2017 Scrambler® 1000 Scrambler® XP 1000 Scrambler® XP 1000 Zugmachine Sportsman® 1000 Sportsman® XP 1000 Sportsman® XP 1000 Zugmachine 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.
2017 Owner’s Manual Scrambler® 1000 Scrambler® XP 1000 Sportsman® 1000 Sportsman® XP 1000 Sportsman® XP 1000 Zugmachine Sportsman® Touring XP 1000...
POLARIS®, SCRAMBLER® and SPORTSMAN® are trademarks of POLARIS Industries Inc. Copyright 2016 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.
INTRODUCTION 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.
INTRODUCTION 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. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Business Center A5 1180 Rolle, Switzerland Telephone +41213-218-700 DECLARATION OF CONFORMITY January 1, 2016 Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements applicable to all terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES: TEST / EVALUATION METHODS...
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.
Failure to follow the warnings in this manual can result in serious injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.
See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road. Equipment Modifications The warranty on your POLARIS vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.
SAFETY Rider Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.
SAFETY Rider Safety Operator and passenger must always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Operating this ATV on public streets could result in a collision with another vehicle.
SAFETY Rider Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.
Never turn sharply at excessive speeds, which can lead to vehicle overturn. If the vehicle has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving on hills. See page 74. Always move the 4X4 switch to 4WDC before ascending or descending a hill. Operating on excessively steep hills could cause a rollover. Never operate on hills too steep for the ATV or for your abilities.
SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 75. Always follow the procedures outlined in this manual for operating over obstacles.
Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
SAFETY Safety Labels and Locations Sportsman XP 1000 Zugmachine Labels 55 kg 110 kg 7181582 Rack Alert 7183226 7181427 kPa/bar 45 kPa/0.5 bar 45 kPa/0.5 bar Clutch Cover Alert Tire Pressure Alert Tire Pressure Alert (7183226) FRONT 45 kPa/0.5 bar REAR 45 kPa/0.5 bar Clutch Cover Alert (7181427) Keep body parts away from belt.
SAFETY Safety Labels and Locations Scrambler XP 1000 Zugmachine Labels 7181543 Override Alert 7181537 < < Hill Operation Alert General Alert General Alert (7181537) Before you operate this vehicle, read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing.
SAFETY Safety Labels and Locations Scrambler XP 1000 Zugmachine Labels Rack Alert 11 kg 23 kg 7181583 < 131kg 7181427 Clutch Cover Alert 35 kPa 35 kPa 7181589 Tire Pressure Alert SCRAMBLER Rack Alert (7181583) DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max.
SAFETY Safety Labels and Locations Scrambler and Sportsman XP 1000 Labels SPEEDO REVERSE OVERRIDE 7182094 SPORTSMAN Override Alert/4X4 (AWD) Alert 7181543 SPEEDO REVERSE OVERRIDE 7181544 SCRAMBLER Override Alert 4X4 (AWD) Alert 7181537 < < 7181426 General Alert Hill Operation Alert General Alert (7181537) Before you operate this vehicle, read the owner’s manual.
SAFETY Safety Labels and Locations Scrambler and Sportsman XP 1000 Labels 55 kg 110 kg 11 kg 23 kg 7181582 7181583 Rack Alert (Sportsman) Rack Alert (Scrambler) < 261kg 45 kPa 45 kPa 7181588 Tire Pressure/Load Alert (Sportsman) < 131kg 680 kg 7181427 68 kg...
SAFETY Safety Labels and Locations Sportsman Touring XP 1000 Labels 15° 7181536 Hill Operation Alert SPEEDO REVERSE OVERRIDE 7181538 7182094 Override Alert 4X4 (AWD) Alert < < General Alert General Alert (7181538) Before you operate this vehicle, read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle.
SAFETY Safety Labels and Locations Sportsman Touring XP 1000 Labels 55 kg 110 kg 7181582 Rack Alert 680 kg 68 kg 7182175 Hitch Capacity Alert < 261kg 7181427 Clutch Cover Alert 45 kPa 45 kPa 7182138 Tire Pressure/Load Alert Tire Pressure/Load Alert (7182138) TIRE PRESSURE IN kPa: FRONT 45 REAR 45 MAXIMUM WEIGHT CAPACITY 261 kg Clutch Cover Alert (7181427)
FEATURES AND CONTROLS Switches Sportsman Zugmachine Switches Fog Light Work Light Switch Switch Switch Left Handlebar Controls Main Key (see page 28) Switch Work Light Switch The work light switch controls a light located in the pod. Use the light when additional light is needed at the front of the vehicle, but turn the work light off when driving the vehicle (on-road).
FEATURES AND CONTROLS Switches Sportsman Zugmachine Switches Engine Stop Switch Headlight and Momentary The engine will not start or run when the Engine High Beam Stop switch is in the OFF position. Switch Switch Headlight and Momentary High Beam Hazard Switch Switch The lights do not operate unless the main...
FEATURES AND CONTROLS Switches Scrambler Zugmachine Switches Main Key Switch Fog Light Switch Momentary High Beam Switch Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released. Winch Switch See page 84 for winch information.
FEATURES AND CONTROLS Switches Main Key Switch STOP: End all electrical power to the PARKING vehicle. STOP LIGHTS ON LIGHTS ON: Turn the headlights on. The engine stop switch must be in the RUN position. PARKING LIGHTS ON: After LIGHTS ON START starting the engine, release the key switch to this position.
FEATURES AND CONTROLS Switches Work Light Switch (if equipped) The work light switch controls a light located in the pod. Use the light when additional light is needed at the front of the vehicle, but turn the work light off when driving the vehicle (on-road). Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light.
FEATURES AND CONTROLS Switches Scrambler/Sportsman Switches Headlight Switch Mode/Reverse Switch Override Main Key Switch Engine Stop Switch Switch Headlight Switch (SPORTSMAN) Use the headlight switch to change the lights between high beam and low beam. Main Key Switch STOP: End all electrical power to the STOP START vehicle.
FEATURES AND CONTROLS Mirrors (if equipped) Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine.
FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle.
FEATURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5.
FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 45 for EPS Warning Indicator information. Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the...
FEATURES AND CONTROLS Front Compartment Foot Brake Fluid Reservoir Brake Fluid Battery SPORTSMAN Reservoir SCRAMBLER Radiator Recovery Bottle Battery Radiator Recovery Bottle Cap Fuse Box/Relay Fuse Box/Relay Front Rack (SPORTSMAN XP 1000) Release the front rack Latches latches and remove the rack to gain access to the front compartment.
FEATURES AND CONTROLS Front Compartment Front Storage Box (Touring) Open the front storage box to access the under-compartment area. 1. Release the front box cover latches and lift the cover. 2. Release the plunger latches that secure the box to the frame. 3.
FEATURES AND CONTROLS Hitches See the specification section beginning on page 148 for hitch weight capacities. Do not tow a vehicle or a trailer with this vehicle unless all instructions have been followed. See pages 80-82. Whenever the vehicle is towing, always stay clear of the area between the vehicle and the towed object.
FEATURES AND CONTROLS Hitches Hitch Removal/Installation 1. To remove the hitch, remove the cotter pin and hitch pin. Remove the hitch, then reinstall the hitch pin and secure the cotter pin. Step 4 Step 5 Hitch Pin Cotter Pin 2. To install the hitch, remove the cotter pin from the hitch pin and remove the hitch pin.
FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the AWD momentary switch. Engage AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are Switch spinning, release the throttle before switching to AWD.
FEATURES AND CONTROLS All Wheel Drive System 4WDC AWD Mode (if equipped) Move the momentary switch to the right, past the AWD setting, to engage 4WDC (if equipped). When the switch is on 4WDC, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.
FEATURES AND CONTROLS Instrument Cluster Speedometer Indicator Lamps Rider Information Center NOTICE: High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.
ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
If this occurs, take the ATV to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. Gear Display - This area displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2.
FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.
FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu.See pages 58-61 for code definitions and failure descriptions. Please see your POLARIS dealer for all major repairs.
FEATURES AND CONTROLS Instrument Cluster Digital Gauge (if equipped) The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions. NOTE: Some features are not applicable to all models.The use of a high pres- sure washer may damage the instrument cluster.
All segments including the fuel icon will flash. Refuel immediately. 5. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 60 for more information.
POLARIS dealer can assist. EPS Warning This indicator illuminates when a fault has occurred (if equipped) in the EPS system. Your authorized POLARIS dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes. Engine Hot This lamp illuminates to indicate an overheated engine.
FEATURES AND CONTROLS Instrument Cluster Display Area 1 Pressing the MODE button will change the information displayed in Area 1. Display Area 1 options: • Speed • RPM • Engine Temperature • Ambiant Temperature (optional)
FEATURES AND CONTROLS Instrument Cluster Display Area 2 Toggle the UP/DOWN buttons to change the information displayed in Area 2. Display Area 2 options: • Odometer • Trip 1 • Trip 2 • Voltage • Trip Timer • Engine Tempurature •...
FEATURES AND CONTROLS Instrument Cluster Options Menu Press and hold the MODE button to enter the Options Menu. Options Menu Notes Diagnostic Codes Only displays if fault codes are present or stored Units - Distance Select MPH or KPH ° °...
FEATURES AND CONTROLS Instrument Cluster 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.
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 Driver Circuit Short to B+...
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition EPS Models Only Vehicle Speed Sensor Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Abnormal Rate Of Change Received Network Data In Error System Power Data Valid But Above Normal Operational Range - Most...
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition EPS Models Only EPAS Inverter Temperature Data Valid But Above Normal 520225 Operational Range - Most Severe Level Data Valid But Above Normal 520225 Operating Range - Moderately Severe Level EPAS Communications Receive Data Erratic, Intermittent Or...
Break-In Period The break-in period for your new POLARIS vehicle is the first 20 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 101. Add oil if necessary to maintain the level between the safe and add marks. 3.
OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Passenger seat latch (if...
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.
OPERATION Driving Procedures 1. Wear protective riding gear. See page 17. 2. Perform the pre-ride inspection. See page 64. 3. Place the transmission in PARK. 4. Mount the vehicle from the left side. 5. Sit upright with both feet on the footrests. Keep both hands on the handlebars.
OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your...
OPERATION Driving with a Passenger 1. Never carry a passenger on a 1-up vehicle. Never carry more than one passenger on a 2-up vehicle. 2. Do not carry a passenger on a 2-up vehicle until you have at least two hours of driving experience with the vehicle. 3.
OPERATION Driving with a Passenger 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 76. 13.
OPERATION Driving on Slippery Surfaces Sideways Turn in direction Skid of skid Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning.
OPERATION Driving Through Water Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of Maximum the footrests.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never attempt to operate over large obstacles, such as rocks or fallen trees.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4.
OPERATION Driving Uphill 1-Up Models 2-Up Models 25° Maximum 15° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to 4WDC before ascending or descending a hill. See page 42. 2. Drive straight uphill. 3. Avoid steep hills. Maximum incline is: •...
OPERATION Driving Uphill If all forward speed is lost: 1. Keep your weight uphill. A passenger should also lean uphill. 2. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 3. Apply the brakes gradually. When fully stopped, lock the hydraulic parking brake.
OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Shift body weight uphill. 3. Keep your feet on the footrests. 4. Avoid hills with slippery or loose surfaces. 5.
OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to 4WDC before ascending or descending a hill. See page 2. Avoid steep hills. Maximum incline is: • 15° (2-Up Models) • 25° (1-Up Models) 3.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to 4WDC before ascending or descending a hill.
OPERATION Turning Around on a Hill (K-Turn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. A passenger should not remount until the vehicle returns to firm, level ground. 11. Apply the foot brake. 12.
OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels.
OPERATION Hauling Cargo 1. Never exceed the weight capacities specified for your vehicle on warning labels and in the specifications section of this manual. 2. On models with front and rear racks, cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
Towing Loads Towing is approved OFF-ROAD ONLY unless your vehicle is approved for on-road operation. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road. • Do not tow any trailer on a grade steeper than 15°.
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.
WINCH GUIDE Winch Safety Precautions 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.
WINCH GUIDE Winch Safety Precautions 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23.
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.
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.
WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 92.
WINCH GUIDE Winch Operation 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.
WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
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 GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.
3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on- road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 160.
► Perform these operations more often for vehicles subjected to severe use. Have an authorized POLARIS dealer perform these services. 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 perform these services.
► Radiator 50 H 1000 (1600) Inspect; clean external surfaces ► Cooling hoses 50 H 1000 (1600) Inspect for leaks ► Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) ► Oil lines and 100 H 1000 (1600) Inspect for leaks and loose fasteners fittings ► Engine oil change 100 H 1000 (1600) Change the oil and filter ►...
Grease fittings (3 pumps maximum) every 500 miles, Shaft Yoke before long periods of storage, or after pressure washing or submerging. A-Arms, Front POLARIS All Grease fittings after extreme use or if suspension and Rear Season Grease becomes squeaky. Front...
POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W- 50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W- 50 oil. Follow the manufacturer's recommendations for ambient temperature operation.
MAINTENANCE Engine Oil Oil and Filter Change See the table on page 100 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 96. Always change the oil filter whenever changing oil.
Oil and Filter Change 10. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counter-clockwise to remove it. 11. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 96. See page 147 for the part numbers of POLARIS products. Maintain the oil level at the bottom of the fill plug hole. The...
Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 96. See page 147 for the part numbers of POLARIS products. 4WDC Models: Change the front gearcase fluid every 25 hours if the 4WDC unit is exposed to extreme use.
Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 96. See page 147 for the part numbers of POLARIS products. The fill plug is located on the rear of the gearcase.
MAINTENANCE Rear Gearcase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain hole. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 147 for the part numbers of POLARIS products.
MAINTENANCE Cooling System 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 Maximum storage compartment. Mark 1. View the fluid level in the bottle. Minimum 2.
MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.
Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 147 for the part numbers of POLARIS products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
MAINTENANCE Brake Fluid Hand Brake Indicator Master Window The master cylinder is located on Cylinder the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface.
MAINTENANCE Brake Inspections The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Perform the following checks to keep the brake systems in good operating condition.
3-6 mm more than the front measurement on each side of the vehicle to obtain the recommended 6-12 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service.
MAINTENANCE Steering Assembly The steering assembly should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Seat Removal 1. Grasp one side of the seat near the rear edge.
MAINTENANCE Side Panel/Footwell Removal Remove the seat before removing a side panel. Remove the screws and rivets securing the side panel or footwell (see illustration). Torx Head Plastic Rivet Screw Plastic Rivet Plastic Rivet Hex Head Screw SPORTSMAN model shown...
2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 4. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.
MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped). 3. Install the wheel nuts and finger-tighten them. 4.
MAINTENANCE Air Filter Strap 1. Remove the seat. 2. Remove the air box cover strap, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal light (also rear signal light on SCRAMBLER) becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly. Rear Turn Signal Lamp Replacement (SPORTSMAN) 1. Place the transmission in PARK. 2.
MAINTENANCE Lights Taillight/Brakelight Lamp Replacement (SPORTSMAN) 1. Place the transmission in PARK. 2. Rotate the taillight socket counter-clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation.
MAINTENANCE Front/Rear Shock Compression (SCRAMBLER) The compression damping clicker knob is located on the top of the front shock reservoir and on the bottom of the rear shock reservoir. When the knob is turned clockwise until it stops, the damping is in the fully closed position.
Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod (if equipped).
Refer to the specifications section beginning on page 148 for the recommended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 18-20 ft.
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1.
MAINTENANCE Spark Arrester 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.
MAINTENANCE Spark Arrester Arrestor Cleaning (SCRAMBLER) If your model is equipped with dual exhaust, periodically perform the following procedure for both arresters to remove accumulated carbon. 1. Remove the retaining nut. Remove the arrester from the end of the muffler. 2.
• See your dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.
MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) 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...
(black) cable last. Your vehicle is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.
POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
See page 137. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
MAINTENANCE Transporting the Vehicle 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Always tie the frame of the vehicle 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.
PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to...
Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug...
SPECIFICATIONS SPORTSMAN XP 1000 Zugmachine Maximum Weight Load Capacity 261 kg Dry Weight 398 kg +/- 5 %, based on configuration Fuel Capacity 20 L Engine Oil Capacity 1.9 L Coolant Capacity 1.9 L Rear Gearcase Oil Capacity 210 ml Demand Drive Fluid Capacity 275 ml Transmission Oil Capacity...
SPECIFICATIONS SPORTSMAN XP 1000 Zugmachine Transmission Power System Shaft drive on all wheels Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 23 cm travel Rear Suspension Progressive rate with 26 cm travel Transmission and Gears...
SPECIFICATIONS SPORTSMAN 1000 / SPORTSMAN XP 1000 Maximum Weight Load Capacity 261 kg Dry Weight 378 kg +/- 5 %, based on configuration (1000) 398 kg +/- 5 %, based on configuration (XP 1000) Fuel Capacity 20 L Engine Oil Capacity 1.9 L Coolant Capacity 1.9 L...
Single Seat, length 650 mm Steering System Akerman Principle, with handlebar controls Transmission Power System Shaft drive on all wheels Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 23 cm travel Rear Suspension Progressive rate with 26 cm travel...
SPECIFICATIONS SPORTSMAN XP Touring 1000 Maximum Weight Capacity 261 kg (includes operator, passenger, cargo, accessories) Dry Weight 416 kg Fuel Capacity 20 L Engine Oil Capacity 1.9 L Coolant Capacity 1.9 L Demand Drive Fluid Capacity 275 ml Transmission Fluid Capacity 1100 ml Rear Gearcase Fluid Capacity 210 ml...
SPECIFICATIONS SPORTSMAN XP Touring 1000 Lubrication System Pressurized Wet Sump Transmission Type Automatic PVT (POLARIS Variable Transmission) In-Line H-L-N-R-P Front Suspension Dual a-arm, 22.9 cm travel Rear Suspension Dual a-arm with Rolled IRS, 25.4 cm travel Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1...
SPECIFICATIONS SCRAMBLER 1000 / SCRAMBLER XP 1000 Maximum Weight Capacity 131 kg (includes operator, cargo and accessories) Dry Weight 371 kg +/- 5 %, based on configuration (1000) 375 kg +/- 5 %, based on configuration (XP 1000) Fuel Capacity...
SPECIFICATIONS SCRAMBLER 1000 / SCRAMBLER XP 1000 Front Suspension Dual a-arm with 23 cm travel (1000) Dual a-arm with FOX Podium X Shocks (XP 1000) Rear Suspension Progressive rate with 26 cm travel(1000) Dual a-arm with FOX Podium X Shocks (XP 1000)
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.
MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...