Polaris Sportsman 850 - Engine Installation Notes

3.46
36. Remove the engine through the right side of the
chassis and place on a work bench to begin engine
disassembly.
ENGINE INSTALLATION NOTES
After the engine is installed in the frame, review this
checklist and perform all steps that apply:
General Items
1. Repeat steps in reverse order in the “Engine
Removal” section above to reinstall the engine.
2. Install previously removed components using new
gaskets, seals, and fasteners where applicable.
3. Perform regular checks on fluid levels, controls, and
all important areas on the vehicle as outlined in the
Daily Pre-ride Inspection Checklist and in the
Periodic Maintenance Table (refer to Chapter 2
“Maintenance”). , page 2.4
Exhaust
4. Replace exhaust seals before installation.
5. Install the exhaust pipe assembly into the cylinder
head and exhaust silencer.
6. Install the nuts and finger tighten only!
7. Install the springs retaining the pipe to the silencer.
8. Torque the exhaust retaining nuts to specification.
TORQUE
Exhaust Retaining Nuts:
Step 1: Front to Rear: 8 ft. lbs (11 Nm)
Step 2: Rear to Front: 14 ft. lbs (19 Nm)
Bleed Cooling System
9. Remove radiator cap and slowly add coolant to top of
filler neck.
10. Fill coolant reservoir tank to full mark.
11. Install radiator cap and squeeze coolant lines to
force air out of system.
12. Again remove radiator cap and slowly add coolant to
top of fill neck.
13. Alternately elevate the front and back of the vehicle
to allow additional air to vent from the system.
14. Start engine and observe coolant level in the
radiator. Allow air to purge and top off as necessary.
Reinstall radiator cap securely and bring engine to
operating temp. Check coolant level in reservoir tank
after engine has cooled and add if necessary.
Engine Break In Period
The engine break-in period is defined as the first 20
hours of engine operation or 2 full tanks of fuel.
15. Use only Polaris PS-4 Synthetic engine oil. Never
substitute or mix oil brands. Serious engine damage
can result.
16. Use fuel with a minimum octane rating of 87 (R+M)/2
method.
17. Change break-in oil and filter at 20 hours.
ENGINE / COOLING SYSTEM