Service Manual

5.21
ENGINE
5
ENGINE SERVICE
Accessible Engine Components
Components serviceable with engine installed:
• Flywheel
• Alternator (Stator)
• Starter Motor/Drive
• Cylinder Head / Valves
• Camshaft / Camshaft Carrier
•Rocker Arms
• Water Pump
Components that require engine removal for service:
• Counterbalance Shaft(s)
• Piston / Rings
• Connecting Rod
• Crankshaft / Main Bearings
•Oil Pump
• Crankcase
• Crankshaft End Seals (Use Driver PA-49320)
Top-End Service (Engine in Chassis)
The top-end of the engine can be serviced while the engine is
mounted in the chassis. A removable upper right-hand frame
support allows access to the valve cover and cylinder head.
To service the top-end of the engine refer to the “Valve
Clearance Adjustment” procedure in Chapter 2, which provides
detailed steps to access the valve cover.
Crankcase Cylinder Service Information
IMPORTANT: Identify which engine you are servicing
before replacing components such as the pistons.
It is important to note that two types of engine crankcases were
produced for the 2009 Sportsman XP 850. Some of the engines
produced have NiCaSil plated cylinder walls, while others have
iron lined cylinder walls.
The crankcase differences can be easily recognized by their
physical appearance.
• A dull, dark gray color identifies the NiCaSil plated.
• A shinny metallic color identifies the iron lined.
The crankcase differences can also be identified by viewing the
engine designation portion of the vehicle’s model number.
• NiCaSil Plated: A09ZN85
• Iron Lined: A09ZN8X.
Engine Removal
IMPORTANT: Some engine repair procedures can be
performed without removing the engine from the
vehicle. Refer to “Accessible Engine Components”
for further information.
NOTE: Upon engine removal, use a mechanical lift
or have an assistant help remove the engine from
the vehicle to prevent personal injury or damage to
vehicle components.
1. If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Clean your work area
4. Drain the engine oil (see Chapter 2 “Maintenance”).
5. Remove the following body components. Refer to Chapter
9 “Body / Frame” for component removal.
• Seat
• Side Panels (upper and lower)
• Footwells
• Mud Guards (both sides)
6. Disconnect negative (-) battery cable.
7. Pull the shift linkage rod straight outward while pushing on
the two ears of the snap retainer to disconnect the rod from
the shift lever. Allow the linkage to hang down out of the
way.
Linkage