Polaris Sportsman 850 Touring EPS Owner'S Manual Download Page 97

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours

Calendar

Miles

(Km)

Oil lines and
fasteners

100 H

6 M

1000 (1600) Inspect for leaks and loose

fittings

Engine oil change

100 H

6 M

1000 (1600) Change the oil and filter

Demand drive fluid
(normal use)

100 H

12 M

1000 (1600) Change fluid

Rear gearcase oil

100 H

12 M

1000 (1600) Change fluid

Transmission oil

100 H

12 M

1000 (1600) Change fluid

Fuel system

100 H

12 M

1000 (1600) Cycle key to pressurize fuel

pump; check for leaks at fill
cap, fuel lines/rail and fuel
pump; replace lines every
two years

Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/
pipe

100 H

12 M

1000 (1600) Inspect

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.

Clutches (drive
and driven)

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

Front wheel
bearings

100 H

12 M

1000 (1600) Inspect; replace as needed

Brake fluid

200 H

24 M

2000 (3200) Change every two years

Suspension
bushings

250 H

24 M

2000 (3200) Inspect; replace if necessary

Spark arrester

300 H

36 M

3000 (4800) Clean out

Coolant

60 M

Replace coolant

Valve clearance

1000 H

10000

(16000)

Inspect; adjust

Toe adjustment

Inspect periodically; adjust
when parts are replaced

Headlight aim

Adjust as needed

Summary of Contents for Sportsman 850 Touring EPS

Page 1: ...formation This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety Sportsman 850 Sportsman 850 SP Sportsman Touring 850 Sportsman Touring 850 SP Sportsman XP 1000 Sportsman XP Touring 1000 ...

Page 2: ...f it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone ...

Page 3: ...1 2016 Owner s Manual Sportsman 850 Sportsman 850 SP Sportsman Touring 850 Sportsman Touring 850 SP Sportsman XP 1000 Sportsman XP Touring 1000 ...

Page 4: ...screpancies may result between the actual vehicle and the 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 ...

Page 5: ...Introduction 4 Safety 9 Features and Controls 30 Operation 56 Winch Guide 79 Emission Control Systems 91 Maintenance 92 Troubleshooting 139 POLARIS Products 143 Specifications 144 Warranty 152 Maintenance Log 160 Index 162 ...

Page 6: ...ced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer MSD Technician Your POLARIS dealer knows your vehicle best and is int...

Page 7: ...ituation that if not avoided 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 indicate...

Page 8: ...r driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Neve...

Page 9: ... condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmen...

Page 10: ...sting keys The ignition switch must be replaced if all keys are lost The manufacturer s label is located on the front right side of the vehicle behind the radiator Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number ________...

Page 11: ...RiderCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A POLARIS ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We stro...

Page 12: ...tablished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label 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 E4...

Page 13: ...otect arms and legs 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 The POLARIS limited warranty on your POLARIS vehicle will be termina...

Page 14: ...rent types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 9 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 1...

Page 15: ...hange clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Oper...

Page 16: ...sult in an accident or overturn Never carry a passenger on a 1 up ATV Do not carry a passenger on a 2 up ATV until you have at least two hours of driving experience with the vehicle Carrying More Than One Passenger on a 2 Up ATV Carrying more than one passenger on a 2 up ATV greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carr...

Page 17: ...owly and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s ri...

Page 18: ...r 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 Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Practice turning at slow spe...

Page 19: ...ys move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 43 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not ...

Page 20: ...owing the procedure described in the owner s manual See page 70 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the foot brake as well and then lock the parking brake Dismount on the uphill side of the vehicle or on the left ...

Page 21: ...in Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating Improperly in Reverse Improperly operating in reverse cou...

Page 22: ...e obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 73 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or ...

Page 23: ...may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacity for this ATV Cargo should be properly distribut...

Page 24: ... highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate ...

Page 25: ...structions 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 No Passenger Warning 1 Up Models WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or...

Page 26: ...while in reverse CAUTION Do not push switch to engage 4x4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage Age 16 Warning All Models WARNING Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger NEVER operate this ATV if you are under age 16 Passenger Warning 2 Up Models General Warnin...

Page 27: ...table get off and walk if conditions require Discretionary Warning 2 Up Models WARNING Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns Discretionary W...

Page 28: ...r training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and con...

Page 29: ...or the conditions on public roads a collision can occur with another vehicle with a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and use extra caution at all times when carrying a passenger dism...

Page 30: ...en rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 lbs 45 kg Tire Pressure Load Warning 2 Up Models WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa Maximum weight capacity 575 lbs 261 kg Lug nut torque values 75 ft lbs 102 Nm N...

Page 31: ...s hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death Hitch Capacity Label All Models TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 6...

Page 32: ...throttle before pressing the override button 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 44 Tip The override button will not function as a MODE button if the transmission is in reverse 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 43 The vehicle automatically e...

Page 33: ...rt or run when the switch is off Both the main switch and the engine stop switch will shut off all electrical power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 61 Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop s...

Page 34: ...ation Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control Engine speed and vehicle movement are controlled by pressing...

Page 35: ...rd 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 Contact yo...

Page 36: ... failure which could 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 ATV 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 f...

Page 37: ...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 ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Fuel Tank Always refuel with the engine stopped and outdoors or i...

Page 38: ... to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level frequent...

Page 39: ...idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and whe...

Page 40: ...e rack to gain access to the front compart ment To reinstall the rack hold the rack as shown in the illustration Position the front edge in the tabs then push the rack downward and secure the latches Brake Fluid Reservoir auxiliary foot brake Radiator Cap Coolant Bottle Cap Electrical Fuse Relay Battery Latches ...

Page 41: ...e cover 2 Release the plunger latches that secure the box to the frame 3 Close the cover and lift the unlatched edge of the box to disengage the plungers Pivot the box forward 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 Cover Latches Plunger Latches ...

Page 42: ... POLARIS dealer can assist Your dealer can provide any installation procedures that may differ for an extreme use battery Beverage Holders Touring This vehicle is equipped with beverage holders on each side of the rear of the 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 the...

Page 43: ...s on 4X4 the ATV is in 4X4 and the 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 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 w...

Page 44: ...If the switch is turned 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 gea...

Page 45: ... following conditions occur 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 pos...

Page 46: ... will damage the speedometer lens 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 Rider Information Center Speedometer ...

Page 47: ...ly reduce engine power EPS Warning This indicator illuminates when the key is turned 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 Your authorized POLARIS dealer can assist Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illum...

Page 48: ...ument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs your POLARIS dealer can provide 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 49 Trip 1 km mi RPM ...

Page 49: ...Your authorized POLARIS dealer can assist 3 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 43 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 f...

Page 50: ...rd or metric units of measurement Tip To exit the set up mode 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 set...

Page 51: ...Release the button 5 Repeat 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 ATV Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip To ...

Page 52: ... button 3 When the service 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 Your POLARIS dealer can provide for all major repairs The diagnostic mode is accessible only when the check en...

Page 53: ...error codes from the display 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 MODE button to...

Page 54: ...sition Sensor Voltage 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 Signal Out of Range 102 2 Crankshaft Position Sensor Circui...

Page 55: ... Circuit Grounded 634 4 Position Out of Range 634 7 Starter Enable Circuit Driver Circuit Open Grounded 1321 5 Driver Circuit Short to B 1321 3 Driver Circuit Grounded 1321 4 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 520207 3 Driver C...

Page 56: ...Or Shorted To High Source 168 3 Voltage Below Normal Or Shorted To Low Source 168 4 Engine Speed Data Valid But Above Normal Operational Range Most Severe Level 190 0 Data Erratic Intermittent Or Incorrect 190 2 Received Network Data In Error 190 19 ECU Memory Bad Intelligent Device Or Component 628 12 Out Of Calibration 628 13 Calibration Out Of Calibration 630 13 Steering Over Current Shut Down ...

Page 57: ...PAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520226 2 Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or Component 520228 12 Condition Exists 520228 31 EPAS Software Error Bad Intelligent Device Or Component 520229 12 Condition Exists 520229 31 EPAS Power Save Condition Condition Exists 520231 31 EPS SEPIC Volt...

Page 58: ... 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 NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive c...

Page 59: ...hecks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 58 6 Pull only light loads 7 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 8 Change both the oil and the filter at 25 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer l...

Page 60: ...cate if necessary 96 Steering Ensure free operation Tires Inspect condition and pressure 111 Wheels fasteners Inspect ensure fastener tightness 112 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 35 97 Coolant level Ensure proper level 105 106 Coolant hoses Inspect for leaks Throttle Ensure proper operation 32 132 Indicator lights switches Ensure operation 30 ...

Page 61: ...ace burned out headlamps promptly 8 Drive in a manner appropriate for your skills your passenger s skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handlebars while operating and always keep both feet on the footrests 9 Never consume alcohol or drugs before or while operating an ATV 10 Always use the siz...

Page 62: ...hicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to onc...

Page 63: ...s not start return 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 ATV ...

Page 64: ...t side 6 Sit upright with 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 le...

Page 65: ... the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse 6 Practice making turns at slow speeds before attempting to turn at faster speeds W...

Page 66: ...ke 7 Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts 8 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 T...

Page 67: ...understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shifts body weight For example the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills ...

Page 68: ... 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 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handl...

Page 69: ...fully before ascending any hill 5 Never climb hills with excessively 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 and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 9 Never go over the top of any hill at high speed An obstacle a ...

Page 70: ...low these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 4 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 5 If the vehicle begins to tip quickly turn the front wheel downhill ...

Page 71: ...the transmission in forward gear Do not descend a hill with the transmission in neutral 5 Slow down Never travel down a hill at high speed 6 Drive straight downhill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side 7 Shift body weight uphill A passenger should also shift body weight uphill 8 Apply the brakes slightly to aid in slowing Applying the br...

Page 72: ...70 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 73: ...nger should not remount 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 uph...

Page 74: ...mand 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 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 122 and take the vehicle in for service at the first opportu...

Page 75: ... constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees 5 Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover ...

Page 76: ... turning at sharp angles 6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may...

Page 77: ... 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 78: ... THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and 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 se...

Page 79: ...l Models NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 lbs 45 kg 5 2 Up Models NEVER exceed 50 MPH 80 km h while carrying a passenger 6 Do not obstruct the headlight beam with cargo 7 Slow down 8 Use low forward ...

Page 80: ...aximum 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 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 ...

Page 81: ... and heavy gloves when 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 88 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while oper...

Page 82: ...feed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s rated capacity 15 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during ...

Page 83: ...Always inspect your winch 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 lif...

Page 84: ...g strategy if it is not 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...

Page 85: ...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 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 ...

Page 86: ... jacket tarp or other soft 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 po...

Page 87: ... frame following instructions 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 ve...

Page 88: ... is complete especially 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...

Page 89: ... cable has already been 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...

Page 90: ... in an attempt to move 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 gener...

Page 91: ...ly never use elastic bungie 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 w...

Page 92: ...ctivation 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 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 ...

Page 93: ...th a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable...

Page 94: ...ARIS parts are available from your POLARIS dealer Equivalent parts may be used for emissions related service Record maintenance and service in the Maintenance Log beginning on page 160 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can perform these operations Maintenance intervals in the foll...

Page 95: ...ected to severe use D Have an authorized POLARIS dealer or other qualified person perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Checklist on page 58 Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Wheels fasteners Frame fasteners Engine oil lev...

Page 96: ...cted to extreme use See page 102 Ź Demand drive fluid 25 H 1 M 250 400 Break in oil level check Ź Rear gearcase oil 25 H 1 M 250 400 Break in oil level check Ź Transmission oil 25 H 1 M 250 400 Break in oil level check Ź 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 Ź Front suspen...

Page 97: ...ears Ź Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect D Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Ź 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 ...

Page 98: ...que See Page Engine Oil PS 4 5W 50 4 Cycle Oil 2 qt 1 9 l 12 ft lbs 16 Nm 97 Transmission Oil AGL Gearcase Lubricant Transmission Fluid 37 oz 1100 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm 100 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 102 Rear Gearcase Oil ATV Angle Drive Fluid or GL5 80 90 weight gear lube 7 1 oz 210 ml 10 14 ft l...

Page 99: ...xing brands or using a non recommended 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 ATV Remove the dipstick Wipe it dry with a clean clot...

Page 100: ...Start the engine Allow it to warm up at idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely CAUTION 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 ...

Page 101: ...is in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 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...

Page 102: ...s Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is located on the bottom rear side of the gearcase Oil Check 1 Remove the footwell see page 109 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...

Page 103: ...emove the drain plug Allow 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 ...

Page 104: ...e facility for service Use the recommended 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 flui...

Page 105: ...Position the vehicle on 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 Cle...

Page 106: ... the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated 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...

Page 107: ... bottle cap under the front box See page 39 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 ...

Page 108: ... level in the radiator Add coolant as needed CAUTION 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 39 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of ...

Page 109: ...erfill The following checks 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 34 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 t...

Page 110: ...straight ahead position 3 Tie a length of 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 fr...

Page 111: ...the seat before 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 Touring Shown ...

Page 112: ... the operator s seat grasp one side of the seat near the rear edge Pull upward abruptly to disengage the under seat fasteners To remove the passenger seat pull the top of the seatback slightly rearward to relieve tension 1 while pulling the seat release latch upward 2 When the latch releases roll the seat assembly forward 3 and lift the seat away from the vehicle Passenger Seat Release Latch 1 2 3...

Page 113: ...ize and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less 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 3 Lock the parking...

Page 114: ... the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING 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...

Page 115: ...e filter 4 Remove the 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 ...

Page 116: ...uits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Access the fuses under the front box See page 39 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 Fuse Box ...

Page 117: ...that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 SP XP Models Remove the seven 7 headlight pod screws Pull the pod cover forward Non SP XP Remove the five 5 headlight pod screws Lift the pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unpl...

Page 118: ...r 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 The adjustment screw is located on the right side of the headlight pod To adjust the beam...

Page 119: ...ghts Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw Phillips Screw ...

Page 120: ...nstall the new housing and reassemble the pod Headlight Housing Replacement Non SP XP Models 1 Remove the five 5 headlight pod screws 2 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 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 l...

Page 121: ...he new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the headlamp 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 Harness Lamp C...

Page 122: ...k the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 121 CAUTION 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 ...

Page 123: ...gine and the service The 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...

Page 124: ...ll the drain plug Make 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 dryin...

Page 125: ...ally purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester 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 p...

Page 126: ...arge 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 POL...

Page 127: ...due to the system s dependence 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 lo...

Page 128: ... 4 Apply varying 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 Your vehicle requires service as soon as possible which your POLARIS dealer can provide C...

Page 129: ...y could result in 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 ...

Page 130: ...ly 4 Secure the battery hold 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 bat...

Page 131: ...DC voltage WARNING An overheated 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 batt...

Page 132: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 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 l...

Page 133: ...ster block tightening bolts 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 p...

Page 134: ...ttle lever A gap of 2 3 mm should be visible 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...

Page 135: ...RIS dealer or other qualified service facility 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 co...

Page 136: ...s 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 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 ...

Page 137: ... washing Allow the engine 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 ...

Page 138: ...nded amount Carbon Clean removes water from fuel systems stabilizes 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 98 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter...

Page 139: ...ting the cylinder with a protective film of fresh oil 5 If 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 92 Battery Storage See pages 128 129 for storage and charging procedures Store th...

Page 140: ...hat are approved for ATV use Your POLARIS dealer can assist Transporting the ATV Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Secure the fuel cap oil cap and seats 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt poc...

Page 141: ...transmission 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 vehic...

Page 142: ...park 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 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 reco...

Page 143: ... 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 Your POLARIS dealer can assist Electronic throttle control malfunction Your POLARIS dealer can assist Other mechanical failure Your POLARIS dealer can assist Possible Lean Fuel Cause Solution Low or contam...

Page 144: ...ons 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 Your POLARIS dealer can assist Electronic throttle control malfunction Your POLARIS dealer can assist Other mechanical failure Your POLARIS dealer can assist Overheated engine ...

Page 145: ...gal 3 8 l 2877922 Demand Drive Plus Fluid qt 95 l 2877923 Demand Drive Plus Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2871460 Premium ...

Page 146: ...h Towing Rating 1500 lbs 680 4 kg Unbraked Trailer Towing Capacity 1914 lbs 868 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO850LE Displacement 850 cc Bore x Stroke 87 x 71 5 Alternator Output 475w 1200 RPM Peak 630w Compression Ratio 11 ...

Page 147: ...r Single Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital Analog Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6000 24 63 PN 56...

Page 148: ...Overall Width 47 6 in 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 37 oz 1100 ml Rear Gearcase Fluid Capacity 7 1 oz 210 ml Engine EH085OLE Displac...

Page 149: ...essure Front 26 x 8 14 7 psi 48 3 kPa Tire Type 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 Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillight 12v 7 watts Brake Light 12v 27 watts Instrumentation Digital Analog...

Page 150: ... lbs 680 4 kg Unbraked Trailer Towing Capacity 1914 lbs 868 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO952LE Displacement 952 cc Bore x Stroke 90 5 x 74 Alternator Output 475w 1200 RPM Peak 630w Compression Ratio 11 1 Starting System El...

Page 151: ...ydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital Analog Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6000 24 70 PN 5633136 Orange PN 70...

Page 152: ...dth 47 6 in 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 37 oz 1100 ml Rear Gearcase Fluid Capacity 7 1 oz 210 ml Engine EHO952LE Displacement 952 ...

Page 153: ... 26 x 8 14 7 psi 48 3 kPa Tire Type 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 Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillight 12v 7 watts Brake Light 12v 27 watts Instrumentation Digital Analog Altitude Sh...

Page 154: ...ginal registration 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...

Page 155: ... 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 This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal ...

Page 156: ...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 ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DUR...

Page 157: ...es vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue...

Page 158: ...chased will continue to be covered by the Limited Warranty 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 If any of the above terms are void bec...

Page 159: ...arranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers com...

Page 160: ...long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally a...

Page 161: ... model number e g R16RTE87B The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS ...

Page 162: ... 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 OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 163: ...161 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 164: ... Operation 61 Compartment Front 38 39 Consumer Product Safety 9 Coolant Bottle 105 Coolant Radiator 106 Cooling System 104 106 Crankcase Emission Control System 91 D Demand Drive Fluid 102 Diagnostic Codes 52 55 Disengaging Active Descent Control 43 Display Units Standard Metric 48 Drink Holders 40 Drive Belt Wear Burn 139 Drivetrain Break In 57 Driving Downhill 69 Driving in Reverse 74 Driving on...

Page 165: ...stment 131 Hauling Cargo 76 78 Headlight Housing Replacement 118 Headlight Lamp Replacement 115 Headlight Switch 31 High Beam Adjustment 116 High Range Use 126 Hub Tightening 111 I Idle RPM Adjustment 132 Immersion Maintenance 122 Indicator Lamps 45 Instrument Cluster 44 55 K Key Switch 31 K Turn 70 71 L Lights Headlight Housing Replacement 118 Headlight Lamp 115 High Beam Adjustment 116 Low Beam ...

Page 166: ...meter 44 Spring Adjustment Rear Shock 131 Starting the Engine 61 Steering Assembly 104 Storage 134 138 Storage Box Front Touring 39 Storage Tips 136 137 S Switches 4X4 Switch 30 41 Engine Stop Switch 31 Headlight Switch 31 Main Key Switch 31 Mode Reverse Override Switch 30 T Taillight Lamp Replacement 119 Throttle Body Adjustment 132 Throttle Cable Freeplay 132 133 Throttle Lever 32 Tires 111 112 ...

Page 167: ...r vehicle S with a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS S use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns S avoid paved surfaces pavement may seriously affect handling and control S reduce speed and use extra caution at all times when carrying a passenger dismount passenger when conditions require S make sure ...

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Polaris Sportsman 850 Touring EPS, Owner'S Manual

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