Polaris Sportsman XP 1000 2017 Owner's Manual For Maintenance And Safety
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Polaris Sportsman XP 1000 2017 Owner's Manual For Maintenance And Safety

Polaris Sportsman XP 1000 2017 Owner's Manual For Maintenance And Safety

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2017
Sportsman® XP 1000
Sportsman® XP 1000 Zugmaschine
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.

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Summary of Contents for Polaris Sportsman XP 1000 2017

  • Page 1 2017 Sportsman® XP 1000 Sportsman® XP 1000 Zugmaschine 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.
  • Page 2 2017 Owner’s Manual Sportsman® XP 1000 Sportsman® XP 1000 Zugmaschine...
  • Page 3 POLARIS®, SPORTSMAN® and SPORTSMAN XP® 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.

  • Page 4: Table Of Contents

    Troubleshooting ..... . . 131 POLARIS Products..... 135 Specifications .

  • Page 5: Introduction

    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.
  • Page 6 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.
  • Page 7 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.
  • Page 8 INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 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).
  • Page 9 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.

  • Page 10: Safety

    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 RiderCourse that is available to you and your eligible family members.
  • Page 11 Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S.
  • Page 12 Riding pants with kneepads and a jersey with shoulder pads provide the best protection. Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 13 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.
  • Page 14 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.
  • Page 15 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving on hills. See page 63. 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.
  • Page 20 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 63. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 21 SAFETY Rider Safety Gasoline is highly flammable and explosive under certain conditions. • Use extreme caution whenever handling gasoline. • Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 22 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.
  • Page 23 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.
  • Page 24 SAFETY Safety Labels and Locations Sportsman XP 1000 Zugmaschine Labels Rack Alert < 261kg 45 kPa 45 kPa 7182138 Tire Pressure Alert / Load Alert 7181427 Clutch Cover Alert Clutch Cover Alert (7181427) Keep body parts away from belt. Tire Pressure / Load Alert (7182138) TIRE PRESSURE IN kPa: FRONT - 45 REAR - 45...
  • Page 25 SAFETY Safety Labels and Locations Sportsman XP 1000 Labels 15° 7181536 Hill Operation Alert 7181543 7181538 Override Alert < < General Alert 4x4 (AWD) 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.
  • Page 26 SAFETY Safety Labels and Locations Sportsman XP 1000 Labels Rack Alert < 261kg 45 kPa 45 kPa 7182138 Tire Pressure Alert / Load Alert 7181427 Clutch Cover Alert Clutch Cover Alert (7181427) Keep body parts away from belt. Tire Pressure / Load Alert (7182138) TIRE PRESSURE IN kPa: FRONT - 45 REAR - 45...

  • Page 27: Features And Controls

    FEATURES AND CONTROLS Switches Fog Light Work Light Switch Switch Left Handlebar Main Key Switch Controls Switch (see page 27) 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).
  • Page 28 FEATURES AND CONTROLS 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 key switch is on and the engine stop switch Turn Override...
  • Page 29 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch. Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.
  • Page 30 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 31 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 32 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 33 FEATURES AND CONTROLS Parking Brake Locking the 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.
  • Page 34 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 35 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear Gear selector is located on the Selector 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.
  • Page 36 FEATURES AND CONTROLS Front Compartment Brake Fluid Reservoir (auxiliary foot brake) Battery Coolant Bottle Cap Radiator Electrical/Fuse/Relay Front Rack If your model is equipped Latches with front compartment storage, unlock both latches on each side and remove the cover to gain access.
  • Page 37 FEATURES AND CONTROLS Hitches See the specification section beginning on page 137 for hitch weight capacities. Do not tow a vehicle or a trailer with this vehicle unless all instructions have been followed. See pages 72-74. Whenever the vehicle is towing, always stay clear of the area between the vehicle and the towed object.
  • Page 38 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.
  • Page 39 POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.
  • Page 40 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 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.
  • Page 41 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3000. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off.
  • Page 42 FEATURES AND CONTROLS Instrument Cluster Digital Gauge 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.
  • Page 43 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 88 for more information.
  • Page 44 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.
  • Page 45 FEATURES AND CONTROLS Instrument Cluster Display Area 1 & 2 Pressing the MODE button will change the information displayed in Area 1. Display Area 1 options: • Speed • RPM • Engine Temperature Toggle the UP/DOWN buttons to change the information displayed in Area 2.
  • Page 46 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 KPH or MPH Units - Temp °...
  • Page 47 FEATURES AND CONTROLS Instrument Cluster Digital 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. 2. Press and hold the MODE button to enter the Options Menu. 3.
  • Page 48 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer can provide 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).
  • Page 49 2. Use the UP or DOWN arrows to display active and historic fault codes. 3. See pages 50-53 for code definitions and failure descriptions. Your authorized POLARIS dealer can provide code details and diagnosis. NOTE: Stored fault codes are cleared from the gauge during a power cycle.
  • Page 50 Bluetooth Icon vehicle’s digital gauge and select BT PAIR. The Bluetooth icon will begin to blink. 3. Find and select Polaris Gauge on your phone’s Bluetooth menu or prompt. Pairing should occur momentarily. Pairing mode will continue for up to 90 seconds or if you exit the BT PAIR menu.
  • Page 51 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.
  • Page 52 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+...
  • Page 53 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...
  • Page 54 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...

  • Page 55: Operation

    Break-In Period The break-in period for your new POLARIS ATV 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.
  • Page 56 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 32. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 94. Add oil if necessary to maintain the level between the safe and add marks. 3.
  • Page 57 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 Brake system/lever travel...
  • Page 58 OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 9. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
  • Page 59 Respect the environment in which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
  • Page 60 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.
  • Page 61 OPERATION Driving Procedures 1. Wear protective riding gear. See page 10. 2. Perform the pre-ride inspection. See page 56. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.
  • Page 62 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 63 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.
  • Page 64 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 65 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 66 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. See page 40. 3. Avoid steep hills. Maximum incline is: •...
  • Page 67 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. 8 ft. (2.4 m)
  • Page 68 OPERATION Turning Around on a Hill (K-Turn) 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 page 40. 3. Leave the transmission in forward and shut off the engine. 4.
  • 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 on page 116, 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.
  • Page 73 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.
  • Page 74 OPERATION Hauling Cargo 1. Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. 2. 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.
  • 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. Maximum Towing Capacities Do not exceed maximum towing capacities. Avoid towing on inclines.

  • Page 76: 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 77 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.
  • Page 78 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. Your dealer can provide service on your winch if this occurs. 22. Always inspect your winch and winch cable before each use. 23.
  • Page 79 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.
  • Page 80 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.
  • Page 81 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.
  • Page 82 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 84.
  • Page 83 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.
  • Page 84 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.
  • 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 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.
  • Page 87 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.

  • Page 88: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1d. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 89: Maintenance

    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 operations 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 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 or other qualified person perform these services.
  • Page 92 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 Demand drive fluid 100 H 12 M...
  • Page 93 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...
  • Page 94 MAINTENANCE Lubrication Guide Greasing Points Greasing Points Front Suspension Greasing Points Greasing Points Rear Suspension Greasing Points Left Bearing Carrier (same on right side) Greasing Points...
  • Page 95 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 96 MAINTENANCE Engine Oil 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 Dipstick the ATV.
  • Page 97 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 92 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 88. Always change the oil filter whenever changing oil.
  • Page 98 Engine 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.
  • Page 99 Periodic Maintenance Chart beginning on page 88. See the table on page 92 for fluid recommendations, capacities and plug torques. See page 135 for the part numbers of POLARIS products. Maintain the oil level at the bottom of the fill plug hole. The...
  • Page 100 Periodic Maintenance Chart beginning on page 88. See the table on page 92 for fluid recommendations, capacities and plug torques. See page 135 for the part numbers of POLARIS products. Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
  • Page 101 Periodic Maintenance Chart beginning on page 88. See the table on page 92 for fluid recommendations, capacities and plug torques. See page 135 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 102 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 135 for the part numbers of POLARIS products.
  • Page 103 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 box. See page 1. View the fluid level in the bottle. 2.
  • Page 104 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 Radiator provide the correct replacement part. 5. Close and secure the front box and cover.
  • Page 105 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.
  • Page 106 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. 1. Position the vehicle on a level surface.
  • Page 107 MAINTENANCE 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. Elevating the Vehicle for Service Some service procedures Elevate at Center require elevation of the vehicle.
  • Page 108 Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer or other qualified service facility. Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK.
  • Page 109 MAINTENANCE Tires 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. 4. Install the wheel nuts and finger-tighten them. 5.
  • Page 110 MAINTENANCE Air Filter Installation 1. Remove the seat. Strap 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.
  • Page 111 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 112 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fingers.
  • Page 113 MAINTENANCE Lights 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 7.6 m (25 ft) from a wall. Place the transmission in PARK.
  • Page 114 MAINTENANCE Lights Low Beam Adjustment Low Beam Adjustment Screw The low beam can be adjusted slightly upward or downward by rotating the adjustment screw, located on either side of the vehicle.
  • Page 115 MAINTENANCE Lights 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. Headlight 4. Use a small Housing screwdriver to remove the o-rings from the headlight mounting tabs.
  • Page 116 Refer to the specifications section beginning on page 137 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...
  • Page 117 Your POLARIS dealer can assist 7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 8. If water has been ingested into the PVT, follow the procedure on...
  • Page 118 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. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
  • Page 119 • 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 120 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.
  • Page 121 5. Allow the engine RPM to settle to idle speed, then shift the transmission to low range. 6. Test for belt slippage. If the belt slips, repeat the process. 7. Your vehicle requires service as soon as possible, which your POLARIS dealer can provide.
  • Page 122 (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 123 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.
  • Page 124 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.
  • Page 125 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.
  • Page 126 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.
  • Page 127 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.
  • Page 128 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.
  • Page 129 126. 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 130 Set the tire pressure and safely support the ATV 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...
  • Page 131 Accessories Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Your POLARIS dealer can assist.

  • Page 132: Troubleshooting

    Your POLARIS dealer can assist. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. Your POLARIS dealer can assist. Slippage from failure to Always warm up the belt by operating below 48 km/h (30 warm up belt mph) for 1.6 km (1 mile) (8km/5 miles or more when...
  • Page 133 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Your POLARIS dealer can assist. Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure Your POLARIS dealer can assist.
  • Page 134 Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your POLARIS dealer can assist. Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause...
  • Page 135 Replace with new fuel Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer can assist. Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections...

  • Page 136: Polaris Products

    U-Joint Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...

  • Page 137: Specifications

    Spark Plug Type / Gap AUTOLITE 5682 / 0.76 mm (.030 in) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transm.) Front Suspension Dual a-arm with 23 cm (9.2”) travel Rear Suspension Progressive rate with 26 cm (10.2”) travel...
  • Page 138 SPECIFICATIONS SPORTSMAN XP 1000 Transmission H/L/N/R/P Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.367:1 Drive Ratio, Front 3.818:1 Drive Ratio, Rear 3.7:1 Tires/Pressure, Front 26x8-14 / 48.3 kPa (7 psi) Tires/Pressure, Rear 26x10-14 / 48.3 kPa (7 psi) Brakes, Front/Rear Single-Control Hydraulic Disc, All Wheel Brakes, Auxiliary...

  • Page 139: 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.
  • Page 140 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.
  • 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.
  • Page 143 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.
  • Page 144 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase...
  • Page 145 POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.
  • Page 146 WARRANTY California Residents Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50-state models available for sale in California are identified by the letter “B” in the ninth position of the model number (e.g., R16RTE87B).

  • Page 147: Maintenance Log

    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...
  • Page 148 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 149: Index

    INDEX Numerics 4X4 Switch ....28, 38 Demand Drive Fluid ... . . 95 Diagnostic Codes... . . 48-51 Disengaging Active Descent Control 39 Drive Belt Wear/Burn .
  • Page 150 INDEX Fluid Immersion Maintenance ..114 Brake ..... . 32 Indicator Lamps ....42 Demand Drive .
  • Page 151 Tires ....103-104 Polaris Product List ... . 133 Front Wheel Hub Tightening . . . 103 Polishing the Vehicle.
  • Page 152 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Route de l’Etraz Business Center A5 1180 Rolle, Switzerland Part No. 9927847 Rev 01...

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