Hey everyone! If you're here, chances are you're either a proud owner of a Polaris Sportsman 850 or you're seriously considering joining the club. Well, you're in the right place! This guide is your ultimate resource for everything related to the repair and maintenance of this beast of an ATV. We'll cover everything from the basics to some more advanced tips and tricks, ensuring you can keep your Sportsman 850 running smoothly for years to come. Buckle up, because we're about to dive deep into the world of Polaris ATV maintenance!

Understanding Your Polaris Sportsman 850

Before we jump into the nitty-gritty of repairs, let's get acquainted with your machine. The Polaris Sportsman 850 is known for its power, reliability, and versatility. Whether you're hitting the trails, working on the farm, or just enjoying a leisurely ride, this ATV can handle it all. Understanding the key components of your ATV is crucial for effective maintenance and repair. This includes the engine, transmission, suspension, brakes, and electrical system. The Sportsman 850 typically features an 850cc, liquid-cooled, four-stroke engine that delivers impressive performance. The automatic transmission, often a CVT (Continuously Variable Transmission), provides smooth power delivery. The suspension system, usually consisting of independent rear suspension (IRS), offers a comfortable and controlled ride. The braking system, usually hydraulic disc brakes, ensures reliable stopping power. Lastly, the electrical system powers everything from the lights and gauges to the fuel injection system. Regularly inspecting and understanding these components will make your repair experience easier. Also, knowing what the problem is will also make it easier for you to fix it. Keep an eye out for any unusual noises, leaks, or performance issues, as these can be early indicators of potential problems. Being proactive with your maintenance can save you a lot of headaches (and money!) down the road. Furthermore, the Sportsman 850 also provides different trim levels, such as the SP (Sportsman) models, which give additional features such as electronic power steering and upgraded suspension systems.

Key Components and Their Functions

Let's break down the main parts of your Sportsman 850 a bit further. The engine is the heart of the ATV, responsible for converting fuel into mechanical power. The transmission transfers this power to the wheels, allowing you to move forward, backward, and at various speeds. The suspension system absorbs shocks and bumps, providing a comfortable ride and maintaining traction. The brakes are essential for slowing down and stopping the ATV safely. The electrical system provides power to all the electronic components, including the lights, gauges, and fuel injection system. The engine air filter cleans the air before it enters the engine, preventing dirt and debris from causing damage. The oil filter removes contaminants from the engine oil, ensuring clean lubrication. The coolant system helps to regulate the engine temperature, preventing overheating. The fuel system delivers fuel to the engine, ensuring proper combustion. The drive system, which includes the axles and differentials, transfers power from the transmission to the wheels. Familiarizing yourself with these key components will help you diagnose problems and perform necessary repairs. And, remember, if you're ever unsure about a particular repair, don't hesitate to consult your owner's manual or seek professional help. The goal is to keep your Sportsman 850 in top condition so you can enjoy all your rides without any worries.

Essential Maintenance Tips for Your Sportsman 850

Alright, now let's talk about keeping your Sportsman 850 in tip-top shape. Regular maintenance is key to preventing major issues and ensuring your ATV performs at its best. Think of it as preventative medicine for your machine – a little care now can save you a lot of trouble later. We will cover routine tasks that you should do to ensure the ATV is working. These tasks are not hard, and with some experience, you will learn and memorize them. Let's start with a crucial element: oil changes. Changing your engine oil and filter at the recommended intervals (usually every 50-100 hours of use, or as specified in your owner's manual) is probably the single most important thing you can do for your ATV. Clean oil lubricates the engine, reduces friction, and prevents wear and tear. Use the correct type and amount of oil specified by Polaris, and always replace the oil filter at the same time. Check and clean or replace your air filter regularly. A clogged air filter restricts airflow to the engine, which can reduce performance and damage the engine. Clean or replace the air filter based on the operating conditions. Clean and inspect the air filter housing for any dirt or damage. The air filter is often located under the seat or in an easily accessible location. Next, let's dive into other important tasks. Inspect and maintain your ATV's cooling system. Overheating can cause major engine damage, so it's critical to ensure the cooling system is functioning properly. Check the coolant level regularly and top it off as needed with the recommended coolant. Inspect the radiator for any leaks or damage, and clean the radiator fins to ensure proper airflow. Inspect your brakes. Check the brake pads for wear and tear and replace them if necessary. Check the brake fluid level and top it off as needed. Also, make sure the brake lines are in good condition and free of leaks. Lubricate all moving parts, such as the suspension components and the steering system, to reduce friction and wear. Use the recommended lubricants and apply them to the specified points. Keep an eye on your tires, checking the tire pressure regularly and inflating the tires to the recommended pressure. Inspect the tires for any damage or wear and replace them if necessary. These are tasks that you should keep in mind to keep your ATV running in good condition. Following these tips will save you from future problems.

Routine Checks and Inspections

Besides the essential maintenance tasks mentioned above, there are several routine checks and inspections you should perform regularly. These checks can help you catch potential problems early, before they become major issues. Start by checking the fluids: engine oil, coolant, brake fluid, and power steering fluid (if equipped). Ensure all fluids are at the correct levels and top them off as needed. Check for any leaks around the engine, transmission, and cooling system. Leaks can indicate a potential problem that needs to be addressed. Inspect the tires for any damage, such as cuts, punctures, or uneven wear. Check the tire pressure and inflate the tires to the recommended pressure. Examine the suspension components for any signs of damage or wear. Check the shocks, springs, and bushings for any leaks or damage. Inspect the brakes for wear and tear. Check the brake pads and rotors for any signs of wear and replace them if necessary. Test the brakes to ensure they are functioning properly. Check the electrical system for any loose connections or damaged wires. Inspect the lights, gauges, and other electrical components to ensure they are functioning properly. Listen for any unusual noises while the engine is running or while riding. These noises could indicate a problem with the engine, transmission, or other components. Check the battery terminals for corrosion and clean them if necessary. A clean battery terminal ensures proper electrical connections. By performing these routine checks and inspections, you can keep your Sportsman 850 running smoothly and prevent major problems from occurring.

Common Repairs and Troubleshooting

Even with the best maintenance practices, you might encounter some issues with your Polaris Sportsman 850. Here's a look at some common problems and how to troubleshoot them. If your ATV won't start, first check the battery, ensure it's fully charged and the terminals are clean and making a good connection. Next, check the fuel supply. Make sure there's fuel in the tank and that the fuel pump is working. Check the spark plugs. Remove the spark plugs and inspect them for wear or damage. Replace the spark plugs if necessary. Check the fuses and wiring for any blown fuses or damaged wires. Repair or replace any damaged components. If the engine is running but not smoothly, check the air filter and replace it if it's clogged. Check the fuel injectors for any clogs or damage. Clean or replace the fuel injectors if necessary. Check the spark plugs and replace them if necessary. Check the throttle body for any dirt or debris. Clean the throttle body if necessary. Check the idle speed and adjust it if necessary. If your ATV is overheating, check the coolant level and top it off if necessary. Inspect the radiator for any leaks or damage. Clean the radiator fins to ensure proper airflow. Check the thermostat for proper operation. Replace the thermostat if necessary. If you're experiencing suspension issues, inspect the shocks and springs for any leaks or damage. Replace the shocks or springs if necessary. Check the bushings and other suspension components for wear and tear. Replace the worn components. Check the tire pressure and inflate the tires to the recommended pressure. If you encounter brake problems, inspect the brake pads for wear and tear. Replace the brake pads if necessary. Check the brake fluid level and top it off as needed. Check the brake lines for leaks or damage. Repair or replace any damaged brake lines. Diagnosing and resolving issues in your Polaris Sportsman 850 can be manageable with the right approach. Knowing how to troubleshoot and perform some repairs can save you both time and money. Always consult your owner's manual for specific instructions and safety precautions. Remember, safety first! Before starting any repairs, make sure your ATV is turned off and the key is removed. Wear appropriate safety gear, such as gloves, eye protection, and a mask if needed. Work in a well-ventilated area to avoid inhaling fumes from gasoline or other chemicals.

Engine Problems and Solutions

Engine problems can range from minor issues to major failures, but knowing how to identify and address these issues can save you a lot of headaches. Loss of power can be caused by a variety of factors, including a dirty air filter, clogged fuel injectors, or worn spark plugs. Start by inspecting these components and replacing them if necessary. Also, check for any air leaks in the intake system, which can also cause a loss of power. Hard starting can be caused by a weak battery, a clogged fuel filter, or a faulty fuel pump. Check the battery and charge or replace it if needed. Replace the fuel filter and check the fuel pump for proper operation. Engine overheating can be caused by a low coolant level, a faulty thermostat, or a clogged radiator. Check the coolant level and top it off if needed. Inspect the radiator for any leaks or damage and clean the radiator fins to ensure proper airflow. Replace the thermostat if necessary. Engine misfires can be caused by worn spark plugs, faulty ignition coils, or a vacuum leak. Inspect the spark plugs and replace them if necessary. Check the ignition coils for proper operation and replace them if needed. Check for any vacuum leaks and repair them. Engine knocking or pinging can be caused by low-octane fuel or a lean fuel mixture. Use the recommended fuel and check the fuel system for proper operation. Adjust the air/fuel mixture if necessary. In case of serious engine problems, such as internal engine damage or complete failure, it's best to consult a qualified mechanic for further diagnosis and repair. They will be able to perform more extensive tests and provide you with a solution.

Electrical System Issues

The electrical system of your Sportsman 850 is a complex network of wires, sensors, and components that work together to power various functions of the ATV. Battery problems are a common issue. If your ATV won't start, the battery is the first thing you should check. Use a multimeter to measure the voltage of the battery. If the voltage is low, try charging the battery. If the battery doesn't hold a charge, it may need to be replaced. Check the battery terminals for corrosion and clean them if necessary. Starting problems can be caused by a faulty starter motor, a bad solenoid, or a loose connection. Check the starter motor by attempting to start the ATV. If the motor doesn't crank, check the solenoid and make sure it's clicking when you turn the key. Check all the connections for any loose connections. Lighting problems can be caused by burned-out bulbs, faulty switches, or wiring issues. Check the bulbs and replace any that are burned out. Check the switches and wiring for any damage or loose connections. Use a multimeter to check for voltage at the light sockets and switches. If the lights still don't work, there may be a problem with the wiring harness. Charging problems can be caused by a faulty stator, a bad rectifier/regulator, or a loose connection. Check the stator by measuring the AC voltage output. If the voltage is low, the stator may need to be replaced. Check the rectifier/regulator for proper operation. Check the connections for any loose connections. Check the fuses for any blown fuses and replace them if necessary. If you're not comfortable working on electrical systems, it's best to consult a qualified mechanic. Electrical problems can be tricky to diagnose, and it's important to make sure everything is connected correctly to avoid further damage to your ATV. Furthermore, any wiring modifications or additions, consult a professional to ensure safety and proper installation. Always disconnect the battery before working on the electrical system.

Resources and Further Information

To make your repair and maintenance journey easier, here are some helpful resources and additional information. Your owner's manual is your best friend. It contains detailed information about your specific model, including maintenance schedules, troubleshooting tips, and part numbers. The Polaris website is a valuable source of information. You can find owner's manuals, parts diagrams, and service bulletins on the website. Online forums and communities are great places to connect with other Polaris Sportsman 850 owners and exchange information. You can ask questions, share tips, and learn from the experiences of others. Service manuals provide detailed instructions on how to perform various repairs and maintenance tasks. You can purchase a service manual online or at your local Polaris dealer. Parts diagrams help you identify and locate the parts you need. You can find parts diagrams in your owner's manual or online. Local Polaris dealers can provide expert advice and assistance with any repairs or maintenance tasks. They can also order parts and provide service. With the proper guidance and resources, you'll be well-equipped to tackle any repair or maintenance task that comes your way. Remember to always prioritize safety and consult a professional if you're ever unsure about a particular repair. If you are not comfortable doing it, always consult an expert. Keep riding, stay safe, and have fun!

Where to Find Parts and Tools

Having the right parts and tools is essential for any repair job. Knowing where to find these items can save you time and hassle. Local Polaris Dealers: Your local Polaris dealer is an excellent source for genuine Polaris parts. They can also provide expert advice and assistance. Online Retailers: Online retailers offer a wide selection of parts and tools at competitive prices. Make sure to choose reputable retailers. Specialty ATV Shops: Specialty ATV shops often carry a variety of aftermarket parts and accessories. Hardware Stores: Hardware stores carry basic tools such as wrenches, screwdrivers, and sockets. Always use high-quality tools that are specifically designed for the job. Using the wrong tools can damage your ATV and make the job more difficult. A basic toolkit should include wrenches, sockets, screwdrivers, pliers, and a multimeter. Additional tools you may need include a torque wrench, a compression tester, and a spark plug wrench. Always keep your tools organized and clean. Clean tools make the job easier and reduce the risk of damaging your ATV. Furthermore, when purchasing parts, ensure you are getting the correct parts for your Sportsman 850 model. Verify part numbers and compatibility before making your purchase. This will help you avoid any returns or delays. Read online reviews for tools and parts before making a purchase. This will give you insight into the quality of the products. Furthermore, don't be afraid to ask for help! The ATV community is generally a helpful bunch and you will be able to find help easily.