Manual

Polaris Scrambler XP 850 H.O. / EPS / INT’L Repair Service Manual 2013

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This workshop repair service manual PDF download for the 2003 Polaris Scrambler XP 850 H.O. / EPS / INT’L has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 

APPLICABLE MODELS :

YEAR – MODEL – MODEL NO.
2013 – SCRAMBLER XP 850 H.O. – A13GH85AJ
2013 – SCRAMBLER XP 850 H.O. EPS – A13GH8EAK 
2013 – SCRAMBLER XP 850 H.O. EPS INT’L – A13GH8EFK

TABLE OF CONTENTS :

Chapter_01_General_Information
Chapter_02_Maintenance
Chapter_03_Electronic_Fuel_Injection
Chapter_04_Cooling_System
Chapter_05_Engine
Chapter_06_Transmission
Chapter_07_Clutching(PVT)
Chapter_08_Final_Drive
Chapter_09_Body_Frame
Chapter_10_Steering_Suspension
Chapter_11_Brakes
Chapter_12_Electrical
Wiring_Diagrams

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9924122
Total Pages : 386

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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Chapter_01_General_Information
    GENERAL INFORMATION
        VEHICLE IDENTIFICATION
            Model Number Designation
            Engine Designation Number
            Vehicle Identification Number (VIN) Designation
            Vehicle and Engine Serial Number Locations
        VEHICLE INFORMATION
            Publication Numbers
            Replacement Keys
        SPECIAL TOOLS
        SPECIFICATIONS
            MODEL: 2013 SCRAMBLER XP 850 H.O. 
            MODEL: 2013 SCRAMBLER XP 850 H.O. EPS / INT’L
            2013 SCRAMBLER XP 850 H.O. / EPS / INT’L
        MISC. SPECIFICATIONS AND CHARTS
            Conversion Table
            Standard Bolt Torque Specification
            Metric Bolt Torque Specification
            SAE Tap / Drill Sizes
            Metric Tap / Drill Sizes
            Decimal Equivalents
            
Chapter_02_Maintenance
    MAINTENANCE
        PERIODIC MAINTENANCE CHART
            Periodic Maintenance Overview
            Break-In Period
            Maintenance Chart Key
            Maintenance Intervals
            Grease Lubrication Points
            Maintenance Quick Reference
            Maintenance Quick Reference, Continued
        LUBRICANTS / SERVICE PRODUCTS
            Polaris Lubricants,Maintenance and Service Products
        GENERAL VEHICLE INSPECTION AND MAINTENANCE
            Pre-ride / Daily Inspection
            Frame, Nuts, Bolts, Fasteners
            Controls
        FUEL SYSTEM AND AIR INTAKE
            Fuel System
            Fuel Lines
            Fuel Filters
            Vent Line
            Throttle Operation
            Throttle Release Switch / Throttle Cable Adjustment
            Air Filter / Pre-Filter Service
        ENGINE
            Engine Oil Level
            Engine Oil and Filter Change
            Engine Breather Hose
            Valve Clearance Adjustment
            Compression and Leakdown Tests
            Exhaust Silencer Cleaning
            Engine Mount Fastener Torque 
        TRANSMISSION AND GEARCASES
            Transmission Lubrication
            Front Gearcase Lubrication
            Rear Gearcase Lubrication
        COOLING SYSTEM
            Cooling System Overview
            Coolant Level Inspection
            Cooling System Hoses
            Coolant Strength / Type
        PVT / FINAL DRIVE / WHEEL AND TIRE
            PVT Drying
            Drive Belt Removal
            Drive Shaft Boot Inspection
            Wheel and Hub Torque Table
            Wheel Removal
            Wheel Installation
            Tire Pressure
            Tire Inspection
        ELECTRICAL AND IGNITION SYSTEM
            Battery Maintenance
            Battery Removal
            Battery Installation
            Extreme Use 30 AH Battery
            Engine / Chassis Ground
            Spark Plug Service
        STEERING
            Steering Inspection
            Power Steering Unit (EPS Models)
            Tie Rod End / Steering Inspection 
            Toe Alignment
            Toe Alignment Adjustment
        SUSPENSION
            Suspension Inspection
            Suspension Spring Pre-Load Adjustment
        Adjustable Shocks (FOX™)
            FOX™ Shock Spring Preload Adjustment
            Shock Compression Adjustment
        BRAKE SYSTEM
            Brake Fluid Inspection
            Brake Pad Inspection
            Hose / Fitting Inspection
            Auxiliary Brake Pedal
            
Chapter_03_Electronic_Fuel_Injection
    ELECTRONIC FUEL INJECTION
        SPECIAL TOOLS
            Part Numbers / Descriptions
            Fuel Pressure Gauge Kit – PU-43506-A
            Fuel Pressure Gauge Adaptor – PS-48762
            Digital Wrench® – Diagnostic Connector
            Digital Wrench® Diagnostic Software PU-47063-B
            Digital Wrench® SmartLink Module Kit – PU-47471
            Digital Wrench® – Download Website
        FUEL TANK
            Exploded View
        FUEL LINE
            Quick Connect Removal / Installation
        EFI SERVICE NOTES
        EFI SYSTEM LAYOUT
            Exploded View
        EFI COMPONENTS
            Identification / Location
        ELECTRONIC FUEL INJECTION
            General Information
            EFI Operation Overview
            Initial Priming / Starting Procedure
        ELECTRONIC CONTROL UNIT (ECU)
            Operation Overview
            ECU Service
            ECU Removal / Replacement
        FUEL PUMP ASSEMBLY
            Operation Overview
            Fuel Sender Test
            Fuel Pump Test
            Fuel Tank Removal
            Fuel Pump Replacement
            Fuel Tank Installation
        FUEL PRESSURE REGULATOR
            Operation Overview
        FUEL INJECTORS
            Operation Overview
            Fuel Injector Service
            Fuel Injector Test
            Fuel Injector Replacement
        CRANKSHAFT POSITION SENSOR (CPS)
            Operation Overview
            CPS Test
            CPS Replacement
        TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
            Operation Overview
            T-MAP Test
            T-MAP Replacement
        IDLE AIR CONTROL VALVE (IAC)
            Operation Overview
            IAC Test
            IAC Replacement
        THROTTLE POSITION SENSOR (TPS)
            Operation Overview
            TPS Resistance Tests
            TPS Replacement / Adjustment
        ENGINE COOLANT TEMPERATURE SENSOR (ECT)
            Operation Overview
            ECT Sensor Test
            ECT Sensor Replacement
        IGNITION COIL
            Operation Overview
            Ignition Coil Tests
            Ignition Coil and HT Lead Replacement
        EFI DIAGNOSTICS
            Instrument Cluster Trouble Code Display
        DIGITAL WRENCH® OPERATION
            Digital Wrench® Diagnostic Software Overview
            Special Tools
            Diagnostic Software Version
            ECU Replacement
            Guided Diagnostic Available
            Digital Wrench® Communication Errors
            Digital Wrench® – Diagnostic Connector
            Digital Wrench® Serial Number Location
            Digital Wrench® Version and Update ID
            Digital Wrench® Updates
            Digital Wrench® Feature Map
            Engine Controller Reprogramming (Reflash)
        FUEL SYSTEM TROUBLESHOOTING
            Fuel Starvation / Lean Mixture
            Rich Mixture
            Poor Idle
            
Chapter_04_Cooling_System
    COOLING SYSTEM
        SPECIAL TOOLS
        TORQUE SPECIFICATIONS
        COOLING SYSTEM
            Cooling System Layout and Testing
            Cooling System Specifications
            Cooling System Bleeding Procedure
        RADIATOR
            Radiator Cleaning
            Coolant Drain / Radiator Service
        WATER PUMP SERVICE
            Water Pump Impeller Removal
            Water Pump Mechanical Seal Replacement
            Water Pump Shaft & Bearing Replacement
            Stator Cover Installation
            Water Pump Assembly / Torque Specifications
            Stator Cover Assembly Torque Specifications
        THERMOSTAT
            Removal (Engine Installed)
            Installation
        TROUBLESHOOTING
            Cooling System
            
Chapter_05_Engine
    ENGINE
        GENERAL INFORMATION – ENGINE
            Special Tools
            Engine Lubrication Specifications
            Oil Pressure Test
            Oil Flow Diagram
            Engine Specifications – SPM850-12
        ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
            Torque Specification and Torque Sequence – Main Engine Components
            Valve Cover
            Camshaft Carrier / Camshaft / Rocker Arm
            Cylinder Head / Valves / Integrated Throttle Body
            Valve and Spring Height Detail
            Piston / Connecting Rod
            Crankshaft
            Crankcase
            Crankcase – Upper
            Balance Shaft / Balance Shaft Timing
            Crankcase (Lower) With Oil Pump
            Stator Cover / Flywheel / Water Pump Coupler
            Water Pump / Water Pump Coupler / Stator
            Drive Coupler (Rear) / Starter Gear
        ENGINE SERVICE
            Accessible Engine Components
            Top-End Service (Engine in Chassis)
            Engine Removal
            Engine Installation Notes
        ENGINE DISASSEMBLY / INSPECTION
            Valve Cover Removal / Inspection
            Rocker Carrier / Camshaft Removal
            Rocker Arm / Rocker Arm Shaft Inspection
            Camshaft / Camshaft Bore Inspection
            Cylinder Head Removal 
            Cylinder Head Cleaning
            Cylinder Head Warp Inspection
            Cylinder Head
            Valve Inspection
            Combustion Chamber
            Valve Guide Removal / Installation
            Valve Seat Reconditioning
            Cylinder Head Assembly
            Valve Sealing Test
            Cylinder Head Installation
            Camshaft / Carrier Assembly
            Camshaft / Camshaft Carrier Installation
            Camshaft Timing
            Cam Chain Tensioner Installation
            Camshaft Timing – Quick Reference
            Crankcase Disassembly
            Crankcase (Lower) / Oil Pump Disassembly
            Crankcase Disassembly (Upper)
            Piston / Connecting Rod Removal
            Counterbalance Shaft Removal / Inspection
            Crankshaft / Cam Chain Removal
            Cam Chain / Sprocket Inspection
            Crankcase Inspection (Lower)
            Crankshaft Inspection
            Connecting Rod Inspection
            Connecting Rod Big End Bearing Selection
            Piston / Piston Ring Inspection
            Piston Ring Removal
            Piston Ring Installed Gap
            Piston Pin Bore Inspection
            Cylinder Inspection
            Piston-to-Cylinder Clearance
        ENGINE ASSEMBLY
            Crankcase Preparation – Upper
            Piston Ring Installation
            Piston / Connecting Rod Assembly
            Piston / Connecting Rod Installation
            Crankshaft Installation
            Oil Passage Tube
            Crankcase Assembly – Upper 
            Balance Shaft Installation
            Balance Shaft Timing
            Crankcase Preparation (Lower)
            Crankcase Sealant and Torque Values
            Crankcase Assembly
        WATER PUMP
            Water Pump Impeller Removal
            Water Pump Mechanical Seal Replacement / Coupler Shaft and Bearing Replacement
        TROUBLESHOOTING
            Engine
            
Chapter_06_Transmission
    TRANSMISSION
        TRANSMISSION SPECIFICATIONS
            Torque Specifications
            Lubrication Specifications
        SHIFT LINKAGE / GEAR SELECTOR
            Shift Linkage Inspection
            Gear Selector Removal
        TRANSMISSION SERVICE
            Transmission Removal
            Transmission Disassembly 
            Transmission Shaft Service
            Transmission Assembly
            Transmission Installation
            Transmission Exploded View
        TROUBLESHOOTING
            Troubleshooting Checklist
            
Chapter_07_Clutching(PVT)
    CLUTCHING (PVT)
        SPECIAL TOOLS AND SUPPLIES
        TORQUE SPECIFICATIONS
            PVT System Fastener Torques
        HIGH ALTITUDE CLUTCH CHART
            2013 850 Scrambler
        PVT SYSTEM OVERVIEW
            General Operation
            Drive Clutch Operation
            Driven Clutch Operation
            Shift Weights
            PVT Break-In (Drive Belt / Clutches)
            Maintenance / Inspection
            Overheating / Diagnosis
        PVT SYSTEM SERVICE
            PVT Sealing and Ducting Components
            PVT Disassembly
            PVT Assembly
        DRIVE BELT
            Belt Removal
            Belt Inspection
            Belt Installation
            PVT Break-In (Drive Belt / Clutches)
        DRIVE CLUTCH SERVICE
            Exploded View
            Shift Weights
            Clutch Disassembly
            Bearing Inspection
            Drive Clutch Spring Inspection
            Shift Weight Inspection
            Button To Tower Clearance Inspection
            Spider Removal
            Roller, Pin, and Thrust Washer Inspection
            Clutch Inspection
            Moveable Sheave Bushing Inspection
            Bushing Service
            Clutch Assembly
        DRIVEN CLUTCH SERVICE
            Clutch Disassembly 
            Clutch Inspection
            Clutch Assembly
            Exploded View
        TROUBLESHOOTING
        
Chapter_08_Final_Drive
    FINAL DRIVE
        GENERAL SPECIFICATIONS
            Torque Specifications
            Special Tools
        WHEELS
            Removal
            Installation
        WHEEL HUBS
            Front Hub Exploded View
            Rear Hub Exploded View
        FRONT BEARING CARRIER
            Inspection / Removal
            Bearing Replacement
            Installation
        FRONT DRIVE SHAFT
            Removal
            Installation
        FRONT PROPSHAFT
            Removal
            Installation
        PROPSHAFT U-JOINT SERVICE
            Disassembly
            Assembly
        FRONT GEARCASE – CENTRALIZED HILLIARD
            Exploded View
            AWD Operation
            AWD Diagnosis
            Gearcase Removal (Non-EPS Models)
            Gearcase Removal (EPS Models)
            Gearcase Disassembly / Inspection
            Gearcase Assembly
            Setting Ring Gear Backlash
            Gearcase Installation (Non-EPS Models)
            Gearcase Installation (EPS Models)
        REAR BEARING CARRIER
            Inspection / Removal
            Bearing Replacement
            Bushing Replacement
            Installation
        REAR DRIVE SHAFT
            Removal
            Installation
        DRIVE SHAFT SERVICE
            Drive Shaft / CV Joint Handling Tips
            Outer CV Joint / Boot Replacement
            Inner Plunging Joint / Boot Replacement
            Drive Shaft Exploded View
        REAR PROPSHAFT
            Removal
            Installation
        REAR GEARCASE
            Gearcase Removal
            Gearcase Disassembly and Inspection
            Gearcase Bearing and Seal Replacement
            Gearcase Assembly
            Gearcase Exploded View
            Gearcase Installation
            
Chapter_09_Body_Frame
    BODY / FRAME
        TORQUE SPECIFICATIONS
        DECAL REPLACEMENT
        SPECIAL TOOLS
            Plastic Push Rivet Removal
            Multi-Function Pliers
        Handlebar POD
            Disassembly / Removal
            Assembly / Installation
        SEAT AND SIDE PANELS
            Removal / Installation
        FRONT RACK
            Removal / Installation
        FRONT BUMPER
            Removal / Installation
        FRONT FASCIA
            Removal / Installation
        MUD GUARDS
            Removal / Installation
        FOOTWELLS
            Removal / Installation
        FRONT CAB
            Removal
            Installation
        REAR RACK
            Removal / Installation
        REAR FENDERS
            Removal / Installation
        REAR CAB/STORAGE BOX
            Removal / Installation
        SKID PLATES
            Removal / Installation
        MAIN FRAME
            Frame Support Exploded View
            
Chapter_10_Steering_Suspension
    STEERING / SUSPENSION
        GENERAL SPECIFICATIONS
            Torque Specifications
        HANDLEBAR
            Removal / Replacement
            Installation
        STEERING (NON-EPS MODELS)
            Steering Post Removal
            Steering Post Installation
            Steering Exploded View (Non-EPS Models)
        STEERING (EPS MODELS)
            Upper Steering Post Removal
            Upper Steering Post Installation
            EPS Unit Removal
            EPS Unit Installation
            Steering Exploded View (EPS Models)
        STEERING TIE ROD
            Tie Rod / Tie Rod End Replacement
        FRONT A-ARMS
            Exploded View
            Removal / Replacement
        BALL JOINT SERVICE
            Service Preparation
            Ball Joint Removal
            Ball Joint Installation
        REAR A-ARMS
            Exploded View
            Removal
            Installation
        REAR STABILIZER BAR
            Exploded View
            Linkage Removal / Installation
            Stabilizer Bar Removal / Installation
        SHOCKS / SPRINGS / FASTENERS
            Shock Exploded View – Base Model
            Shock Exploded View – EPS/INTL. Models
            Shock Removal / Installation
            Shock / Spring Replacement
            Shock Removal / Installation
            Shock Replacement
        FOX™ SHOCK EXPLODED VIEWS
            FOX™ Piggyback Shock
        FOX™ SHOCK SERVICE
            General Service Information
            Front Shock Service Information
            Rear Shock Service Information
            FOX™ Shock Rebuild Information
            Special Tools
            FOX™ Shock Disassembly
            FOX™ Shock Body and Reservoir Service
            FOX™ Shock Component Rebuild
            FOX™ Shock Assembly
            
Chapter_11_Brakes
    BRAKES
        General Brake Specifications
            FRONT BRAKES
            REAR BRAKES
        General Torque Specifications
        Special Tools / Brake Fluid
    BRAKE SYSTEM SERVICE NOTES
    BRAKE NOISE TROUBLESHOOTING
    HYDRAULIC BRAKE SYSTEM OPERATION
    BRAKE SYSTEM EXPLODED VIEW
        XP 850 / XP 850 EPS Models
        850 INT’L Models
        Brake Caliper Exploded View
        Hand Master Cylinder Exploded View
    INTERNATIONAL BRAKE SYSTEM OPERATION
        Hand Master Cylinder Hydraulic Operation
        Foot Master Cylinder Hydraulic Operation
    BRAKE BLEEDING
        Fluid Replacement
        Always wear safety glasses during these procedures. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces.
            1. Clean reservoir cover thoroughly.
            2. Remove screws, cover and diaphragm from master cylinder reservoir.
            3. Inspect vent slots in cover and remove any debris or blockage.
            4. If changing fluid, remove old fluid from reservoir and lines at the bleeders with a Mity Vacä or similar tool.
            5. Add brake fluid to .25” – .30” (6 – 8 mm) from the top of the reservoir.
        Polaris DOT 4 Brake Fluid
        PN: 2872189
            Bleeding Procedure
                1. Remove the reservoir cover from the hand brake master cylinder and verify fluid is at specified level.
                2. If fluid level is low, add brake fluid to .25” – .30” (6 – 8 mm) from the top of the reservoir.
                3. Install a box end wrench on foot master cylinder bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting.
                4. Slowly pump the hand brake lever until pressure builds and holds.
                5. While maintaining lever pressure, open bleeder screw.
                6. Close bleeder screw and release brake lever.
                7. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
            Maintain at least 1/2” (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
                8. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm).
                9. Repeat the procedure on the two remaining front calipers.
                10. Add DOT 4 brake fluid to .25” – .30” (6 – 8 mm) from the top of the reservoir.
                11. Install diaphragm, cover and screws. Torque the screws to 7 in. lbs. (0.8 Nm).
                12. Proceed to “Rear Brake System Bleeding” to complete bleeding procedure.
                1. Thoroughly clean the fluid reservoir cover before removal.
                2. Remove the cap and diaphragm from the reservoir and verify fluid level is at the MAX level mark.
                3. If changing fluid, remove old fluid from reservoir with a Mity Vacä (PN 2870975) or similar tool.
                4. Using a funnel, add brake fluid to the MAX level mark on the reservoir.
                5. Install a box end wrench on the rear caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting.
                6. Slowly pump the foot brake pedal until pressure builds and holds.
                7. While maintaining pedal pressure, open bleeder screw.
                8. Close bleeder screw and release brake pedal.
                9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
                10. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm).
                11. Repeat the procedure on the remaining rear caliper.
                12. Using a funnel, add brake fluid to the MAX level mark on the reservoir.
                13. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2”, (1.3 cm) from handlebar.
                14. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found.
    HAND BRAKE MASTER CYLINDER
        Removal
            1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components.
            2. Place a shop towel or suitable catch container under the master cylinder brake line connection. Remove the banjo bolt fitting that connects the brake line to the master cylinder. Discard the sealing washers.
        Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces.
            3. Remove the Torx screws from the master cylinder clamp.
            4. Hold master cylinder upright and lift the master cylinder from the handlebars. Cover brake line orifice to avoid spilling fluid.
            Disassembly
            Installation
                1. Install master cylinder on handlebars. Torque bolt furthest from the reservoir first, followed by the bolt closest to the reservoir. Torque clamp bolts to 70 in. lbs. (8 Nm).
                2. Place new sealing washers on each side of banjo line and torque banjo bolt to specification.
                3. Fill reservoir with DOT 4 brake fluid (PN 2872189).
                4. Follow brake bleeding procedures. Check all connections for leaks and repair if necessary.
            Brake Switch Replacement
                1. Set the parking brake lock and locate the brake switch behind the hand brake lever.
                2. Using a small screwdriver or similar tool, push up on the mounting tabs through the holes on the bottom side while rotating the switch to disengage the tabs from the holes.
                3. Install the new switch. The tabs should snap in place.
    FOOT BRAKE MASTER CYLINDER
        Foot Master Cylinder Removal / Installation
            1. Remove the RH mud guard and footwell (see Chapter 9).
            2. Remove the front and rear brake line from the master cylinder. Use a suitable container to catch the brake fluid. Dispose of brake fluid properly.
            3. Remove the (2) through-bolts retaining the master cylinder to the mount bracket. Replace components as needed.
            4. Reverse this procedure when reinstalling and torque mounting fasteners to specification.
            5. Reinstall the brake line and torque the banjo bolt (with new sealing washers installed) to specification.
            6. Bleed the master cylinder following the procedure outlined in the “Brake Bleeding” section of this chapter.
        Brake Pedal Removal / Installation
            1. Remove the RH mud guard and footwell (see Chapter 9).
            2. Remove the through-bolt retaining the brake pedal to the mount bracket.
            3. Remove the bolt, bushings, spacer, spring and brake lever.
            4. Inspect and replace components as needed.
            5. Reverse this procedure when reinstalling and torque mounting fastener to specification.
    BRAKE PADS
        Pad Removal
            1. Loosen the (4) wheel nuts.
            2. Elevate and support the side of the ATV in which the caliper brake pads are being serviced.
        Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
            3. Remove the wheel nuts and wheel.
            4. Remove the (2) brake caliper mounting bolts and caliper.
            5. Push mounting bracket inward and slip the outer brake pad past the edge of the pin. Remove the inner brake pad.
            Pad Inspection
                1. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
            Pad Installation
                1. Lubricate mounting bracket pins and external slide pin O-ring with a light film of silicone grease.
                2. Compress mounting bracket. Install pads with friction material facing each other.
        If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean brake pads.
            3. Install the caliper and torque new mounting bolts to specification.
        New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
            4. Slowly pump the brake lever/pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
            5. Verify fluid level in reservoir is at specified level inside reservoir and install reservoir cap.
            6. Install the wheel(s) and wheel nuts. Torque wheel nuts to specification.
            Brake Burnishing Procedure
    CALIPER SERVICE
        Caliper Removal
            1. Loosen the (4) wheel nuts.
            2. Elevate and support the side of the ATV in which the caliper is being serviced.
        Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
            3. Remove the wheel nuts and wheel.
            4. Place a suitable container under the caliper to catch brake fluid draining from brake line. Using a wrench, loosen and remove brake line from the caliper.
            5. Remove (2) caliper mounting bolts and remove the caliper assembly from the bearing carrier.
            Caliper Disassembly
                1. Push mount bracket inward and slip outer brake pad past the edge of the pin. Remove the inner brake pad.
                2. Remove mount bracket, pin assembly and dust boot.
                3. Using a hammer and a small punch, remove the piston from the caliper body, then remove the square O-rings (see “BRAKE CALIPER – Exploded View”).
                4. Clean the caliper body, piston, and mounting bracket with brake cleaner or denatured alcohol.
            Caliper Inspection
                1. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.
                2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit.
                3. Inspect the brake pad and disc as outlined in this chapter (see “Pad Inspection” and “Brake Disc Inspection”).
            Caliper Assembly
                1. Install new O-rings (A) in the caliper body (B). Be sure grooves are clean or brakes may drag upon assembly.
                2. Coat piston with DOT 4 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of the bore smoothly, with light resistance.
                3. Lubricate the mounting bracket pins with silicone grease, and install the rubber dust seal boots.
                4. Compress the mounting bracket and make sure the dust seals are fully seated.
                5. Install the brake pads.
                6. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
            Caliper Installation
                1. Install caliper assembly over the brake disc and onto the bearing carrier. Torque mounting bolts to specification.
        New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
            2. Install brake line and torque the banjo bolt fitting to specification.
            3. Perform brake bleeding procedure as outlined earlier in this chapter.
            4. Install the wheel and (4) wheel nuts. Torque wheel nuts to specification.
    BRAKE DISC SERVICE
        Disc Inspection
            1. Visually inspect brake disc for scoring, scratches, or gouges. Replace disc if deep gouges are evident.
            2. Measure the disc thickness at 8 different points around the pad contact surface using a 0–1” micrometer. Replace disc if worn beyond service limit.
            3. Mount a dial indicator as shown and measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification.
        Disc Removal / Replacement
            1. Loosen the (4) wheel nuts.
            2. Elevate and support the side of the ATV in which the brake disc is being serviced.
        Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
            3. Remove the wheel nuts and wheel.
            4. Remove the cotter pin, castle nut and cone washers.
            5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line.
            6. Remove the wheel hub assembly from the bearing carrier.
            7. Press out the wheel studs and remove the brake disc.
            8. Clean the wheel hub mating surface.
            9. Install the new disc and press new wheel studs into the hub until they are flush with the mating surface.
        Always use new wheel studs if removed from the wheel hub assembly.
            10. Install wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out.
            11. Install the brake caliper and torque the new mounting bolts to specification.
        New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
            12. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
            13. Install the wheel and (4) wheel nuts. Torque wheel nuts to specification.
            14. Field test the ATV for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation.
    TROUBLESHOOTING
        Brake Squeal
        
Chapter_12_Electrical
    ELECTRICAL
        General Information
            Special Tools
            Electrical Service Notes
            Component Locations
        Instrument Cluster (EPS Models)
            Overview
            Rider Information Display
            Speed Information
            Information Display Area
            Diagnostic Mode
            Instrument Cluster Pinouts
        Instrument Cluster (NON-EPS Models)
            Overview
            Rider Information Display
            Information Display Area
            Diagnostic Mode
            Instrument Cluster Pinouts
        Brake Switch
            Function Test
        Ignition Switch
            Function Test
            Function Test (INT’L)
        4×4 / 2×4 Switch
            Function Test
        LH Switch Function Tests
            Base/EPS Models
            International Models
        THROTTLE RELEASE SWITCH (TRS)
            Throttle Release Switch (TRS)
        Gear Selector Switch
            Selector Switch Function Test
            Resistor Module Function Test
        Speed Sensor
            Vehicle Speed Sensor
        AWD Coils
            Operation Overview
            Diagnosing System Failures
            AWD Function Tests
        Fuse/Relay Box Layout
        Fuses
            Protected Circuits
        Relays
            Relay Overview
            Chassis Relay
            Fan Relay
            EFI Relay
            Low Beam Relay – Base Models
            High Beam Relay – Base Models
            Start Solenoid Relay
            Power Steering Relay (EPS Models)
            Low Beam Relay – International Models
            High Beam Relay – International Models
        Lights
            Headlamp Adjustment – Base Models
            Headlamp Adjustment – EPS/INTL. Models
            Headlamp Replacement – Base Models
            Headlamp Replacement – EPS Models
            Headlamp Installation – EPS Models
            Headlamp / DRL Replacement – International Models
            Tail / Brake Lamp Replacement
        Charging System
            Charging System Diagram
            Voltage Rectifier / Regulator (600 Watt)
            Current Draw – Key Off
            Battery Charge Test
            Stator / Alternator Tests
            Stator / Alternator Removal
            Stator / Alternator Installation
        BATTERY SERVICE
            Battery Specifications
            General Battery Information
            Battery Removal / Installation
            Battery Off Season Storage
            Battery Testing
            OCV – Open Circuit Voltage Test
            Load Test
            Battery Conductance Analyzer
            Extreme Use 30 AH Battery
            Charging Procedure 
        Starter Motor
            Starter/Starter Lockout System Diagram
            Troubleshooting
            Voltage Drop Testing
            Starter Motor Removal / Replacement
        Instrument Cluster Troubleshooting
            Instrument Cluster – Key OFF / No Power
            Instrument Cluster – Key ON / No Power
            Instrument Cluster – No High Beam Indicator
            Instrument Cluster – No / Incorrect Fuel Level
        Electronic Power Steering (EPS)
            EPS Operation
            Proper EPS System Diagnosing
            EPS Troubleshooting
        Controller Area Network (CAN)
            Overview
            CAN Troubleshooting
            
9924122_Wiring_Diagrams
    2013 Scrambler 850_1.pdf
    2013 Scrambler 850_2
    2013 Scrambler 850 EPS.pdf
        2013 Scrambler 850 EPS_1.pdf
        2013 Scrambler 850 EPS_2
    2013 Scrambler 850 Intl.pdf
        2013 Scrambler 850 Intl_1.pdf
        2013 Scrambler 850 Intl_2
    2013 Scrambler 850 Intl.pdf
        2013 Scrambler 850 Intl_1.pdf
        2013 Scrambler 850 Intl_2
        
        –
        

 

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Polaris Scrambler XP 850 H.O. / EPS / INT’L Repair Service Manual 2013.pdf

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