Polaris Sportsman 850 2014 Owner'S Manual Download

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135

TROUBLESHOOTING

Engine Pings or Knocks

Engine Runs Irregularly, Stalls or Misfires

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

Possible Cause

Solution

Fouled or defective spark plug(s)

Inspect, clean and/or replace spark plugs

Worn or defective spark plug wires

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Loose ignition connections

Check all connections and tighten

Water present in fuel

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Kinked or plugged fuel tank vent line

Inspect and replace

Incorrect fuel

Replace with recommended fuel

Clogged air filter

Inspect and clean or replace

Reverse speed limiter malfunction

See your dealer

Throttle release switch malfunction

See your dealer

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Add or change fuel, clean the fuel system

Kinked or plugged fuel tank vent line

Inspect and replace

Low octane fuel

Replace with recommended fuel

Incorrect fuel

Replace with recommended fuel

Possible Rich Fuel Cause

Solution

Fuel is very high octane

Replace with lower octane fuel

Stopping/starting without adequate
warm-up

Allow engine to warm up before operat-
ing and/or stopping

Incorrect fuel

Replace with recommended fuel

Clogged air filter

Inspect and clean or replace

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Summary of Contents for Sportsman 850 2014

Page 1: ...nual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Sportsman 550 Touring International Sportsman 850 Touring International 2014 Downloaded from ManualsNet com search engine ...

Page 2: ... terrain vehicles ATVs Low emission vehicles LEVs RANGER utility vehicles RZR sport vehicles VICTORY motorcycles GEM electric vehicles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service...

Page 3: ...e information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided...

Page 4: ... Features and Controls 21 Operation 48 Winch Guide 69 Emission Control Systems 81 Maintenance 82 Troubleshooting 133 POLARIS Products 137 Specifications 138 Warranty 142 Maintenance Log 146 Index 149 Downloaded from ManualsNet com search engine ...

Page 5: ...voided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to tak...

Page 6: ...tification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ______________...

Page 7: ...OLARIS vehicle Safety Training Never operate this vehicle without proper instruction Take a training course For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polarisindustries com Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never allow anyone under 16 years of age to operat...

Page 8: ...fications 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 The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only POLARIS approved accessories Know their function and effect on the vehicle Downloaded fr...

Page 9: ...it others to operate the vehicle unless they have read and understand this manual and all product labels and have completed a certified safety training course Never allow anyone under 16 years of age to operate this vehicle Never allow anyone under 12 years of age to ride as a passenger on this 2 up vehicle Never carry more than one passenger on this 2 up vehicle Do not carry a passenger until you...

Page 10: ...boots long sleeves and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience Never attempt jumps or other stunts Downloaded from ManualsNet com search engine ...

Page 11: ...handlebars Keep both feet on the footrests A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Always travel slowly when operating on unfamiliar terrain Use extra caution Use caution when operating on rough slippery or loose terrain Downloaded from Manu...

Page 12: ...ng on hills See page 57 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 35 Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 15 Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 59 Always move ...

Page 13: ...ual 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 60 Always follow the procedures outlined in this manual for operating over obstacles See page 63 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding S...

Page 14: ... flowing water See page 62 Always follow the procedures outlined in this manual for driving in reverse See page 64 Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure Never modify the vehicle through improper installation or use of accessories Downloaded from ManualsNet com search engine ...

Page 15: ...t the weight and moving force of the vehicle you and your cargo together with any other vehicles in your party Variances in snow depth and or water currents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Oper...

Page 16: ...ated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combust...

Page 17: ...of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Helmet Eye Protection Gloves Boots Long Pants Long Sleeves E4 051039 0006 31 Downloaded fr...

Page 18: ...pment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads...

Page 19: ... always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label 2x4 Trip 1 km mi RPM F E 88 88 General Alert Age 16 Alert Hill Operation Alert Reverse Override Warning D...

Page 20: ... steeper than 15 degrees 15 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually 7174361 Tire Pressure Load Alert TIRE PRESSURE IN PSI KPa Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa MAXIMUM WEIGHT CAPACITY 735 lbs 333 kg INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES Read Owner s Manual for more detailed loading information NEVER exceed 50 MP...

Page 21: ...mage 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 7175448 Clutch Cover Alert Clutch Cover Alert under seat Rack Box Warning Rack Box Warning Hitch Capacity Label Downloaded from ManualsNet com search engine ...

Page 22: ...e The headlights are not on in this position After starting the engine release the key switch to the POSITION LIGHTS ON position 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 35 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Trip 1 km mi RPM F E 88 88 Main Key Switch 4X4 Switch Downloaded from ManualsNet com search ...

Page 23: ...usly Use this feature to alert others of an emergency or other situation requiring caution Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light Return the toggle to the center position to end the signal Horn Switch Press the horn switch to sound the horn Momentary High Beam Switch Press this switch with your left forefinger to activate the ...

Page 24: ...r death Always release the throttle before pressing the override switch The reverse override button also acts as a MODE button when held down for approximately one half second See the instrument cluster information beginning on page 36 Tip The override button will not function as a MODE button if the transmission is in reverse Headlight Switch The main key switch must be on and the engine stop swi...

Page 25: ...h sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement Throttle Release Switch The throttle release switch causes the engine to stop if the throttle cable sticks in an open position when the operator releases th...

Page 26: ...ver toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding 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 Co...

Page 27: ... result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master cylinder before each ride 1 Position the vehicle on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator window on the top of the master cylinder The eye will appear dark when the fluid level is fu...

Page 28: ...ng the vehicle 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 The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill Another option is to park the vehicle in a...

Page 29: ...ould the main system fail use the auxiliary foot brake The foot brake operates both front and rear brakes The brake is located on the inside of the right footrest Press the brake pedal down with your foot to apply the brakes Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the front storage box See page 32 Maintain the fluid lev...

Page 30: ...To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed Extreme Use 30 AH Battery If your factory installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories please see your POLARIS dealer to purchase a 30 AH battery 1 Fully c...

Page 31: ...ervice See pages 101 102 for passenger seat adjustment procedures See page 101 for passenger seat removal and installation procedures Beverage Holders This vehicle is equipped with beverage holders on each side of the passenger seat To secure a beverage or other container remove the rubber retainer strap from one side of the holder Place the container into the recess and reinstall the strap over t...

Page 32: ...Do not fill the tank neck Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle 1 Turn the handlebars to the full right position Tip The handlebars may also be locked in the full left position 2 Insert the steering lock key and turn it clockwise 3 Remove the key Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 4 Reverse the p...

Page 33: ...4 To remove the box completely disengage the plungers and slide the box rearward and upward 5 Always secure the plunger latches and the cover latches before operating the vehicle Access the following components under the front box Radiator cap Coolant recovery bottle cap Brake fluid reservoir Electrical fuse relay components ADC fluid reservoir Battery Cover Latches Plunger Latches ADC Fluid Reser...

Page 34: ...e 4X4 indicator icon in the instrument cluster display will be visible When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction in forward or reverse When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 The vehicle automatically engages 4X4 when operati...

Page 35: ... off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always swi...

Page 36: ...ccur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the following conditions occur The 4X4 switch is moved out of the ADC 4X4 position Vehicle speed exc...

Page 37: ...s and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Digital Analog Gauge Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h Trip 1 km mi RPM F E 88 88 Rider Information Center Speedometer Indic...

Page 38: ...ed to the 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 High Beam This lamp illuminates when the headlamp switch is set to high beam Direction Indicators A di...

Page 39: ...inate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle 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 To change to metric and or a 24 hour clock see page 41 Trip 1 km mi RPM E F 88 88 1 2 6 ...

Page 40: ...Information Display This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval 4 Active Descent Control Display This icon displays when ADC is active See page 35 5 Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See page 41 for resetting in...

Page 41: ...de at any time wait 10 seconds The display automatically exits and returns to the odometer display 1 Turn the key to the OFF position 2 Place the transmission in neutral 3 Press and hold the MODE button while turning the key to the ON position 4 When the display flashes the distance setting tap the MODE button to advance to the desired setting 5 Press and hold the MODE button to save the setting a...

Page 42: ...t steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the t...

Page 43: ...vice hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval 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 ...

Page 44: ...your POLARIS dealer for all major repairs 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the numbers displayed in the gear position if any clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and hold the M...

Page 45: ...tage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Crankshaft Position Sensor Circuit Fault 636 8 Gear Sensor Signal Voltage To...

Page 46: ...or T1 Partial Failure T1 Shorted to Ground 520223 4 T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Partial Failure T2 Shorted to Ground 520224 4 T2 Shorted to Bus 520224 3 Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Shorted to Ground T2 Shorted to Bus 520225 16 T2 Shorted to Ground T1 Shorted to Bus 520225 17 T1 and T2 are Sho...

Page 47: ...Injector 1 MAG SDI Part Load Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Driver Circuit Grounded 651 4 Injector 2 PTO SDI Part Load Driver Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Dr...

Page 48: ...or Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Par tial Failure T1 Shorted to Ground 520223 4 T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Par tial Failure T2 Shorted to Ground 520224 4 T2 Shorted to Bus 520224 3 Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Short to Ground T2 Short to Bus 520225 16 T2 Sho...

Page 49: ... 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 NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do no...

Page 50: ...vels controls and areas outlined on the daily pre ride inspection checklist See page 50 6 Pull only light loads 7 Change both the oil and the filter at 25 hours 8 Check the fluid level of the transmission after the first 25 hours of operation and every 100 hours thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance B...

Page 51: ... oper ation 31 Steering Ensure free operation Tires Inspect condition and pressure 104 Wheels fasteners Inspect ensure fastener tightness 106 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 31 87 Coolant level Ensure proper level 97 98 Coolant hoses Inspect for leaks Throttle Ensure proper operation 24 126 Switches Ensure operation 21 Engine stop switch Ensure...

Page 52: ...ts Never remove your hands from the handlebars while operating and always keep both feet on the footrests 6 Never consume alcohol or drugs before or while operating this vehicle 7 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 8 Never operate a damaged vehicle After any overturn or accident have a qualified service dealer inspect the entire ma...

Page 53: ...n the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the vehicle is used year ...

Page 54: ...th both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up 8 Shift the transmission into gear 9 Check your surroundings and determine your path of travel 10 Release the parking brake 11 Slowly depress the throttle with your right thumb and begin driving 12 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Downloaded...

Page 55: ...rection of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest Use the same leaning technique for turning in reverse 3 Practice making turns at slow speeds before attempting to turn at faster speeds Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds Downloaded from ManualsNet c...

Page 56: ... or dismounts 8 Allow a passenger to ride only in the approved passenger seat 9 Do not carry more than one passenger 10 Slow down Control may be more difficult with a passenger on board Allow more time and distance for braking 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 ...

Page 57: ...traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Be alert Watch the trail Avoid quick sharp turns 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body ...

Page 58: ... carefully before ascending any hill 5 Avoid hills with slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill A passenger should also shift body weight uphill 8 Proceed at a steady rate of speed to avoid stalling 9 Never open the throttle suddenly or make sudden gear changes 10 Be alert Be prepared to take emergency action This may include dismounting quickly 15 M...

Page 59: ...with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 3 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 4 If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Downloaded from ManualsNet com search engine ...

Page 60: ...ion in neutral 3 Slow down Never travel down a hill at high speed 4 Drive straight downhill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side 5 Shift body weight uphill A passenger should also shift body weight uphill 6 Apply the brakes slightly to aid in slowing Applying the brakes too firmly may cause the rear wheels to lock which could result in l...

Page 61: ...60 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 Downloaded from ManualsNet com search engine ...

Page 62: ...t until the vehicle returns to firm level ground 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 7 Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill A passenger should...

Page 63: ...ration in water Perform the services outlined in the maintenance chart See page 82 The following areas need special attention engine oil transmission oil demand drive fluid and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before ...

Page 64: ...erating in a new area 2 Be alert Watch the terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches 5 Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover Downloaded from ManualsNet com search engine ...

Page 65: ...ive slowly Apply the brakes lightly for stopping 4 Avoid turning at sharp angles 5 Never open the throttle suddenly 6 Do not use the override switch unless additional wheel speed is required for vehicle movement Use with caution NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Downloaded from M...

Page 66: ...ing 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 Downloaded from ManualsNet com search engine ...

Page 67: ...nd creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point d...

Page 68: ...50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg 4 NEVER exceed 50 MPH 80 km h while carrying a passenger 5 NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 lbs 45 kg 6 Do not obstruct the headlight beam with cargo 7 Slow down 8 Use low forward gear when hauling or towing heav...

Page 69: ...nger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your POLARIS warranty Never install a hitch longer than 10 cm Never install automotive accessories on your POLARIS vehicle Always install POLARIS approved or equ...

Page 70: ... operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 78 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch 8 Alwa...

Page 71: ...ble evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s rated capacity 15 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winchin...

Page 72: ...h and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons 25 Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable Downloade...

Page 73: ... working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 met...

Page 74: ... 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 C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If fr...

Page 75: ...oft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you 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 ...

Page 76: ...ctions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle I Stop winching as soon as the stuck vehicle is able to propel...

Page 77: ...y if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook strap E Slowly winch ...

Page 78: ...n permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C A wi...

Page 79: ... an object This is a dangerous practice It gener ates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat fr...

Page 80: ...ungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable a...

Page 81: ... 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardwar...

Page 82: ... Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle European Vibration and Noise The driver perceived noise and hand arm and whole body vib...

Page 83: ...intenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weath...

Page 84: ...intenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Checklist on page 50 Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Passenger seat latch Wheels fasteners Frame fasteners Engine oil level Winch See pages 69 80 E Air filter pre filter Daily Inspect clean often replace as neede...

Page 85: ...in oil level check Rear gearcase oil 25 H 1 M 250 400 Break in oil level check Transmission oil 25 H 1 M 250 400 Break in oil level check General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 500 800 Inspect lubricate D Steering 50 H 6 M 500 800 Lubricate Front suspension 50 H 6 M 500 800 Lubricate Rear suspension 50 H 6 M 500 800 Lubricate D E Thrott...

Page 86: ... 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect D E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace ...

Page 87: ...e 87 850 Engine Oil PS 4 5W 50 4 Cycle Oil 2 qt 1 9 l 12 ft lbs 16 Nm Page 87 Transmission Oil AGL Gearcase Lubricant Transmission Fluid 32 oz 946 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm Page 90 Demand Drive Fluid Front Gearcase Demand Drive Fluid 9 3 oz 275 ml 8 10 ft lbs 11 14 Nm 11 ft lbs 15 Nm Page 92 Rear Gearcase Oil ATV Angle Drive Fluid or GL5 80 90 weight gear lube 7 1 oz 210 ml 10...

Page 88: ...ended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 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 vehicle Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall and tighten the...

Page 89: ... warm up at idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs ni...

Page 90: ...tall the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 3 4 turn 13 Remove the dipstick Add the proper amount of the recommended oil Do not overfill 14 Reinstall the dipstick 15 Place the transmission in PARK 16 Lock the parking brake 17 Start the engine Allow it to idle for one to two minutes 18 Stop the engine 19 Check f...

Page 91: ...at the bottom of the fill plug hole The fill plug is located on the right side of the vehicle behind the footwell The drain plug is located on the bottom rear side of the gearcase Oil Check 1 Remove the footwell see page 103 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to ...

Page 92: ...low the oil to drain completely 3 Clean and reinstall the drain plug Torque to specification 4 Remove the fill plug Add the proper amount of the recommended oil 5 Reinstall the fill plug Torque to specification 6 Check for leaks 7 Reinstall the footwell 8 Dispose of used oil properly Downloaded from ManualsNet com search engine ...

Page 93: ...d fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as ne...

Page 94: ... of POLARIS Demand Drive Fluid for the ADC unit Maintain the fluid level between the minimum and maximum marks on the reservoir See page 137 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system Fluid Check 1 Access the reservoir under the front box See page 32 2 View the fluid level in the reservoir 3 If the level ...

Page 95: ...loosen one of the bleeder valve screws turn counter clockwise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valve screws before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped air If the level drops b...

Page 96: ... a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to specification 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 dr...

Page 97: ...eated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by ...

Page 98: ...ront box See page 32 1 View the fluid level in the bottle 2 If the level is low remove the bottle cap and add coolant as needed Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 Reinstall the cap 4 Close and secure the front box and cover Maximum Mark Minimum Mark Recovery Bottle Cap Downloaded from ManualsNet com search engine ...

Page 99: ...coolant as needed Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Access the pressure cap under the front box See page 32 2 Remove the pressure cap 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 no...

Page 100: ...cks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 26 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 m...

Page 101: ... string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 8 1 4 inch 3 6 mm more than the front measurement on each side of the vehic...

Page 102: ...djustments The passenger backrest can be adjusted horizontally and vertically 1 Unzip the two zippers at the bottom of the backrest pad Lift the pad upward to remove it from the backrest frame 2 To adjust the backrest forward or rearward loosen the top adjuster bolt Pivot the adjuster forward or rearward to one of the three adjustment positions and tighten the bolt 3 To adjust the backrest upward ...

Page 103: ...necessary use a suitable pliers or spanner wrench Adjust the shock to the desired spring preload Rotate the adjustment cam to the left to increase preload 5 Reinstall the shock 6 Torque the upper and lower shock fasteners to 38 ft lbs 51 Nm 7 Reinstall the passenger seat Operator Seat Removal 1 Remove the passenger seat See page 101 2 Grasp one side of the operator s seat near the rear edge 3 Pull...

Page 104: ... removing a side panel 2 To remove a side panel or footwell remove the fasteners securing it to the frame Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Hex Head Screw Plastic Rivet Downloaded from ManualsNet com search engine ...

Page 105: ...y 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 Refer to the specifications section beginning on page 138 for recommended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less 1 8 3 mm Downloaded from ManualsN...

Page 106: ...LARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel Downloaded from ManualsNet com search engine ...

Page 107: ...nd 6 Torque the wheel nuts to specification Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for service Wheel Type Nut Type Nut Torque Aluminum Lug Nut 75 ft lbs 102 Nm Steel Lug Nut...

Page 108: ...fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main filter if needed 6 Reinstall the filter into the air box 7 Reinstall the air box cover and the seat Main Filter Pre Filter Strap Downloaded from ManualsNet com search engine ...

Page 109: ...he blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Access the fuses under the front box See page 32 2 Remove the fuse box cover 3 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating 4 Reinstall the fuse box cover 5 Close and secure the front box and cover 550 850 Fuse Box Downloaded from ManualsNet com search...

Page 110: ...sidue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 Remove the five 5 headlight pod screws 2 Lift the pod cover and disconnect the speedometer harnesses from the speedometer Hot components can cause burns to skin Allow lamps to cool before servicing 3 Unplug the headlamp from the wiring harness Be sure to pull on the connecto...

Page 111: ... the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring 5 Tighten or loosen the three 3 headlight screws to adjust the beam upward or dow...

Page 112: ...the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK 2 Open the front rack cover 3 Remove the plug at the back of the headlight 4 Pull the harness plug to disconnect it from the back of the headlight 5 Position light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight Turn the collar counter c...

Page 113: ...edometer 3 Unplug the headlamp from the wiring harness 4 Use a small screwdriver to remove the o rings from the headlight mounting tabs 5 Pull the headlight housing up to release it from the locking tabs 6 Carefully pull the assembly up and out of the pod 7 Reverse the steps to install the new housing and reassemble the pod Downloaded from ManualsNet com search engine ...

Page 114: ... the entire signal lamp assembly Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light assembly 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp 4 Reinstall the harness connector 5 Test the light for proper operation Lamp Connector Downloaded from ManualsNet com search engine ...

Page 115: ... has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 115 A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spa...

Page 116: ...he tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or in...

Page 117: ... sure the E ring is on the drain plug and reinstall the drain plug NOTICE Serious damage could occur if the air box drain plug is not reinstalled and tightened properly 3 Remove the spark plugs 4 Turn the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying procedure NOTICE Ser...

Page 118: ...ated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge carbon from the system 5 If carbon comes out of the exhaust cover or plug the exhaust outlet s Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber ...

Page 119: ...ge amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your deale...

Page 120: ...on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1600 1800 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed t...

Page 121: ...arying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 5 seconds 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 Take the vehicle to your dealer for service as soon as possible Condition Range to Use Operating at...

Page 122: ...electrolyte leakage which would shorten the life of the battery considerably Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Ba...

Page 123: ...down strap 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 8 Close and secure the front box and cover Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure ...

Page 124: ...eated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the battery voltage with a voltmete...

Page 125: ...n top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours Downloade...

Page 126: ...s can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when tu...

Page 127: ...ble between the throttle arm stop pin and the throttle arm If adjustment is needed 1 Locate the throttle cable adjuster Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 2 3 mm of freeplay is achieved between the stop pin and the throttle arm While adjusting freepla...

Page 128: ...dealer for service 7 With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommended setting If idle speed increases it may be necessary to increase the gap between the stop pin and throttle arm but do not exceed the recommended 2 3 mm gap 8 When adjustments are complete tighten the locknut 9 Squeeze the...

Page 129: ...le 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 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to ...

Page 130: ...ine to run for a while to evaporate any water that may have entered the engine or exhaust system 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 Always use cle...

Page 131: ... fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 88 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 107 2 Clean the air box Fluid Levels Inspect the fluid le...

Page 132: ...ective film of fresh oil 5 If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 82 Battery Storage See pages 122 123 for storage and charging procedures Store the battery in a cool d...

Page 133: ...our vehicle Please see your POLARIS dealer Transporting the Vehicle 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 vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets rack...

Page 134: ... to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn ...

Page 135: ...ecessary 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 Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non r...

Page 136: ...ked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kinked or...

Page 137: ...tions Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine ext...

Page 138: ...4 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 l 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 l 2871460 Premium Starter Grease 2871515 U Joint Grease 3 oz ...

Page 139: ...121 cm Overall Height 58 25 in 148 cm Wheelbase 57 in 145 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 96 in 244 cm unloaded Fuel Capacity 5 25 gal 20 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 qts 1 9 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Fluid Capacity 32 oz 946 ml Rear Gearcase Fluid Capacity 7 1 oz 210 ml Fuel System Visteon Electronic Fuel Injection ...

Page 140: ...Front 26 x 8 14 7 psi 48 3 kPa Tire Size Pressure Rear 26 x 10 14 7 psi 48 3 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc All Wheel Brake Parking Hydraulic lock all wheel Headlight 2 Hi Lo beam on bumper 55 60 watt Taillight 12v 7 watts Brake Light 12v 27 watts Instrumentation Digital Analog Altitude Shift Weight Drive Clutch Spring Dr...

Page 141: ...cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 96 in 244 cm unloaded Fuel Capacity 5 25 gal 20 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 qts 1 9 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Fluid Capacity 32 oz 946 ml Rear Gearcase Fluid Capacity 7 1 oz 210 ml Fuel System Bosch Multi Port Sequential Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump in ...

Page 142: ... Front 26 x 8 14 7 psi 48 kPa Tire Size Pressure Rear 26 x 10 14 7 psi 48 3 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc All Wheel Brake Parking Hydraulic lock all wheel Headlight 2 Hi Lo beam on bumper 55 60 watt Taillight 12v 7 watts Brake Light 12v 27 watts Instrumentation Digital Analog Altitude Shift Weight Drive Clutch Spring Dri...

Page 143: ...tion and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LI...

Page 144: ...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 THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTI...

Page 145: ...thorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present do...

Page 146: ...OTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will contin...

Page 147: ...l 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 OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS Downloaded from ManualsNet com search engine ...

Page 148: ...147 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS Downloaded from ManualsNet com search engine ...

Page 149: ...148 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS Downloaded from ManualsNet com search engine ...

Page 150: ...Radiator 98 Cooling System 96 98 D Demand Drive Fluid 92 Diagnostic Codes 550 XP EPS 44 45 Diagnostic Codes 850 XP EPS 46 47 Disengaging Active Descent Control 35 Display Units Standard Metric 40 Drink Holders 30 Drive Belt Wear Burn 133 Drivetrain Break In 49 Driving Downhill 59 Driving in Reverse 64 Driving on a Sidehill 58 Driving on Slippery Surfaces 56 Driving Over Obstacles 63 Driving Proced...

Page 151: ...5 Hauling Cargo 66 68 Hazard Switch 22 Headlight Housing Replacement 112 Headlight Lamp 111 Headlight Lamp Replacement 109 Headlight Switch 23 H Helmet 16 High Beam Adjustment 110 High Beam Switch Momentary 22 High Range Use 120 Horn Switch 22 Hub Tightening 105 I Idle RPM Adjustment 126 Immersion Maintenance 116 Indicator Lamps 37 Instrument Cluster 36 47 K Key Switch 21 K Turn 60 61 L Lights Fro...

Page 152: ...ining 6 Safety Winch Maintenance 80 Seat Backrest Adjustments 101 Seat Removal Operator 102 Seat Removal Passenger 101 Seat Suspension Passenger 102 Seats 101 102 Severe Use 82 Shock Loading the Winch 78 79 Side Panel Removal 103 Sidehilling 58 Signal Words 4 Spark Arrestor 117 Spark Arrestor Requirements 81 Spark Plug Inspection 114 115 Spark Plug Recommendations 114 Spark Plug Torque Specificati...

Page 153: ...nsmission 29 Transmission Oil 90 91 Transporting the Vehicle 132 Turn Signal Switch 22 Turning Around on a Hill 60 61 Turning the Vehicle 54 V Vehicle Identification Numbers 5 Vehicle Immersion 116 VIN 5 W Warning Symbols 4 Washing the Vehicle 128 129 Wheel Installation 106 Wheel Nut Torque Specifications 106 Wheel Removal 105 Winch Cable Care 77 Winch Maintenance Service Safety 80 Winch Operation...

Page 154: ...zeug bedienen oder fahren Antes de operar o conducir este vehículo lea el Manual del propietario Lire le Manuel d utilisation avant d utiliser ou de conduire ce véhicule Prima di usare o guidare il veícolo leggere il Manuale di istruzioni Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista Antes de utilizar ou andar neste veículo leia o Manual do proprietário Innan du hanterar elle...

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Polaris Sportsman 850 2014, Owner'S Manual

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