Sportsman® Touring 850 SP Sportsman® Touring XP 1000 Owner's Manual For Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
! WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. ! WARNING Operating, servicing, and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
2019 Owner’s Manual Sportsman® Touring 850 SP Sportsman® Touring XP 1000
POLARIS®, ACE™, OUTLAW®, and SPORTSMAN® are trademarks of POLARIS Industries Inc. Copyright 2018 Polaris Industries 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.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
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Introduction . . . . . . . Safety . . . . . . . . . . Features and Controls . . Operation . . . . . . . . Winch Guide. . . . . . . Emission Control Systems . Maintenance . . . . . . Specifications . . . . . . POLARIS Products . . . . Troubleshooting . . . . . Warranty . . . . . . . . Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in serious injury.
INTRODUCTION EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
INTRODUCTION VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost. The manufacturer’s label is located on the front right side of the vehicle behind the radiator.
SAFETY SAFETY SAFETY TRAINING ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCoursesm that is available to you and your eligible family members. This training is included in the purchase price of your ATV.
SAFETY HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Parents should verify that the young operator has a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures. OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident.
SAFETY USING ALCOHOL OR DRUGS Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating this vehicle. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
SAFETY OPERATING ON PAVEMENT This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops.
SAFETY JUMPS AND STUNTS Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See the New Operator Driving Procedures section for details.
SAFETY STALLING WHILE CLIMBING A HILL Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to 4WDC (if equipped) before ascending or descending a hill. If all forward speed is lost: • • • • Lean forward to keep body weight uphill. A passenger should also lean uphill. Apply the brakes. Lock the parking brake when fully stopped.
SAFETY OPERATING ON SLIPPERY TERRAIN Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the vehicle on such terrain. Always use extra caution on rough, slippery or loose terrain.
SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly).
SAFETY OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route.
SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.
SAFETY SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
SAFETY GENERAL WARNING WARNING Improper use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • • • • without proper training or instruction at speeds too fast for your skills or the conditions on public roads - a collision can occur with another vehicle with a passenger unless passenger seat is securely in place ALWAYS: • use proper riding techniques to avoid v
SAFETY PASSENGER SAFETY WARNING WARNING To reduce the risk of SEVERE INJURY or DEATH: • NEVER CARRY MORE THAN ONE PASSENGER • NEVER RIDE AFTER USING DRUGS OR ALCOHOL • NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.
SAFETY RACK/BOX WARNING WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg) TIRE PRESSURE/LOAD WARNING WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: – Front: 7.0 psi (48.3 kPa) – Rear: 7.0 psi (48.3 kPa) • Maximum weight capacity: 575 lbs.
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FEATURES AND CONTROLS FEATURES AND CONTROLS SWITCHES NOTE Image below is for reference only. Your model may differ slightly. q Ignition Switch w Engine Stop Switch e Mode/Reverse Override Switch r Headlight Switch t Drive Line Switch y Auxiliary Outlet IGNITION SWITCH/LIGHT SWITCH Use the ignition switch to start the engine. The key can be removed from the switch when it is in the OFF position. OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off.
FEATURES AND CONTROLS 4X4 SWITCH (IF EQUIPPED) The drive mode switch q controls the All Wheel Drive (AWD/4X4) system. Use this switch to engage AWD (4X4) or 2X4. The vehicle automatically engages 4X4 when operating in reverse if the drive mode is set to AWD (4X4). See page 37 for drive mode (AWD) operating instructions. ENGINE STOP SWITCH Move the stop switch w either left or right to the OFF position to stop the engine quickly.
FEATURES AND CONTROLS HEADLIGHT SWITCH Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position. THROTTLE LEVER WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle.
FEATURES AND CONTROLS BRAKE LEVER WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever q toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.
FEATURES AND CONTROLS MASTER CYLINDER/BRAKE FLUID WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
FEATURES AND CONTROLS PARKING BRAKE LOCKING THE PARKING BRAKE WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating. 1. Place the transmission in PARK. 2. Squeeze and release the brake lever q two or three times, then squeeze and hold. 3. Push the parking brake lock w forward to engage the lock. 4. Release the brake lever. 5.
FEATURES AND CONTROLS AUXILIARY FOOT BRAKE WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. The auxiliary brake system is intended to be used as a backup for the main brake system.
FEATURES AND CONTROLS AUTOMATIC TRANSMISSION GEAR SELECTOR The transmission gear selector q is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
FEATURES AND CONTROLS FRONT COMPARTMENT q Coolant Bottle Cap w Radiator Cap e Electrical/Fuse/Relay r Battery FRONT RACK If your model is equipped with front compartment storage, unlock both latches on each side and remove the cover to gain access.
FEATURES AND CONTROLS ELECTRONIC POWER STEERING (EPS) Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See the Instrument Cluster section for EPS Warning Indicator information. EXTREME USE BATTERY An optional extreme use battery may be available for your model.
FEATURES AND CONTROLS ALL WHEEL DRIVE SYSTEM The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 MODE When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. 4X4 MODE When the switch is on 4X4, the ATV is four-wheel drive, and the 4X4 indicator icon in the instrument cluster display will be visible.
FEATURES AND CONTROLS ACTIVE DESCENT CONTROL (ADC) SYSTEM The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
FEATURES AND CONTROLS INSTRUMENT CLUSTER OVERVIEW NOTE The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
FEATURES AND CONTROLS INDICATOR LAMPS q Check Engine w EPS Warning (if equipped) This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your authorized POLARIS dealer can assist. This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.
FEATURES AND CONTROLS DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 q.
FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 w.
FEATURES AND CONTROLS OPTIONS MENU Press and hold the MODE button to enter the Options Menu.
FEATURES AND CONTROLS UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Units-Distance” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (MPH or KPH) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu. 3.
FEATURES AND CONTROLS UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (°F or °C) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu. 3.
FEATURES AND CONTROLS CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (12H or 24H) e With the correct unit displayed, Press the mode button which will set the unit.
FEATURES AND CONTROLS 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Backlight Color” from the Options Menu by pressing the MODE button.
FEATURES AND CONTROLS BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Backlight Level” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button.
FEATURES AND CONTROLS SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (0, 5, 10, - 95,100) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu.
FEATURES AND CONTROLS DIAGNOSTIC CODE NOTE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. 1. Press and hold the MODE button to enter the Options Menu. NOTE “OPTIONS” will display on the screen for 3 seconds before showing first menu item 2. Select “Diagnostic Codes” from the Options Menu by pressing the MODE button. Toggle the Up/Down Buttons to cycle through Code(s).
FEATURES AND CONTROLS DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground:The wire is shorted to ground between the electronic control unit and the item listed in the chart. Shorted Load:The wires leading to the item listed in the chart are shorted together, or the item has shorted internally.
FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT SPN FMI Driver Circuit Open/ Grounded 651 5 Driver Circuit Short to B+ 651 3 Driver Circuit Grounded 651 4 Driver Circuit Open/ Grounded 652 5 Driver Circuit Short to B+ 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3 Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3 Fuel Pump Driver Circuit Driver Circuit Open/ Grounded 1347 5 Driver Circuit Short
FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT Chassis Relay All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed CONDITION SPN FMI Driver Circuit Short to B+ 1321 3 Driver Circuit Grounded 1321 4 Driver Circuit Open/ Grounded 520208 5 Driver Circuit Short to B+ 520208 3 Driver Circuit Grounded 520208 4 Driver Circuit Open/ Grounded 520207 5 Driver Circuit Short to B+ 520207 3 Driver Circuit Grounded 520207 4 Voltage Too Hig
FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI EPS MODELS ONLY Vehicle Speed Sensor Data Valid But Above Normal Operational Range - Most Severe Level 84 0 Data Erratic, Intermittent Or Incorrect 84 2 Abnormal Rate Of Change 84 10 Received Network Data In Error 84 19 Data Valid But Above Normal Operational Range - Most Severe Level 168 0 Voltage Above Normal, Or Shorted To High Source 168 3 Voltage Below Normal, Or Shorted To Low Source 168 4 Data Valid But Above
FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI EPS MODELS ONLY Steering Torque Partial Failure Condition Exists Steering Torque Full Failure Condition Exists EPAS Inverter Temperature EPAS Communications Receive Data Error Position Encoder Error EPAS Software Error 520223 31 520224 31 Data Valid But Above Normal Operational Range - Most Severe Level 520225 0 Data Valid But Above Normal Operating Range - Moderately Severe Level 520225 16 Data Erratic, Intermittent Or
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OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. VEHICLE BREAK-IN PERIOD The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline.
OPERATION ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See the Oil Check section for reference. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Avoid aggressive use of the brakes. 5.
OPERATION PRE-RIDE CHECKLIST Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
OPERATION SAFE OPERATION PRACTICES 1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751. 2. Do not allow anyone under 16 years of age or without a valid driver’s license to operate this vehicle. 3. Never carry a passenger on this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5.
OPERATION TRAIL ETIQUETTE Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely. KNOW YOUR RIDING AREA/TREAD LIGHTLY Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
OPERATION COLD WEATHER OPERATION If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. NEW OPERATOR DRIVING PROCEDURES 1. Wear protective riding gear. See the Safe Riding Gear section. 2. Perform the pre-ride inspection.
OPERATION TURNING THE VEHICLE Both rear wheels drive equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2. Never turn quickly when carrying cargo. 3. Steer in the direction of the turn. 4. Keep both feet on the footrests. 5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest.
OPERATION TURNING AROUND ON A HILL (K-TURN) If the vehicle stalls while climbing a hill, never back it down the hill! Use the Kturn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See the Switch Location section for details. 3. Leave the transmission in forward and shut off the engine. 4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
OPERATION DRIVING THROUGH WATER Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines. 3. Avoid operating through deep or fast-flowing water. NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water.
OPERATION 4. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads. If it’s unavoidable to enter water deeper than the footrest level: • Proceed slowly. Avoid rocks and obstacles. • Balance your weight carefully. Avoid sudden movements. • Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle changes. DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles: 1.
OPERATION DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or rollover. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 47. Never operate in TURF mode while operating on a hill or other irregular terrain. 2. Drive straight uphill. 3. Avoid steep hills. Maximum incline is: • 15° (Touring) 4.
OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. Never operate in TURF mode while operating on a hill or other irregular terrain. 2. Avoid steep hills. Maximum incline is: • 15° (Touring) 3. Always check the terrain carefully before descending a hill. 4. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 5. Slow down.
OPERATION DRIVING ON A SIDEHILL (SIDEHILLING) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Avoid crossing the side of a steep hill. 3. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests. 4.
OPERATION DRIVING IN REVERSE Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. 7. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased.
OPERATION PARKING ON AN INCLINE Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
OPERATION STOPPING THE ENGINE 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off. 4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. WARNING A rolling vehicle can cause serious injury. Always place the transmission in PARK when stopping the engine. BRAKING 1. Release the throttle pedal completely.
OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION 3. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. 4. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg). 5. Do not obstruct the headlight beam with cargo. 6. Slow down. 7.
WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise. WINCH SAFETY PRECAUTIONS 1.
WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use.
WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. TIP Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • • • • • • • Take your time to think through the winching you are about to do. Proceed slowly and deliberately.
WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. TIP A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to stretch. WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH.
WINCH GUIDE WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
WINCH GUIDE b. Lay the damper on top of the mid-point of the winch cable length that is spooled out. c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. d. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation. 9.
WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15.
WINCH GUIDE 2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition. A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged.
WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders. Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to “jerk” a load with the winch.
WINCH GUIDE WINCH MAINTENANCE AND SERVICE SAFETY WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware. 2. Permit your winch motor to cool down prior to servicing your winch. 3.
EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.
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MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer or other qualified person perform these services. WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) XU D XU XU MILES (KM) HOURS CALENDAR Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically Battery 20 H Monthly 200 (320) Check terminals; clean; test Fuel System 20 H Monthly - Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion Engine Oil Change 25 H 1M - Break-in oil and filter change 1M 250 (400) Break-in fluid level check Break-in fluid level check ITEM Demand Drive Fluid
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) HOURS ITEM CALENDAR MILES (KM) Change fluid REMARKS Transmission oil 100 H 12 M 600 (1000) Fuel System 100 H 12 M 600 (1000) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/ rail and fuel pump; replace lines every two years Engine Mounts 100 H 12 M 1000 (1600) Inspect Exhaust Pipe / Silencer 100 H 12 M 1000 (1600) Inspect XU Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed XU Wiring
MAINTENANCE LUBRICATION GUIDE Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil. Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause.
MAINTENANCE OIL LEVEL Check the oil level when the engine is cold. Never check the oil with the engine running. 1. Position the vehicle on a level surface. 2. Access the oil dipstick and fill tube from the left side of the ATV q. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall and tighten the dipstick. 4. Remove the dipstick and check the oil level 5. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill. 6.
MAINTENANCE OIL AND FILTER CHANGE See the fluid recommendation table for capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 88. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to warm up at idle for two to three minutes. 3. Stop the engine. 4. Clean the area around the drain plug. 5. Place a drain pan under the crankcase. 6.
MAINTENANCE 11. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 13. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 3/4 turn. 14. Remove the dipstick. Add the proper amount of the recommended oil. Do not overfill. 15. Reinstall the dipstick. 16.
MAINTENANCE TRANSMISSION OIL Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. See the Fluid Recommendation table for capacities and plug torques. Maintain the oil level at the bottom of the fill plug hole w. The fill plug is located on the right side of the ATV behind the footwell. The drain plug q is located on the bottom rear side of the gearcase. OIL CHECK 1. Remove the fill plug. Check the oil level. 2.
MAINTENANCE FRONT GEARCASE (DEMAND DRIVE) FLUID Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart. Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
MAINTENANCE REAR GEARCASE OIL Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart. See page 129 for the part numbers of POLARIS products. The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase. Maintain the fluid level at the bottom of the fill hole threads. Do not overfill. OIL CHECK 1. Position the vehicle on a level surface. 2. Remove the fill plug q. Check the oil level. 3.
MAINTENANCE POWER STEERING UNIT If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas q thoroughly. STEERING ASSEMBLY The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your authorized dealer or other qualified service facility before operating the vehicle.
MAINTENANCE RECOVERY BOTTLE COOLANT The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. 1. View the fluid level in the bottle. 2. If the level is low, remove the bottle cap and add coolant as needed. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 3. Reinstall the cap. 4. Close and secure the front box and cover.
MAINTENANCE BRAKES HAND BRAKE The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed.
MAINTENANCE AUXILIARY FOOT BRAKE The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. SEAT REMOVAL 1. Locate the seat removal latch in the center of the seat’s rear. 2. Pull on the latch handle to disengage the seat from the vehicle’s frame. 3. Remove the seat.
MAINTENANCE FRONT WHEEL HUB TIGHTENING Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized dealer or other qualified service facility. WHEEL REMOVAL 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Loosen the wheel nuts slightly. WARNING Do not service axle nuts that have a cotter pin installed. Your authorized dealer can assist. 5.
MAINTENANCE WHEEL NUT TORQUE SPECIFICATIONS Check the wheel nut torques occasionally and when they've been loosened for service. WHEEL TYPE NUT TORQUE All 75 ft-lbs (102 Nm) TOE ALIGNMENT WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer or other qualified service facility. Use the following procedure to check the toe alignment of the vehicle.
MAINTENANCE AIR FILTER INSTALLATION 1. Remove the seat, the air box cover strap, and remove the air box cover. 2. Remove the filter. 3. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 4. Reinstall the pre-filter over the main filter. Install a new main filter if needed. 5. Reinstall the filter into the air box. 6. Reinstall the air box cover and the seat.
MAINTENANCE HEADLIGHT LAMP REPLACEMENT When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. CAUTION Hot components can cause burns to skin. Allow lamps to cool before servicing. 1. Remove the four (4) headlight pod screws. Pull the pod cover forward. 2. Unplug the headlamp from the wiring harness.
MAINTENANCE 3. Start the engine. Turn the headlight switch to high beam. 4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be 2 in. (5 cm) below the mark on the wallw. Include rider weight on the seat when measuring. 5. The adjustment screw is located on the left side of the headlight pod. To adjust the beam, loosen the screw. Adjust the headlamp to the desired position, then tighten the screw.
MAINTENANCE 4. Reinstall the harness connector. Test the light for proper operation TO REPLACE RIGHT TAILLIGHT: 1. Remove the heat shield covering the light assembly. 2. Remove the harness connector from the back of the light assembly. 3. Remove the 3 fasteners securing the light assembly, and then remove the assembly. 4. Install the new light assembly, then re-affix and tighten the 3 fasteners. 5. Reinstall the harness connector. 6. Reinstall the heat shield. 7. Test the light for proper operation.
MAINTENANCE SPARK PLUGS SPARK PLUG RECOMMENDATIONS Refer to the specifications section for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent.
MAINTENANCE WET FOULED PLUG The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil or poor fuel quality. VEHICLE IMMERSION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine.
MAINTENANCE SPARK ARRESTER WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined.The exhaust system can get extremely hot. Do not perform service on the spark arrester while the system is hot.
MAINTENANCE PVT SYSTEM WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components.
MAINTENANCE the clutch cover greatly extends the life of the PVT components (belt, cover, etc.). WHEN TO USE LOW RANGE AND HIGH RANGE CONDITION RANGE TO USE Operating at speeds less than 7 MPH (11 km/h) Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 7 MPH (11 km/h) High PVT DRYING There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1.
MAINTENANCE BATTERY WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Your ATV is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle.
MAINTENANCE 6. Connect and tighten the black (negative) cable last. 7. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery. 8. Close and secure the front box and cover. BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place.
MAINTENANCE BATTERY CHARGING (SEALED BATTERY) Always verify battery condition before and 1-2 hours after the end of charging. STATE OF CHARGE VOLTAGE ACTION CHARGE TIME (USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100% 12.5-12.8 volts May need slight charge, if no charge given, check in 3 months 3-6 hours 50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.
MAINTENANCE 3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right. 4. Torque the front two bolts to 10-12 ft-lbs (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks. SIDE PANEL/FOOTWELL REMOVAL 1. Remove the seat before removing a side panel. 2. To remove a side panel or footwell, remove the fasteners q securing it to the frame.
MAINTENANCE THROTTLE BODY/IDLE RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service facility for adjustment. THROTTLE CABLE FREEPLAY 1. Remove the four cover screws from the right handlebar control and remove the cover. 2. With the handlebars straight ahead, place very light pressure on the throttle lever. A gap of 2-3 mm should be visible between the throttle arm stop pin and the throttle arm.
MAINTENANCE CLEANING AND STORAGE WASHING THE VEHICLE If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals.
MAINTENANCE CLEANING AND STORAGE STORAGE TIPS NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. CLEAN THE EXTERIOR Make any necessary repairs and clean the vehicle as recommended. See the Washing the Vehicle section. STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers.
MAINTENANCE INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart. FOG THE ENGINE 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of engine oil.
MAINTENANCE TRANSPORTING THE ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seats. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks or handlebars. 6. Remove the key to prevent loss during transporting.
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPORTSMAN TOURING 850 SP Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories) Dry Weight 817 lbs. (370 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 7.1 oz. (210 ml) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 37 oz. (1100 ml) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs.
SPECIFICATIONS SPORTSMAN TOURING 850 SP Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° +/- 5° BTDC @ 1200 RPM Idle RPM 1200 +/- 50 Throttle Body/Size Mikuni Dual Bore/42 mm Spark Plug Type / Gap REA6MC / .035 in. (0.9 mm) Lubrication System Pressurized Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 9" (23 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10" (25.
SPECIFICATIONS CLUTCHING SHIFT WEIGHT ALTITUDE 0-1800 (0-6000) 23-58 PN 5632218 1800-3700 (6000-12000) 24-56 PN 5632394 Meters (Feet) DRIVE CLUTCH SPRING DRIVEN CLUTCH SPRING HELIX 42-140 Purple PN 7043805 Black/White 0516_140/ 220 PN 7044511 64-66FR BA45 PN 3235971 SPECIFICATIONS SPORTSMAN TOURING XP 1000 Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories) Dry Weight 851 lbs. (386 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.
SPECIFICATIONS SPORTSMAN TOURING XP 1000 Engine EHO952LE Displacement 952 cc Bore x Stroke 90.5 x 74 Alternator Output 475w @ 1200 RPM/Peak 630w Compression Ratio 11:1 Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° +/- 5° BTDC @ 1200 RPM Idle RPM 1200 +/- 50 Throttle Body/Size Mikuni Dual Bore/42 mm Spark Plug Type / Gap AUTOLITE 5682 / .030 in. (0.
SPECIFICATIONS SPORTSMAN TOURING XP 1000 Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt) Taillights 12v/7 watts Brake Light 12v/7 watts Instrument Cluster Digital CLUTCHING ALTITUDE SHIFT WEIGHT 0-1800 (0-6000) 23-62 PN 5632337 1800-3700 (6000-12000) 24-60 PN 5632216 Meters (Feet) DRIVE CLUTCH SPRING DRIVEN CLUTCH SPRING HELIX 42-140 Purple PN 7043805 Black/White 0516_140/ 220 PN 7044511 64-66FR BA45 PN 3235971 127
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POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PRODUCT SIZE (QUANTITY) PART NUMBER 12 oz aerosol (12) 2870791 1 qt (12) 2871517 1 qt (12) 2876244 2 qt (8) 2877490 Fogging Oil PS-4 PS-4 Extreme Duty 1 gal (4) 2876245 1 qt (12) 2878920 2 qt (8) 2878922 1 gal (4) 2878919 1 qt (12) 2878068 1 gal (4) 2878069 AGL Pump for Gallon Jug 3.8 l 2870465 1 qt (12) 2877922 2.
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TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes.
TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.
TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Mechanical failure Your dealer can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plug ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean
TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to
WARRANTY WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY LUBRICANTS AND FLUIDS 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
WARRANTY U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY The following parts are considered emission-related components for evaporative emissions: • • • • • • • • • Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls* • • • • • • • • • Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the evaporative emission control syste
WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle.
MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance.
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2X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4x4 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Crossing Hillsides . . . . . . . . . . . . . . . . . . . . . . 16 D A Active Descent Control (ADC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ADC 4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . 37 Age 16 Warning . . . . . . . . . . . .
F Failure to Inspect Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Fluid Part Numbers . . . . . . . . . . . . . . . . . . 129 Fog the Engine . . . . . . . . . . . . . . . . . . . . . . . 121 Front Compartment. . . . . . . . . . . . . . . . . . . . 35 Front Gearcase (Demand Drive) Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Front Rack . . . . . . . . . . . . . . . . . . . . . . .
O Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Oil and Filter Change. . . . . . . . . . . . . . . . . . 94 Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Oil Recommendations . . . . . . . . . . . . . . . . 92 Operating at Excessive Speeds . . . . 15 Operating Improperly in Reverse. . . 18 Operating in Unfamiliar Terrain . . . . . 18 Operating on Frozen Bodies of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . 96 Transporting the ATV. . . . . . . . . . . . . . . . 122 Turning Around on a Hill (KTurn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Turning Improperly. . . . . . . . . . . . . . . . . . . . . 15 U Unauthorized Use of the Vehicle . . . 20 V Vehicle Break-in Period. . . . . . . . . . . . . . . 57 Vehicle Identification Numbers . . . . .
WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS ON A 1-UP ATV (TYPE I) NEVER CARRY MORE THAN 1 PASSENGER ON A 2-UP ATV (TYPE II) NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper ATV training or instruction. • at speeds too fast for your skills or the conditions. • on public roads - a collision can occur with another vehicle.
