Polaris Sportsman 2009 Service

Polaris Sportsman · 2009 · service manual · 309 pages

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Engine Breather Hose16.3 N·m16 N·mp. 23
Radiator hose clamp4.1 N·m4 N·mp. 32
Aluminum Wheels (Long)101.7 N·m102 N·mp. 34
Steel Wheels (Short)61 N·m61 N·mp. 34
ECU Retaining Screws1.1 N·m1.1 N·mp. 55
Ignition Coil Tests23 N·m23 N·mp. 67
Engine Temperature23 N·m23 N·mp. 82
Engine Temperature10.1 N·m10 N·mp. 82
Water Pump Assembly /10.1 N·m10 N·mp. 90
Stator wire routing13.6 N·m10 ft·lbp. 90
Pipe Fitting10.1 N·m89 in·lbp. 91
Valve Cover / Breather Valve10 N·mp. 100
Cylinder Head / Valve / IAFM10 N·mp. 102
Outer screws28.5 N·m21 ft·lbp. 109
Outer screws12 N·mp. 133
M3 end cap screws89 N·mp. 134
Bolts snug32.5 N·m33 N·mp. 139
Connecting Rod Bolt32.5 N·m33 N·mp. 145
Bolt threads20.3 N·m15 ft·lbp. 170
Bolt threads19 N·mp. 170
Drive Clutch Spider271.2 N·m271 N·mp. 174
Driven Clutch Retaining Bolt17.6 N·m18 N·mp. 174
Drive Clutch Cover Bolts11.3 N·m11 N·mp. 174
Brake Caliper Mount Bolts50.2 N·m50 N·mp. 204
Shock Mounting Bolts50.2 N·m50 N·mp. 204
Front Gearcase Mount Bolts48.8 N·m49 N·mp. 204
Rear Upper A-Arm54.2 N·m54 N·mp. 204
Bearing Carrier Bolts61 N·m61 N·mp. 204
Rear Propshaft Bolts24.4 N·m24 N·mp. 204
Rear Gearcase Mount Bolts54.2 N·m54 N·mp. 204
Aluminum Rim Valve108 N·mp. 205
Hub Cover Castle Nut108.5 N·m80 ft·lbp. 205
Bearing carrier50.2 N·m50 N·mp. 208
Cone Washers59.7 N·m60 N·mp. 208
Fill plug hole29.8 N·m30 N·mp. 226
Cotter Pin59.7 N·m44 ft·lbp. 226
Short Bolt54.2 N·m40 ft·lbp. 230
Pin holes108.5 N·m80 ft·lbp. 231
Tie Rod Jam Nuts16.3 N·m16 N·mp. 258
Handlebar Block Bolts19 N·m19 N·mp. 258
Steering post frog19 N·m19 N·mp. 259
Steering Exploded View27.1 N·m20 ft·lbp. 261
Steering Exploded View20.3 N·m15 ft·lbp. 266
Shock bolt50.2 N·m50 N·mp. 269
Handlebar Master Cylinder Clamp Bolts7.9 N·m70 in·lbp. 278
Hand Master Cylinder Reservoir Cover0.8 N·m7 in·lbp. 278
Bleeder Screw5.3 N·m47 in·lbp. 278
Hand Master Cylinder20.3 N·m20 N·mp. 280
Brake Caliper Exploded View5.3 N·m47 in·lbp. 281
Hand Master Cylinder Exploded View7.9 N·m70 in·lbp. 281
Banjo bolt20.3 N·m20 N·mp. 284
Caliper Disassembly61 N·m61 N·mp. 287
Caliper Disassembly101.7 N·m102 N·mp. 287
Rear Caliper Shown20.3 N·m15 ft·lbp. 289
Wheel hub assembly50.2 N·m50 N·mp. 291
Brake Squeal108.5 N·m80 ft·lbp. 292
Worn disc and/or friction pads108.5 N·m108 N·mp. 292
Disc damaged61 N·m61 N·mp. 292

Spark plugs

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
T20—p. 68

Service intervals

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Coolant change2 yearsp. 16
Air filter service1 yearsp. 21

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