 b 9 e 6 44 ft Ibs q 7 60 Nm do SAS o E 44 ft Ibs E m 60 Nm REF DESCRIPTION REF DESCRIPTION 1 Tie Rod 9 Cotter Pin 2 Steering Post 10 Nut 3 Rod End RH 11 Upper Steering Bracket 4 Jam Nut RH 12 Upper Steering Bushing 5 Tie Rod Assembly 13 Carriage Bolt 6 Jam Nut LH 14 Nut 7 Rod End LH 15 Bolt 8 Washer 10 5 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION STEERING EPS MODE LS 7 Remove the 2 fasteners retaining the upper steering post bushing bracket Upper Steering Post Removal 1 Remove the front rack and front cover see Chapter 9 2 Remove the upper and lower headlight pods from the handlebar bracket see Chapter 9 IMPORTANT Take note of all vent line wire harness and throttle cable routing for reassembly purposes 3 Remove the 4 fasteners retaining the handlebar bracket y t and block to the steering post 8 Lift the upper steering post up from the power steering unit remove it from the chassis Upper Steering Post Installation 1 Reverse the Upper Steering Post Removal procedure to reinstall the steering post 2 Apply anti seize to the shaft splines to aid assembly 3 Align the mark on the upper steering post nut side with 4 Carefully remove the handlebar assembly from the steering the skip tooth spline on the upper power st
9. ODED VIEW mE Eme D Ret a td EREMO 10 18 LINKAGE REMOVAL INSTALLATION sssesse n RII 10 19 STABILIZER BAR REMOVAL INSTALLATION lisse ree 10 19 SHOGKS SPRINGS o ence Ei PER RR ESI Tee Me greece tee one BS 10 20 EXPLODED VIEW ooo Gel eg td eee M IUD Ca teats 10 20 SHOCK REMOVAL INSTALLATION 0 0 0 000002 Ie 10 20 SHOCK SPRING REPLACEMENT 0 0000000 eee 10 20 10 1 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION GENERAL SPECIFICATIONS Torque Specifications Item Specification Aluminum Wheels Steel Wheels Wheel Hub Retaining Nuts front and rear Steering Post to Bulkhead 75 ft lbs 102 Nm 45 ft lbs 61 Nm 80 ft Ibs 108 Nm 20 ft lbs 27 Nm 22 ft Ibs 30 Nm 12 ft lbs 16 Nm Steering Post to Gearcase Tie Rod Jam Nuts Tie Rod to Bearing Carrier Tie Rod to Steering Frog Handlebar Block Bolts Shock Mounting Bolts Front Ball Joint Pinch Bolts upper and lower Replace fasteners if loosened Front A arm to Frame Bolts upper and lower 44 ft lbs 60 Nm 14 ft lbs 19 Nm 37 ft lbs 50 Nm 17 ft lbs 23 Nm 1 4 Turn or 90 40 ft Ibs 54 Nm Rear A arm to Frame Bolts upper and lower 45 ft Ibs 61 Nm Rear Upper A Arm to Bearing Carrier Bolts AQ AS SANTO Rear Lower A Arm to Bearing Carrier Bolts SO
10. STEERING SUSPENSION CHAPTER 10 STEERING SUSPENSION GENERAL SPECIFICATIONS 551a esca PRG ex se See eae a GP e a 10 2 HANDLEBAR eres ep nee REE E ee eae Rant AAA A 10 2 REMOVAL REPLACEMENT 0 00000 rl 10 2 INSTALLATION ot at ia 10 3 STEERING NON EPS MODELS ocioso aims lei ed ake 10 3 STEERING POST REMOVAL 0 000000 rne 10 3 STEERING POST INSTALLATION 0 0 000000000 eee ee eee eee ee 10 4 STEERING EXPLODED VIEW NON EPS MODELS 0 0 04 10 5 STEERING EPS MODELS uscar eat ib kate oe Pes ao yee 10 6 UPPER STEERING POST REMOVAL INSTALLATION sese nens 10 6 EPS UNIT REMOVAL rui psp UN Rb e und aere pce rus 10 7 EPS UNIT INSTALLATION sssssssene RR I II Ih 10 8 STEERING EXPLODED VIEW EPS MODELS 2 0 0 10 10 STEERING TIE ROD e excu dnt dei ERR Ee odo OE CE ERA eh 10 11 TIE ROD TIE ROD END REPLACEMENT 00 0 e 10 11 FRONTA ARMS mica dao ach welt Simoes FANS qa RU AES Avatar RR E pd d 10 12 EXPLODED VIEW Roue did tette tend 10 12 REMOVAL REPLACEMENT ccoo 10 13 BALL JOINT SERVICE cocoa arre 10 14 REMOVALS sit hse tie ik RA E Quad te a nak iat de ieee 10 14 INSTALLATION Rn eet Dg rd tte 10 15 BEAR PEABNIS G4 2a E 50 O A ht d 10 16 EXPLODED VIEW oo ete ed pte I RE eae Bee 10 16 REMOVAL INSTALLATION 2 0 00000 RII II ll 10 17 HEAR STABILIZER BAR crasas tai fae act aoa taa BE 10 18 EXPL
11. e fasteners and torque fasteners to specification Refer to Steering Exploded View EPS Models 6 Reconnect the 2 electrical harnesses to the power steering unit CAUTION The 8 way connector two rows of four pins does not have a channeled lock on both sides allowing it to be installed 180 from its intended position The connector will not positively engage or snap into place while in the wrong position but can still be installed If the connector is not installed correctly the Power Steering Unit will not function 10 8 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION 7 Align the mark on the upper steering post nut side with 9 Install the pinch bolts and torque to specification Refer to the skip tooth spline on the upper power steering shaft upon Steering Exploded View EPS Models installation Upper Steering Post Pinch Bolts 15 ft Ibs 20 Nm 10 Install the fuel tank assembly fuel line and reconnect the fuel pump harness see Chapter 3 11 Reinstall the upper steering post bushing bracket and torque the 2 fasteners to specification NOTE Apply anti seize to the shaft splines to aid assembly 8 Position the upper steering post on the shaft so the pinch bolts are aligned with the recess in the power steering shaft Steering Post to Bulkhead Bolts 20 ft Ibs 27 Nm 12 Turn the ignition
12. eering shaft upon post and place it on the front cab installation IMPORTANT Take care not to bend the throttle cable 4 Carefully slide the upper steering post onto the upper power or brake line while the handlebar is removed steering shaft and install the pinch bolts 5 Disconnect and remove the battery to access the upper steering post pinch bolts see Chapter 2 Battery Removal 6 Remove the pinch bolts retaining the upper steering post to the power steering unit CAUTION Striking the steering post can permanently damage the EPS unit and cause a Power Steering Fault 10 6 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION 5 Refer to Steering Exploded View EPS Models on page EPS Unit Removal 10 12 for torque values 1 Remove the front rack or front storage box and front cover see Chapter 9 2 Remove both front mud guards upper side panels front cab Upper Steering Post Pinch Bolts and right hand footwell see Chapter 9 15 ft Ibs 20 Nm 3 Remove the fuel tank see Chapter 3 NOTE Make sure to route all vent lines wire 4 Remove the pinch bolts retaining the upper steering post to harness and throttle cable correctly into the lower the power steering unit headlight pod 6 When installing the headlight into the lower pod be sure to install the O rings prior to installing the headlight 7 Place the headlig
13. ht into the lower pod mounting tabs and press firmly until the headlight snaps into place 8 Lift the O ring over the headlight mounting tab to secure it PS ev Q 5 Disconnect the 2 electrical harnesses from the power steering unit 6 Remove the 2 fasteners retaining the upper steering post bushing bracket 9 Reinstall the adjustment screw and be sure to adjust the upper headlight after reassembly NOTE Refer to Chapter 9 when reassembling the upper and lower headlight pods 7 Lift the upper steering post up from the power steering unit 10 7 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION 8 Remove the 4 mounting fasteners that retain the power EPS Unit Installation steering unit and mount plate to the frame 1 Position the vehicle so the front wheels are pointing straight forward Power Steering Unit 2 Clean the lower steering post so the alignment mark is visible Mark the skip tooth spline on the lower power steering shaft 3 Apply anti seize to the shaft splines to aid assembly 4 Align the two marks and install the power steering unit Upper aa Steering Post Mount removed only for clarity Power Steering Unit Alignment Marks 9 Carefully lift the power steering unit up to disengage the lower steering coupler and remove it from the chassis Alignment Marks 5 Install the 4 mount plat
14. nd remove the front wheel s 3 Remove the cotter pins A and tie rod end fasteners B 8 Install the front wheel s and wheel nuts Torque wheel nuts to specification Wheel Nuts Steel Wheels 45 ft Ibs 61 Nm Aluminum Wheels 75 ft Ibs 102 Nm 4 Remove the tie rod assembly C 9 Check wheel toe alignment and adjust as necessary see Chapter 2 10 11 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION FRONT A ARMS Exploded View 40 ft Ibs 0 E ZA 54 Nm 11 40 ft Ibs 54 Nm 11 8 Always replace pinch bolt fasteners if loosened REF DESCRIPTION REF DESCRIPTION 1 Upper A arm 8 Bushing 2 Lower A arm 9 Pivot Shaft 3 Retaining Ring 10 Bolt 4 Ball Joint 11 Nut 5 Nut 12 CV Shield 6 Bolt replace if loosened or removed 13 Screw 7 Grease Fitting 14 Washer 10 12 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Removal Replacement The following procedure details upper and lower A arm A WARNING removal and replacement on one side of the vehicle The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 1 Elevate and safely support the front of the vehicle and remove the
15. ner Adjusting Cam 37 ft Ibs 50 Nm Shock Removal Installation 1 Elevate the vehicle off the ground to relieve the suspension load 2 Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle 3 Reverse the procedure to reinstall the shock Torque new fasteners to 37 ft Ibs 50 Nm Shock Spring Replacement 1 Using a spring compressor compress the shock spring far enough to remove the spring retainer Shock Spring Compressor Tool 2870623 2 Remove the spring and adjusting cam from the existing shock and install components onto the new shock 3 Compress the shock spring and install the spring retainer 4 Reinstall the shock onto the vehicle and torque new fasteners to 37 ft Ibs 50 Nm 10 20 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc
16. ngs and pivot shafts see Exploded View Replace if worn and discard the hardware A WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 5 Ifnot replacing the A arm thoroughly clean the a arm and pivot shafts 6 Insert new bushings and pivot shafts into the new A arm Lower A arm Removal 7 Remove the through bolt fastener attaching the lower A arm to the bearing carrier see Exploded View 8 Remove the lower shock fastener from the lower A arm NOTE Nut must face front of vehicle on INT L models Figure 10 19 9 Remove the brake line retainer from the lower A arm if applicable 10 Remove the fastener retaining the stabilizer linkage to the lower A arm Hold here with a 5 16 open end wrench 11 Remove the through bolt fasteners attaching the lower A arm to the frame and remove the A arm from the vehicle 12 Examine A arm and bearing carrier bushings and pivot shafts see Exploded View Replace if worn and discard the hardware 13 If not replacing the A arm thoroughly clean the a arm and pivot shafts Insert new bushings and pivot shafts into the new A arm Installation 1 Install upper and lower A arm assemblies onto the vehicle frame Torque new fasteners to 45 ft Ibs 61 Nm 2 Grease all 3 A arm grease fitting
17. nkage rod and remove the lower linkage bushing Rotate the stabilizer bar up and remove the stabilizer linkage from the lower A arm Repeat this procedure if removing or replacing the other linkage Reverse this procedure to reinstall the stabilizer linkage Refer to the Exploded View on the previous page for torque values Stabilizer Bar Removal Installation 1 Elevate the rear of vehicle and safely support machine under the frame area Serious injury may result if machine tips or falls CAUTION Be sure machine is secure before beginning this service procedure Always wear eye protection Remove the upper linkage bushing from each side and rotate the stabilizer bar up Remove the 2 fasteners from each stabilizer bar bracket retaining the stabilizer bar to the frame Remove the upper shock mounting fastener from the right rear shock and swing the shock out from the frame wW i FAN Remove Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed Inspect the rubber bushings on the stabilizer linkage s and replace if needed Reverse this procedure to reinstall the stabilizer bar Refer to the Exploded View on the previous page for torque values 10 19 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc STEERING SUSPENSION SHOCKS SPRINGS Exploded View 37 ft Ibs 50 Nm Spring Retai
18. r 20 Insert new bushings and pivot shafts into the new A arm Figure 10 2 21 Install new lower A arm assembly onto vehicle frame Torque new bolts to 40 ft Ibs 54 Nm t Remove the Digs tine Tetunec TOR Me Upper ssa 22 Insert lower A arm ball joint end into the bearing carrier 5 Using a soft face hammer tap on bearing carrier to loosen Install new pinch bolt and fastener hardware Torque new the upper ball joint end while lifting upward on the upper pinch bolt to 17 ft Ibs 23 Nm 1 4 Turn 90 A arm Completely remove the ball joint end from the Decade 23 Grease all 4 A arm grease fittings after reassembly 6 Remove the upper A arm through bolt fasteners and WARNING remove the A arm from the vehicle see Exploded View A Upon A arm installation completion test vehicle at low speeds before putting into service 10 13 7 Examine A arm bushings and pivot shafts see Exploded View Replace if worn and discard the hardware 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION BALL JOINT SERVICE Removal IMPORTANT Do not reuse a ball joint if it has been removed for any reason If removed it must be replaced Use this removal procedure only when replacing the ball joint 1 The A arm must be removed to perform this procedure see FRONT A ARMS Removal Replacement Ball Joint Upper A arm Retaining
19. s after reassembly Attach lower A arm to bearing carrier Torque new fastener to 45 ft Ibs 61 Nm 4 Attach upper A arm to bearing carrier Torque new fasteners to 40 ft Ibs 54 Nm Grease both rear bearing carrier fittings after reassembly 5 Route brake line on top of lower A arm and install retainer if applicable 6 Reinstall the lower portion of the shock and lower portion of the stabilizer linkage to the lower A arm Torque shock mounting fastener see Figure 10 19 to 37 ft Ibs 50 Nm Torque linkage fastener to 17 ft Ibs 23 Nm 7 Install the wheel and torque wheel nuts to specification see page 10 2 A WARNING Upon A arm installation completion test vehicle at low speeds before putting into service 10 17 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc STEERING SUSPENSION REAR STABILIZER BAR Exploded View 2 gS 22 ft Ibs ce men ee i 6 17 ft Ibs 23 Nm Q y O V DX REF DESCRIPTION REF DESCRIPTION 1 Bolt 5 Stabilizer Bar 2 Stabilizer Bar Bracket 6 Bushing Linkage 3 Bushing Stabilizer Bar 7 Linkage Assembly Stabilizer Bar 4 Nut 10 18 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Linkage Removal Installation 1 Remove the upper linkage bushing from each side Using an 5 16 open end wrench hold the li
20. teering post Steering Post Installation bracket to the front gearcase 1 Reverse the Steering Post Removal procedure to reinstall the steering post Refer to the Steering Exploded View for torque values NOTE Make sure to route all vent lines wire harness and throttle cable correctly into the lower headlight pod 2 When installing the headlight into the lower pod be sure to install the O rings prior to installing the headlight 3 Place the headlight into the lower pod mounting tabs and press firmly until the headlight snaps into place 4 Lift the O ring up and over the headlight mounting tab to secure it 7 Remove the 2 fasteners retaining the upper steering post bushing bracket KE 0 uster CY 5 Reinstall the adjustment screw and be sure to adjust the upper headlight after reassembly 8 Lift the steering post assembly up from the front gearcase and carefully remove it from the chassis NOTE Refer to Chapter 9 when reassembling the upper and lower headlight pods 10 4 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc STEERING SUSPENSION Steering Exploded View Non EPS Models 20 ft Ibs 12 Chey Se DUET 27 Nm 2 Steering Lock N 11 INT L Models AO l gi e 13 i 14 es ee et preise 10 44 ft Ibs 12 ft Ibs 30 Nm Lo 60 Nm 16 o 3 5 foe TON S 12 ft
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