Polaris ATV 2011 XP 850 / EPS / X2 / Touring Repair Manual

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Stichworte: 2011 ATV EPS Polaris Powersports Sportsman Series Touring X2 XP 850

Produktvarianten

Beschreibung

The Polaris Sportsman XP 850 Series, specifically for the 2011 model year, represents a premium, high-performance utility All-Terrain Vehicle (ATV). Powered by the robust 850cc ProStar engine, this ATV delivers substantial power and torque, making it ideal for demanding tasks such as ranch work, hunting expeditions, and challenging trail riding. Key features include a sophisticated independent rear suspension (IRS) for superior comfort and control, and the option of Electronic Power Steering (EPS) to reduce rider fatigue. Its engineering quality is evident in the powerful ProStar platform and the reliable Variable Transmission (PVT) with engine braking, ensuring consistent performance across varied terrain and conditions. This comprehensive 396-page Factory Service Manual provides essential information for maintaining and repairing the Sportsman XP 850, Sportsman XP 850 EPS, Sportsman XP 850 EPS International, Sportsman X2 850, Sportsman Touring 850, and Sportsman Touring 850 International models. It covers all major systems, including the engine, fuel, cooling, transmission, clutch, final drive, body, frame, steering, suspension, brakes, and electrical systems. The manual details routine maintenance, troubleshooting procedures, engine and transmission repair, electrical diagnostics, and component overhauls, offering factory-level technical data, exploded views, torque specifications, and detailed wiring diagrams to assist owners and technicians in keeping their vehicles in optimal condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model Family:

Sportsman XP 850 Series

Year Covered:

Vehicle Type:

All-Terrain Vehicle (ATV)

Generation

Platform:

Polaris 850 High Output ProStar

Codes

Engine Code General:

ProStar 850

👋 Introduction

Market Position

Category:

Premium High-Performance Utility ATV

Target User:

Ranchers, hunters, trail riders, and recreational users demanding robust power and capability.

Competitive Analysis

Key Competitors:

Can-Am Outlander 800R, Yamaha Grizzly 700, Arctic Cat 700/1000 series.

Unique Selling Points:

850cc ProStar engine, independent rear suspension (IRS), available Electronic Power Steering (EPS), Polaris Variable Transmission (PVT).

Key Features

Engine Power:

High output 850cc, liquid-cooled, DOHC, 8-valve, 4-stroke engine.

Suspension Design:

Dual A-arm front suspension with 8.2" travel; Dual A-arm rear suspension with 9.5" travel (IRS).

Steering Assistance:

Optional Electronic Power Steering (EPS) reduces steering effort significantly.

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking.

📋 Manual Details

Coverage Areas

Models Covered:

Sportsman XP 850, Sportsman XP 850 EPS, Sportsman XP 850 EPS International, Sportsman X2 850, Sportsman Touring 850, Sportsman Touring 850 International

Page Count

Total Pages:

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Delivery Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Complete diagnosis, repair, and overhaul procedures for the 850cc ProStar engine.

Fuel System:

Detailed coverage of Electronic Fuel Injection (EFI) system, including fuel pump, injectors, sensors, and ECU troubleshooting.

Cooling System:

Radiator, fan, coolant flow, thermostat, and water pump diagnostics and service.

Transmission System:

Service and repair procedures for the Automatic (PVT) transmission, including belt inspection, clutch assembly, and gearbox.

Clutching System:

Primary and secondary clutch inspection, maintenance, and adjustment for optimal performance.

Final Drive System:

Front and rear differential, driveshaft, and axle service, including lubrication and seal replacement.

Body Frame:

Body panel removal and installation, frame inspection, and mounting hardware.

Steering Suspension:

Front and rear suspension component service, steering linkage, tie rods, wheel bearings, and shock absorbers.

Brake System:

Hydraulic brake system diagnosis, caliper service, pad replacement, bleeding procedures, and parking brake.

Electrical System:

Comprehensive electrical system coverage including starting, charging, lighting, ignition, sensors, ECU, and detailed wiring diagrams.

Procedures Included

Routine Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, and pre-ride inspections.

Troubleshooting:

Diagnostic charts and step-by-step troubleshooting guides for common and complex issues.

Engine Repair:

Detailed procedures for engine disassembly, component inspection, reassembly, and tuning.

Transmission Repair:

Procedures for PVT belt replacement, clutch adjustment, and general transmission upkeep.

Electrical Diagnostics:

Step-by-step diagnosis of electrical faults using wiring diagrams and component testing.

Suspension Alignment:

Front-end alignment procedures and specifications.

Brake Bleeding:

Proper hydraulic brake bleeding techniques.

Component Overhaul:

Detailed instructions for overhauling major components like the engine, transmission, and differentials.

Technical Depth

Depth Of Coverage:

Comprehensive, factory-level technical information suitable for both novice DIYers and professional mechanics.

Detail Level:

Includes exploded views, torque specifications, diagnostic codes, and detailed wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text within the PDF for quick information retrieval.

Print Quality

Printability:

Printable for individual sections or the entire manual.

Binding Type

Recommended Binding:

3-ring binder (user supplied)

Paper Type

Ideal Paper Format:

Standard letter/A4 (user printable)

⚙️ Engine Specifications

Primary Engine

Engine Family:

ProStar

Displacement:

850cc

Engine Type:

4-stroke, DOHC, 4-valve per cylinder

Cooling Method:

Liquid-cooled

Performance

Horsepower Estimate:

~70 HP (specific to model variants, manual provides detailed dyno data)

Torque Estimate:

~60 lb-ft (specific to model variants, manual provides detailed dyno data)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type Recommendation:

Unleaded gasoline, 87 octane (minimum)

🔧 Transmission

Standard

Transmission Type:

Automatic PVT (Polaris Variable Transmission)

Drive Modes:

High, Low, Neutral, Reverse, Park

Engine Braking:

Standard feature on PVT for downhill control.

Features

Clutch System:

Dual centrifugal clutch system with primary and secondary sheaves.

Final Drive:

Sealed, constant velocity (CV) shaft drive to rear wheels, shaft drive to front differential (on 4x4 models).

📐 Dimensions

Exterior

Length Approx:

83.7 inches (212.6 cm)

Width Approx:

48 inches (121.9 cm)

Height Approx:

50 inches (127 cm)

Weights

Dry Weight Approx:

670-700 lbs (304-318 kg) - varies by model

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

200 lbs (90.7 kg)

Rack Capacity Rear:

400 lbs (181.4 kg)

🛡️ Safety Features

Ratings

Vehicle Classification:

Class 1 ATV (recreational use, often requires registration and safety training depending on jurisdiction)

Active Features

Braking System:

Hydraulic disc brakes front and rear, sealed mechanical rear wheel brake.

Parking Brake:

Standard on transmission/rear brake caliper.

Passive Features

Lighting:

Dual 50W halogen headlights, dual brakelights/taillights.

Seat Belt Requirement:

Not standard on ATVs; riders must wear DOT-approved helmets and appropriate protective gear.

💡 Technology Features

Infotainment

Display Features:

Basic digital instrument cluster displaying speed, RPM, fuel level, gear selection, odometer, trip meter, engine hours.

Driver Assistance

Power Steering:

Available Electronic Power Steering (EPS) system reduces rider fatigue.

Connectivity

Diagnostic Ports:

Access to EFI system diagnostics via a dedicated diagnostic connector.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 100 hours or annually (whichever comes first).

Air Filter Cleaning:

Inspect every 50 hours, clean/replace as needed based on operating conditions.

Pvt Belt Inspection:

Inspect every 100 hours for wear and damage.

Spark Plug Replacement:

Every 100 hours or annually.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Synthetic 4-stroke engine oil (or equivalent API CI-4 rated oil).

Engine Oil Capacity:

Approximately 2.5 US quarts (2.37 liters) with filter change (refer to manual for exact capacity).

Coolant Type:

Polaris Premium 2-Stroke Oil/Antifreeze (or equivalent ethylene glycol-based coolant with corrosion inhibitors).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Differential Oil Type:

Polaris Demand Drive Fluid (front differential); SAE 75W-90 Synthetic Gear Oil (rear differential/gearbox).

Known Issues

Common Wear Items:

PVT belt wear, tie rod ends, wheel bearings, front driveshaft U-joints (especially in heavy mud).

Potential Efi Concerns:

Dirty throttle body, faulty TPS (Throttle Position Sensor) or MAP (Manifold Absolute Pressure) sensor readings, fuel injector clogs.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, founded 1954, known for snowmobiles and later ATVs and UTVs.

Model Evolution

Predecessor Models:

Polaris Sportsman series (e.g., 700 Twin, 800 Twin).

Innovation Introduction:

The 850cc ProStar engine platform was a significant upgrade in power and efficiency for Polaris ATVs.

Production

Manufacturing Location:

Roseau, Minnesota, USA (primary manufacturing)

🏆 Awards & Recognition

Recognitions

Industry Perception:

Polaris Sportsman models are generally well-regarded for their power, comfort, and utility in the ATV market.