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Polaris 850 MATRYX SWITCHBACK ASSAULT 146 2021 User Manual

Polaris 850 MATRYX SWITCHBACK ASSAULT 146 2021
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FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed October 2020 (PN 9850064 R03)
© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2021 650 / 850 Matryx Trail Performance /
Crossover Snowmobile

Table of Contents

Questions and Answers:

Polaris 850 MATRYX SWITCHBACK ASSAULT 146 2021 Specifications

General IconGeneral
BrandPolaris
Model850 MATRYX SWITCHBACK ASSAULT 146 2021
CategorySnowmobiles
LanguageEnglish

Summary

Chapter 1 General Information

Clutch Settings (Model Year 2021)

Clutch settings for 650 and 850 models based on altitude, including drive, driven, and chaincase specifications.

Service Precautions

Essential precautions for performing service work safely and correctly, including torque and fastener handling.

Diagnostic Trouble Codes (DTC)

List of diagnostic trouble codes (DTCs) for MATRYX models, including SPN, FMI, P-Code, and condition.

Troubleshooting - Engine Will Not Start

Guide for troubleshooting engine starting issues, covering fuel system, switches, and engine mechanical/electrical components.

Performance Troubleshooting Guide

Steps for documenting and troubleshooting performance concerns, including checking clutches and suspension.

Digital Wrench Diagnostic Software

Overview of Digital Wrench software capabilities, including tests and diagnostic procedures.

Digital Wrench – ECU / Injector / Oil Pump Replacement Menu

Menu for ECU, fuel injector, and oil pump replacement procedures using Digital Wrench.

Digital Wrench – ECU Reprogramming (Reflash)

Procedure for reprogramming the ECU fuel and ignition map using Digital Wrench.

PVT System Diagnostics

Diagnostic procedures for the PVT system, including drive belt, drive clutch, and driven clutch.

Belt Wear / Burn Diagnostics

Troubleshooting guide for belt wear and burn issues, covering possible causes and solutions.

Electrical Diagnostics

Notes on diagnosing electrical problems, including static and dynamic testing methods.

Testing for a Short to Ground

Procedure for testing circuits for shorts to ground and identifying potential causes.

Testing for a Short to Voltage

Procedure for testing circuits for shorts to voltage and identifying potential causes.

Testing for Intermittent Conditions

Diagnosing intermittent electrical failures, often related to poor connections.

Testing Voltage Drop

Procedure for measuring voltage drop in a circuit to understand resistance variations.

Chapter 2 Maintenance

Pre-Ride Inspection

Items to inspect before each ride, covering drive/driven clutch, engine, brake system, and electrical system.

Periodic Maintenance Chart

Maintenance intervals based on vehicle miles for various components.

Engine Maintenance

Procedures for engine maintenance, including throttle lever freeplay inspection and adjustment.

Spark Plug Maintenance

Inspection and replacement of spark plugs as outlined in the periodic maintenance table.

Cooling System Maintenance

Overview of the cooling system, coolant bottle level check, and system bleeding procedures.

Cooling System Bleeding

Procedure for bleeding the cooling system, which is self-bleeding.

Drive Belt / Clutch Maintenance

Procedures for drive belt removal and installation, and clutch maintenance.

Fuel / Air Intake / Exhaust Maintenance

Maintenance procedures for the fuel system, air intake, and exhaust system.

Fuel System Maintenance

Warnings and recommendations for servicing the fuel system.

Drive System Maintenance

Maintenance procedures for the drive system, including drive chain tension adjustment and chaincase oil.

Chaincase Oil Change

Procedures for changing chaincase oil using pump or cover drain methods.

Brake System Maintenance

Inspection of brake system components, including lever travel, feel, and caliper/pad components.

Steering / Suspension Maintenance

Maintenance for controls and handlebar components, including fastener torque.

Front Suspension Inspection - Wide Fixed Camber

Weekly inspection of front suspension components for damage and loose fasteners.

Rear Suspension Inspection - PRO-CC

Inspection of PRO-CC rear suspension components for damage and loose fasteners.

Rear Suspension Inspection - IGX 146

Inspection of IGX 146 rear suspension components for damage and loose fasteners.

Electrical System Maintenance

Maintenance procedures for the battery and other electrical components.

Chapter 3 Engine / Cooling / Exhaust

Important Engine Service Notes

Notes on resetting the oil pump enrichment mode timer after specific engine service actions.

Oil Injector Check Valves

Testing and replacement procedures for oil injector check valves.

Cross Shaft Oil Gallery Outlet Check Valve

Testing and replacement procedures for the cross shaft oil gallery outlet check valve.

Cross Shaft Oil Gallery Outlet Check Valve Testing

Procedure for testing the cross shaft oil gallery outlet check valve.

Cross Shaft Oil Gallery Outlet Check Valve Replacement

Procedures for replacing the cross shaft oil gallery outlet check valve.

Oil Tank Removal

Step-by-step instructions for removing the oil tank.

Oil Tank Installation

Step-by-step instructions for installing the oil tank.

Engine Service

Procedures for engine removal and installation.

Engine Removal

Step-by-step instructions for removing the engine from the chassis.

Engine Installation

Step-by-step instructions for installing the engine into the chassis.

650 / 850 Engine

General information, model number matrix, and engine specifications for 650 and 850 engines.

Component Torque Sequences

Fastener torque sequences for various engine components.

Reed Valve Service

Inspection, disassembly, and installation procedures for the reed valve assembly.

Reed Valve Inspection

Procedure for inspecting reed valve operation and air gap.

Reed Petal Removal

Step-by-step instructions for removing reed petals using specialized tools.

Reed Petal Installation

Step-by-step instructions for installing new reed petals with proper orientation.

Engine Disassembly / Inspection - Top End

Procedures for disassembly and inspection of top-end engine components.

Cylinder Head Removal

Step-by-step instructions for removing the cylinder head.

Cylinder Head Inspection

Procedure for inspecting the cylinder head for warping using a straight edge and feeler gauge.

Cylinder Removal

Step-by-step instructions for removing the cylinder.

Cylinder Inspection

Procedure for inspecting cylinder walls for wear and damage.

Cylinder Honing

Procedure for honing the cylinder bore to remove glaze and create a crosshatch pattern.

Piston Removal

Step-by-step instructions for removing the piston and piston circlips.

Piston Ring Installed Gap

Measurement and importance of checking piston ring installed gap.

Engine Disassembly / Inspection - Bottom End

Procedures for disassembly and inspection of bottom-end engine components.

Crankcase Disassembly

Step-by-step instructions for disassembling the crankcase halves.

Crankshaft Removal

Procedure for removing the crankshaft from the crankcase.

Lower Connecting Rod Bearing Inspection

Procedure for measuring connecting rod side clearance and checking for rough spots.

Main Bearing Inspection

Inspection of main bearings for discoloration, scoring, or galling.

Crankshaft Truing

Procedure for rebuilding and straightening a crankshaft for optimal run-out.

Crankshaft Runout Inspection

Procedure for measuring crankshaft runout and comparing to specification limits.

Water Pump Service

Procedures for water pump removal, installation, and seal replacement.

Water Pump Removal

Step-by-step instructions for removing the water pump assembly.

Water Pump Installation

Step-by-step instructions for installing the water pump assembly.

Electronic Oil Pump

Information on electronic oil pump mounting, flow offset identification, and line connections.

Electronic Oil Pump Prime Procedure

Procedure to purge engine oil supply lines of air and verify ECU drives the oil pump.

Electronic Oil Pump Manual Prime Procedure

Procedure for manually priming the oil pump to purge air from supply lines.

Digital Wrench - Electronic Oil Pump Flow Offset

Procedure for setting the oil pump flow offset using Digital Wrench.

Electronic Oil Pump – Trouble Codes / Protection Mode

Diagnostic trouble codes related to the electronic oil pump and protection modes.

Chapter 4 Engine Electrical

Engine Protection Features

Information on ECU engine hot LED, overheat modes, and troubleshooting.

Engine Overheating Troubleshooting

Table of possible causes and solutions for engine overheating.

Detonation (DET) Protection Modes

ECU actions when sensing detonation, including RPM drop and performance reduction.

Detonation (DET) Troubleshooting

Troubleshooting guide for DET activation based on instrument cluster indicators.

Cleanfire Fuel Injection (CFI) System

Overview of the CFI system, detailing components and their functions.

Exhaust Gas Temperature (EGT) Sensor

Location, testing, and resistance values for the EGT sensor.

Air Temperature / Pressure Sensor (T-MAP)

Location and function of the T-MAP sensor, and testing procedures.

Crankshaft Position Sensors (CPS)

Function of CPS sensors in determining engine direction, ignition/fuel angles, and speed.

Crankshaft Position Sensor Air Gaps

Inspection and adjustment of CPS air gaps to prevent starting issues.

Electronic Control Unit (ECU)

Pinout information for ECU connectors and ECU label details.

Throttle Position Sensor (TPS)

Overview and testing procedures for the Throttle Position Sensor.

Throttle Position Sensor (TPS) Testing

Tests to determine if further diagnostic testing is required for the TPS.

Polaris Electronic Reverse Control (PERC)

Overview, operation, and troubleshooting notes for the PERC system.

PERC Operation

Warnings and cautions for operating the reverse system.

Chapter 5 Fuel System

Service Warnings

Important warnings regarding gasoline flammability, EFI component pressure, and engine operation.

Fuel Recommendation

Recommendations for North American and International fuel, including octane and ethanol content.

Fuel Pump Prime Procedure

Procedure to purge air from the fuel system using Digital Wrench or manual methods.

Fuel Pump Prime Procedure Without Service Tool

Procedure for priming the fuel system without a service tool, for electric start and recoil start models.

Fuel Injectors / Fuel Rail / Throttle Body

Procedures for fuel rail, fuel injector, and throttle body removal and installation.

Throttle Body Removal

Step-by-step instructions for removing the throttle body.

Throttle Body Installation

Step-by-step instructions for installing the throttle body.

Fuel Rail / Fuel Injector Removal

Procedure for removing the fuel rail and fuel injectors.

Fuel Rail / Fuel Injector Installation

Procedure for installing new fuel injectors and the fuel rail assembly.

Fuel Tank Service

Assembly view, removal, and installation procedures for the fuel tank.

Fuel Tank Removal

Step-by-step instructions for removing the fuel tank.

Fuel Tank Installation

Step-by-step instructions for installing the fuel tank.

Fuel Pump Service

Specifications and procedures for fuel pump wire harness, pressure, level sensor, and pickup filter media.

Fuel Pump Removal

Procedure for removing the fuel pump from the fuel tank.

Fuel Pump Installation

Procedure for installing the new fuel pump assembly.

Fuel Line Service

Procedures for servicing fuel lines, including supply and return line routing.

Chapter 6 Final Drive / Brake Systems

Gearing Change Reprogramming

Procedure to re-calibrate speedometer offset using Digital Wrench after changing sprockets.

Chaincase Service

Procedures for chaincase assembly, drive chain tension, oil level check, and oil change.

Drive Chain Tension Adjustment

Procedure for adjusting drive chain tension and torque specifications.

Chaincase Oil Level Check

Procedure for checking and filling the chaincase oil level.

Chaincase Oil Change - Pump Method

Procedure for changing chaincase oil using a hand pump oil extractor.

Chaincase Oil Change - Cover Drain Method

Procedure for changing chaincase oil using the cover drain method.

Chaincase Disassembly

Step-by-step instructions for disassembling the chaincase cover.

Chaincase Assembly

Procedures for cleaning, inspecting, and assembling the chaincase.

Chaincase Housing Removal

Procedure for removing the chaincase housing from the chassis.

Chaincase Housing Installation

Procedure for installing the chaincase housing using adhesive and fasteners.

Driveshaft Service

Assembly view, removal, and installation procedures for the driveshaft.

Driveshaft Removal

Step-by-step instructions for removing the driveshaft.

Driveshaft Installation

Step-by-step instructions for installing the driveshaft.

Jackshaft Service

Assembly view, removal, and installation procedures for the jackshaft.

Jackshaft Removal

Step-by-step instructions for removing the jackshaft.

Jackshaft Installation

Step-by-step instructions for installing the jackshaft.

Brake System

General notes, assembly views, and service procedures for the brake system.

Brake System General Notes

Important points to remember when bleeding hydraulic brakes.

Brake System Inspection

Inspection of brake system components, including lever travel, feel, and caliper/pad components.

Brake Reservoir Fluid Level

Procedure for checking and adding brake fluid to the master cylinder reservoir.

Brake System Bleeding

Procedure for bleeding the hydraulic brake system to remove air.

Phantom Brake Pad Inspection / Replacement

Inspection and replacement of phantom brake pads.

Brake Lever / Master Cylinder Service

Disassembly and service procedures for the brake lever and master cylinder.

Brake Disc Inspection / Replacement

Procedure for inspecting and replacing the brake disc.

Track Studding / Lug Height

Guidelines for track studding, including maximum stud height and penetration.

Chapter 7 PVT System

Drive Belt Removal

Step-by-step instructions for removing the drive belt.

Drive Belt Installation

Step-by-step instructions for installing the drive belt, including cleaning and break-in.

Belt-to-Sheave Clearance Adjustment

Procedure for adjusting belt-to-sheave clearance for optimal drive clutch performance.

Belt Deflection Inspection / Adjustment

Procedure for inspecting and adjusting belt-to-sheave clearance.

Clutch Alignment / Offset – PS-51607

Procedure for inspecting and adjusting clutch alignment and offset using the Clutch Alignment Tool.

Clutch Offset / Float Adjustment

Procedure for adjusting clutch offset and float using washers and spacers.

Chapter 8 Steering / Suspensions

Rail Slider Inspection

Procedure to measure rail slider thickness and inspect for wear.

Track Inspection

Checking track for damage to cover, lugs, drive windows, cogs, and rods.

Track Alignment

Procedure to ensure the track is centered and running evenly on the slide rails.

Track Tension Inspection

Inspection of track tension, especially during break-in period.

Track Tension Adjustment

Procedure for adjusting track tension to provide equal adjustment on both sides.

Left Hand Control Adjustment

Procedure for adjusting the left hand control block position.

Ski Alignment / Toe Adjustment

Procedure for inspecting and adjusting ski toe setting.

Ski Skag Inspection / Skag Replacement

Inspection and replacement of ski skags.

Front Suspension

Factory spring settings and clicker settings for IFS shocks.

Rear Suspension

Factory spring and clicker settings for front and rear track shocks.

Chapter 9 Chassis

General Information

General cautions and notes regarding bonded components and adhesive usage.

General Cautions and Notes

Important safety precautions and notes for working with bonded components and adhesive.

Bonded Component Service

Procedures for breaking adhesive bonds for repairs.

Chapter 10 Battery / Electrical

Electrical System General Cautions

General warnings and precautions for the electrical system.

Battery

Battery specifications, removal, and installation procedures.

Battery Installation

Step-by-step instructions for installing a new battery.

Battery Activation (Electric Start Models Only)

Procedure for activating a dry-shipped AGM battery.

Dry Shipped AGM Battery Charging and Testing

Procedures for charging and testing dry-shipped AGM batteries.

Battery Testing

Methods for testing battery conductance, open circuit voltage, and specific gravity.

Battery Load Test

Procedure for performing a battery load test.

LED Headlight Removal

Step-by-step instructions for removing the LED headlight assembly.

LED Headlight Installation

Step-by-step instructions for installing the LED headlight assembly.

LED Taillight Removal

Step-by-step instructions for removing the LED taillight assembly.

LED Taillight Installation

Step-by-step instructions for installing the LED taillight assembly.

Power Boosting Regulator (PBR)

Overview, location, details, circuit diagram, and troubleshooting for the Power Boosting Regulator.

PBR Testing

Testing the PBR and its diagnostic trouble code list.

PBR Diagnostic Trouble Code List

List of diagnostic trouble codes for the PBR, including description, cause, and action.

PBR Update / Replacement

Procedure for updating PBR software using Digital Wrench.

Stator Testing

Tests to determine the condition of the stator, including resistance and AC voltage output.

How Do You Troubleshoot SmartWarmers?

Troubleshooting steps for SmartWarmers, including useful tools and temperature measurement.

Heated Grip Calibration Procedure

Procedure for calibrating heated grips using Digital Wrench.

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