Polaris SPORTSMAN 850 2019 Owner's Manual
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Polaris SPORTSMAN 850 2019 Owner's Manual

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2019
OWNER'S MANUAL
SPORTSMAN® 850
SPORTSMAN XP® 1000
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.

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Summary of Contents for Polaris SPORTSMAN 850 2019

  • Page 1 2019 OWNER’S MANUAL SPORTSMAN® 850 SPORTSMAN XP® 1000 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.
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it...
  • Page 3 2019 Owner’s Manual Sportsman® 850 Sportsman XP® 1000...
  • Page 4 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.
  • Page 5 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.
  • Page 6 WELCOME...

  • Page 7: Table Of Contents

    Specifications ....123 POLARIS Products ....129 Troubleshooting ....131 Warranty .

  • Page 9: Introduction

    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.
  • Page 10 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.
  • Page 11 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.

  • Page 13: Safety

    You should review this information on a regular basis. If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887- 2887 or visit www.atvsafety.org.
  • Page 14 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. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 15 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.
  • Page 16 SAFETY 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. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 17 SAFETY OPERATING ON PUBLIC ROADS Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use). OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 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.
  • Page 22 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.
  • Page 23 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.
  • Page 24 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. The part number is printed on the label. Age Warning General Warning Reverse Override Warning/AWD “No Passenger”...
  • Page 25 SAFETY AGE 16 WARNING The Age 16 warning is located on the left-hand wheel well. WARNING Operating this vehicle if you are under the age of 16 increases the chances of severe injury or death to operator. NEVER operate this vehicle if you are under age 16.
  • Page 26 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) GENERAL WARNING WARNING Improper use can result in SEVERE INJURY or DEATH...
  • Page 27 SAFETY 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) •...

  • Page 29: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS SWITCHES NOTE Image below is for reference only. Your model may differ slightly. Ignition Switch Headlight Switch Engine Stop Switch Drive Line Switch Mode/Reverse Override Switch 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.
  • Page 30 FEATURES AND CONTROLS 4X4 SWITCH (IF EQUIPPED) The drive mode switch 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.
  • Page 31 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. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise.
  • Page 32 When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your POLARIS dealer or other qualified service facility for proper diagnosis and repairs.
  • Page 33 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.
  • Page 34 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.
  • Page 35 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.
  • Page 36 FEATURES AND CONTROLS AUTOMATIC TRANSMISSION GEAR SELECTOR The transmission gear selector 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.
  • Page 37 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.
  • Page 38 POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.
  • Page 39 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.
  • Page 40 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. ENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically engage when all four of the following conditions occur:...
  • Page 41 Fuel Gauge segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled Service Indicator maintenance. See page 50 for more information.
  • Page 42 This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine Check Engine damage could result. Your authorized POLARIS dealer can assist. This indicator illuminates when a fault has occurred in the EPS Warning (if EPS system.
  • Page 43 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 the Periodic Maintenance Chart section for more information.
  • Page 44 FEATURES AND CONTROLS DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 Engine Speed Temperature Ambient Temperature (Optional)
  • Page 45 FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 Engine Odometer Temperature Ambient Trip 1 Temperature (Optional) Trip 2 Voltage Speed Engine Hours Service Hours...
  • Page 46 FEATURES AND CONTROLS 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 Units - Temp Select between °F and °C Clock Select between 12H or 24H, and set...
  • Page 47 FEATURES AND CONTROLS UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “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.
  • Page 48 FEATURES AND CONTROLS UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “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: Press the MODE button.
  • Page 49 FEATURES AND CONTROLS CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTICE “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: Press the MODE button.
  • Page 50 FEATURES AND CONTROLS BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTICE “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.
  • Page 51 FEATURES AND CONTROLS BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “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.
  • Page 52 FEATURES AND CONTROLS SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “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: Press the MODE button.
  • Page 53 FEATURES AND CONTROLS DIAGNOSTIC CODE NOTICE 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. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
  • Page 54 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.
  • Page 55 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Injector 1 (MAG) (SDI Driver Circuit Open/ Part Load) Grounded Driver Circuit Short to Driver Circuit Grounded Injector 2 (PTO) (SDI Driver Circuit Open/ Part Load) Grounded Driver Circuit Short to Driver Circuit Grounded Ignition Coil Primary Driver Circuit Short to...
  • Page 56 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Driver Circuit Short to 1321 Driver Circuit 1321 Grounded Chassis Relay Driver Circuit Open/ 520208 Grounded Driver Circuit Short to 520208 Driver Circuit 520208 Grounded All Wheel Drive Driver Circuit Open/ 520207 Control Grounded Driver Circuit Short to 520207...
  • Page 57 FEATURES AND CONTROLS 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 Severe...
  • Page 58 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Steering Torque Condition Exists 520223 Partial Failure Steering Torque Full Condition Exists 520224 Failure EPAS Inverter Data Valid But Above Temperature Normal Operational 520225 Range - Most Severe Level Data Valid But Above Normal Operating 520225 Range - Moderately...

  • Page 59: Operation

    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. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
  • Page 60 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.
  • Page 61 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. ITEM REMARKS PAGE page 30...
  • Page 62 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).
  • Page 63 Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
  • Page 64 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.
  • Page 65 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.
  • Page 66 OPERATION DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 67 OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. 3. Avoid steep hills. Maximum incline is 25° 4.
  • Page 68 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.
  • Page 69 If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section of this manual, and take the vehicle in for service at the first opportunity.
  • Page 70 OPERATION DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.
  • Page 71 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.
  • Page 72 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. STOPPING THE ENGINE 1.
  • Page 73 OPERATION BRAKING 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.
  • Page 74 OPERATION HAULING CARGO CARGO WARNING 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.
  • Page 75 ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use.
  • Page 76 OPERATION 850 / 850 SP XP 1000 Maximum Towed Load 1500 lbs. (680 kg) 1500 lbs. (680 kg) (Level Ground) Maximum Vertical Hitch 150 lbs. (68 kg) 150 lbs. (68 kg) Weight...

  • Page 77: Winch Guide

    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.
  • Page 78 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.
  • Page 79 WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. 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.
  • Page 80 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.
  • Page 81 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.
  • Page 82 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.
  • Page 83 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.
  • Page 84 Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 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 person.
  • Page 85 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.
  • Page 86 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, or other qualified person.

  • Page 87: Emission Control Systems

    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.

  • Page 89: 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.
  • Page 90 SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. 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.
  • Page 91 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES HOUR- (KM) ITEM CALENDAR REMARKS Engine Oil Level Winch (if equipped) Air Filter (Pre- Inspect; clean often; replace as Daily Filter) needed Air Box Sediment Daily Drain deposits when visible Tube Check level daily, change coolant Daily Coolant every two years...
  • Page 92 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES HOUR- (KM) ITEM CALENDAR REMARKS 1000 Inspect coolant strength seasonally; Cooling System 50 H (1600) pressure test system yearly 1000 Inspect; clean external surfaces Radiator 50 H (1600) 1000 Cooling Hoses Inspect for leaks 50 H (1600) 1000...
  • Page 93 U-Joint Grease fittings (3 pumps maximum) every 500 miles, before long Shaft Yoke Grease periods of storage, or after pressure washing or submerging. A-Arms, POLARIS All- Grease fittings after extreme use or if suspension becomes Front and Season squeaky. Rear...
  • Page 94 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.
  • Page 95 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 .
  • Page 96 9. Remove the oil filter cover plate by loosening the three screws holding into place. 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.
  • Page 97 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.
  • Page 98 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 .
  • Page 99 • ADC is the primary mode of all-wheel-drive operation If the front gearcase is making excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service.
  • Page 100 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.
  • Page 101 Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. 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 the Polaris Products section for the part numbers.
  • Page 102 3. Using a funnel, slowly add coolant through the radiator filler neck. 4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
  • Page 103 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.
  • Page 104 MAINTENANCE TIRES WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.
  • Page 105 MAINTENANCE WHEEL INSTALLATION 1. Place the transmission in PARK. 2. Lock the parking brake. 3. 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). 4.
  • Page 106 1/4–1/2 inch (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. AIR FILTER INSTALLATION 1. Remove the seat, the air box cover strap, and remove the air box cover.
  • Page 107 MAINTENANCE FUSE REPLACEMENT If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.
  • Page 108 MAINTENANCE HIGH BEAM ADJUSTMENT The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall .
  • Page 109 MAINTENANCE HEADLIGHT HOUSING REPLACEMENT 1. Remove the four (4) headlight pod screws. 2. Pull the pod cover forward. 3. Unplug the headlamp from the wiring harness. 4. Use a small screwdriver to remove the o-rings from the headlight mounting tabs. 5.
  • Page 110 MAINTENANCE TAILLIGHTS/BRAKE LIGHTS REPLACEMENT Procedure to replace taillights: TO REPLACE LEFT TAILLIGHT: 1. Remove the harness connector from the back of the light assembly. 2. Remove the 3 fasteners securing the light assembly and remove the light assembly. 3. Install the new light assembly and tighten the 3 fasteners to secure the light assembly.
  • Page 111 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. PLUG CONDITION TORQUE SPECIFICATION New Spark Plug...
  • Page 112 Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
  • Page 113 MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrester. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
  • Page 114 • See your POLARIS dealer, or other qualified person, for service and repair assistance. • 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.
  • Page 115 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) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 High...
  • Page 116 (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. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.
  • Page 117 Check battery voltage each month during storage and recharge as needed to maintain a full charge. 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.
  • Page 118 CAMBER AND CASTER The camber and caster are non-adjustable. REAR SPRING The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer.
  • Page 119 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.
  • Page 120 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 •...
  • Page 121 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. 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.
  • Page 122 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.
  • Page 123 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.

  • Page 125: Specifications

    SPECIFICATIONS SPECIFICATIONS SPORTSMAN 850 / 850 SP SPORTSMAN 850 / 850 SP Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories) Dry Weight 773 lbs. (350 kg) (850) 792 lbs. (359 kg) (850 SP) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts.
  • Page 126 Spark Plug Type / Gap REA6MC / .035 in. (0.9 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm) travel...
  • Page 127 SPECIFICATIONS SPORTSMAN 850 / 850 SP CLUTCHING DRIVEN DRIVE CLUTCH ALTITUDE SHIFT WEIGHT CLUTCH HELIX SPRING SPRING 0-1800 (0-6000) 42-140 Black/White 64-66FR BA45 Meters (Feet) 0516_140/220 Purple PN 3235971 1800-3700 PN 7044511 PN 7043805 (6000-12000) SPORTSMAN XP 1000 SPORTSMAN XP 1000 Maximum Weight Capacity 575 lbs.
  • Page 128 Spark Plug Type / Gap AUTOLITE 5682 / .030 in. (0.76 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm) travel...
  • Page 129 SPECIFICATIONS SPORTSMAN XP 1000 Brake, Parking Hydraulic lock, all wheel Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt) Taillights 0.26 watts Brake Light 3.6 watts Instrument Cluster Digital SPORTSMAN XP 1000 CLUTCHING DRIVEN DRIVE CLUTCH ALTITUDE...

  • Page 131: Polaris Products

    Dielectric Grease (Nyogel™) — 2871329 12 oz bottle (12) Carbon Clean 2871326 16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) 2872280 DOT 4 Brake Fluid — 2872189 Loctite™ 565 Thread Sealant — 2871956 POLARIS Battery Tender™ — 2859044 Charger...

  • Page 133: Troubleshooting

    Your dealer can assist. Check for fouled plug or foreign material in gas tank or fuel lines. Poor engine performance Your POLARIS dealer can assist. Slippage from failure to warm Always warm up the belt by operating below 30 mph for one mile up belt (5 miles or more when temperature is below freezing).
  • Page 134 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE...
  • Page 135 TROUBLESHOOTING ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark Inspect, clean and/or replace spark plug plug Incorrect spark plug gap Set gap to specs or replace plug or heat range Old or non- Replace with fresh recommended fuel recommended fuel Incorrectly installed Your dealer can assist spark plug wires...
  • Page 136 TROUBLESHOOTING ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plug heat range Loose ignition connections Check all connections and tighten...
  • Page 137 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent Inspect and replace line 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 Your dealer can assist wires...

  • Page 139: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.
  • Page 140 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.
  • Page 141 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.
  • Page 142 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. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 143 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.
  • Page 144 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.
  • Page 145 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...
  • Page 146 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.

  • Page 147: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 149 2X4 Mode ....... . 37 Crossing Hillsides ..... . 16 4X4 Mode .
  • Page 150 Eye Protection ......12 Improper Hill Climbing ....16 Inspect and Lubricate .
  • Page 151 Storage Area ......120 Polaris Products ..... . 129 Switches.
  • Page 152 Tires ........102 Toe Alignment......104 Towing Loads .
  • Page 154 • (Type II / 2-Up ATV only) make sure passenger reads and understands all safety labels. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No.

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