Polaris Sportsman 850 XP Owner'S Manual Download

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PMS 419

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

Owner's Manual

for Maintenance and Safety

Sportsman 550

Sportsman 550 EPS

Sportsman 850 XP

Sportsman 850 XP EPS

Summary of Contents for Sportsman 850 XP

Page 1: ...t contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety Sportsman 550 Sportsman 550 EPS Sportsman 850 XP Sportsman 850 XP EPS ...

Page 2: ...er s manual on the next page If you cannot locate this card or if 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 ...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...r your skills or the conditions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control 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 READ OWNER S MANUAL FOLLOW ALL INS...

Page 5: ...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 should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested i...

Page 6: ...ep ancies may result between the actual vehicle and the information presented in this publi cation 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 t...

Page 7: ...tion 4 Safety 7 Features and Controls 24 Operation 53 Emission Control Systems 71 Maintenance 72 Troubleshooting 121 POLARIS Products 125 Specifications 126 Declaration of Conformity 130 Warranty 131 Maintenance Log 139 Index 142 ...

Page 8: ...al injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The ...

Page 9: ...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 10: ...ing 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 ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number _________________________________________________...

Page 11: ...iderCoursesm 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 stron...

Page 12: ...eds estab lished 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 l...

Page 13: ...o protect 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 warranty on your POLARIS ATV is terminated if any equipment ...

Page 14: ...s vehicle See page 7 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 16 years of age Even though a child may be within the recommended age group for operating some ATVs he she may not have the skill...

Page 15: ...onous 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 Protective Apparel Riding in this vehicle without wearing an approved helmet and protective ey...

Page 16: ... on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public stree...

Page 17: ...ction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or ...

Page 18: ...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 recommended Improper procedure could cause loss of control or overturn Avoid crossing the s...

Page 19: ...mount following the procedure described in the owner s manual See page 64 If the ATV begins rolling downhill Keep 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 rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uph...

Page 20: ...ent or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 67 Before shifting into reverse gear always check for obstacles o...

Page 21: ...ra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 65...

Page 22: ...y of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV 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 ATV o...

Page 23: ...l disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry gra...

Page 24: ... the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper 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 passenge...

Page 25: ...is ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 Reverse Override Warning 4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse CAUTION Do not...

Page 26: ...ressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 5 0 psi 34 5 kPa Maximum weight capacity 575 lbs 261 kg Lug nut torque values Steel rims 45 ft lbs 61 Nm Aluminum rims 75 ft lbs 102 Nm 7175440 No Passenger Warning Tire Pressure Load Warning ...

Page 27: ... in serious injury or death 7175488 Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 120 lbs 54 kg Rear 240 lbs 109 kg 7175448 Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 L...

Page 28: ...or approximately one half second See the instrument cluster information beginning on page 34 The transmission cannot be in reverse when using the override button as a MODE button 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 33 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Headlight Switch Use the headlight switch ...

Page 29: ...dures Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ...

Page 30: ...tle 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 the throttle lever The throttle lever is s...

Page 31: ...e the brake lever 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 be...

Page 32: ... 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 win dow on the top of the master cylinder The eye will appear dark when the ...

Page 33: ... unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating 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 ATV if leaving it parked on a hill Another option i...

Page 34: ...ould 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 fre quently for the auxiliary brake sys tem The reservoir is...

Page 35: ...ation Fuel Tank Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap and add fuel Use either leaded or unleaded gasoline with a mini mum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 such as E 85 fuel The fuel tank is designed to allow for the normal expansion of fuel Do not o...

Page 36: ...n 4X4 the ATV is in 4X4 and the 4X4 indi cator icon in the instrument clus ter 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 wh...

Page 37: ...s switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest Active Descent Control ADC System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Engaging Active Descent Control The ADC system will automatically engage when all four of the follow ing conditi...

Page 38: ...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 Trip 1 km mi RPM F E 88 88 Rider Information Cente...

Page 39: ...utomatically 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 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 ...

Page 40: ...t cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the ATV to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 39 Trip 1 km mi...

Page 41: ...uit See your dealer 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 33 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 pa...

Page 42: ...p To exit the set up mode at any time wait 10 seconds The display automati cally 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 butt...

Page 43: ... 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 44: ... 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 Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check eng...

Page 45: ...he dis play Please see 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...

Page 46: ...V 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 45 1 Gear Display This area displays gear shifter posi tion H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 2 Information Display This area displa...

Page 47: ...tions 8 Service Reminder Display A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehi cle should be brought to your dealer for scheduled maintenance See page 46 for resetting instructions 9 Under Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is ...

Page 48: ...n held down for approximately one half second The reverse override but ton also acts as the SELECT but ton when pressed and released quickly The transmission cannot be in reverse when using the override but ton as a MODE or SELECT button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Speed Display Use the MODE button to toggle through the spee...

Page 49: ...h the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new clock format either 24 hour or 12 hour Release the button 4 New settings remain until changed using the same procedure Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meters record the distance tra...

Page 50: ...utton to advance the hours to the desired setting including OFF When the digits stop flashing the interval has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1 Select the Hour Meter Mode 2 Press and hold the mode button on the instrument cluster until the hour display flashes Release the button 3 Press and release the SELECT button to advance the hours 4 After...

Page 51: ...ctive codes are stored in the history of the unit Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the transmission in PARK 2 Press and release the SELECT button until the flashing check engine warning indicator appears in the display 3 A set of two numbers will also appear in the display The 2 6 digit ...

Page 52: ...le Position 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 Crankshaft Position Sensor Circuit Fault 636 8 Gear Se...

Page 53: ... 6 Steering Torque Sensor 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 5202...

Page 54: ...523 3 Signal fault 523 2 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...

Page 55: ...ring Excessive Current Error 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 Sho...

Page 56: ... illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following components in the front compartment Radiator cap Brake fluid reservoir ADC fluid reservoir Battery Coolant recovery bottle cap Electrical fuse relay components Latches ADC Fluid Reservoir Brake Fluid Reservoir Radiator Cap Coolant Bottle Cap Electrical Fuse Relay Battery ...

Page 57: ...s of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 31 Always exercise extreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 77 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4...

Page 58: ...pect lubricate if necessary 76 Steering Ensure free operation Tires Inspect condition and pressure 92 Wheels fasteners Inspect ensure fastener tightness 92 94 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 31 77 Coolant level Ensure proper level 87 88 Coolant hoses Inspect for leaks Throttle Ensure proper operation 26 110 Indicator lights switches Ensure oper...

Page 59: ... headlamps promptly 8 Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars 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 size and type of tires specified for yo...

Page 60: ...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 61: ... engine starts 7 If the engine does 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 ...

Page 62: ... handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 63: ...r in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This tech nique alters the balance of trac tion between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turni...

Page 64: ... 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 65: ...ways check the terrain carefully 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 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 sharp drop or another ...

Page 66: ...verturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Shift body weight uphill 3 Keep your feet on the footrests 4 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately ...

Page 67: ... or descending a hill See page 33 2 Avoid steep hills 25 maximum 3 Shift body weight uphill 4 Drive straight downhill 5 Slow down Excessive speed when traveling downhill can cause loss of control 6 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol ...

Page 68: ...hicle or on the left if the vehi cle is pointing straight uphill 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 7 Lock the parking brake and remount the vehicle from the uphill side keeping body weight up...

Page 69: ...rcase oil ADC 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 restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 104 then see your dealer for...

Page 70: ...ting in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards 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 ...

Page 71: ... 6 Never open the throttle suddenly 7 Do not use the override button 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 cause fuel to build in ...

Page 72: ... 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 securely fasten the load and operate with extra cau...

Page 73: ...argo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator 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 ...

Page 74: ... 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 75: ...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 com ponents are set at the factory for optimal performance and are not adjustable The...

Page 76: ...orm these operations Maintenance 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 idl...

Page 77: ...services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride See Pre Ride Checklist on page 54 Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pr...

Page 78: ...ansmission oil 25 H Monthly 250 400 Inspect level X General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 500 800 Inspect lubricate n Steering 50 H 6 M 500 800 Lubricate X Front suspension 50 H 6 M 500 800 Lubricate X Rear suspension 50 H 6 M 500 800 Lubricate nE Throttle Cable ETC Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary ...

Page 79: ...iring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc n Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts n Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed n Brake fluid 200 H 24 M 2000 3200 Change every two years X n ADC fluid 200 H 24 M 2000 3200 Change every two years Spark ...

Page 80: ...t lbs 20 23 Nm Page 77 850 Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 12 ft lbs 16 Nm Page 77 Transmission Oil AGL PLUS Transmission Fluid 32 oz 950 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm Page 80 Demand Drive Fluid Front Gearcase Demand Drive Plus Fluid 9 3 oz 275 ml 8 10 ft lbs 11 14 Nm 11 ft lbs 15 Nm Page 81 Rear Gearcase Oil ATV Angle Drive Fluid or GL5 80 90 weight ge...

Page 81: ...ng 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 dip stick Wipe it dry with a clean cloth...

Page 82: ...engine Allow it to warm up at idle for two to three min utes 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 should be...

Page 83: ... good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing sur face 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 Sto...

Page 84: ...n plug is located on the bottom rear of the gearcase Oil Check 1 Remove the footwell see page 91 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 specification 5 Reinstall the footwell Oil Change 1 Remove the footwell 2 Place a drain pan under the gearcase Remove the drain ...

Page 85: ...vice 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 sur face Remove the fill plug Check the fluid level 2 Add the...

Page 86: ...the fluid level between the minimum and maximum marks on the reservoir See page 125 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 Remove the front rack 2 View the fluid level in the reservoir 3 If the level is below the minimum mark remove the cap and add the recommended fluid 4 Reinstall the c...

Page 87: ...eeder valves 6 Slowly loosen one of the bleeder valve screws turn counter clock wise 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 a...

Page 88: ... products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Maintain the fluid level at the bottom of the fill hole threads Do not overfill Oil Check 1 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 overf...

Page 89: ... 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks 8 Dispose of used oil properly ...

Page 90: ...ng heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure 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 recommend...

Page 91: ... cap under the front storage com partment 1 View the fluid level in the bottle 2 If the level is low remove the front rack 3 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 4 Reinstall the cap 5 Reinstall the front rack Recovery Bottle Cap Maximum Mark Minimum Mark ...

Page 92: ...un dry check the 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 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add cool ant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pr...

Page 93: ...or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill 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 28 2 Check the brake system for fluid leaks 3 Check the brakes...

Page 94: ...tands 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 5 mm more than the front measurement on each side of the vehicle to obtain the recommended 0 to 1 8 0 3 mm toe out alignment 5 Repeat the measure...

Page 95: ...asteners 3 Remove the seat Side Panel Footwell Removal Remove the seat before removing a side panel 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 Plastic Rivet Torx Head Screw ...

Page 96: ...in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 126 for recom mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less WARNING 1 8 3 mm...

Page 97: ...your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING 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 ...

Page 98: ...hicle 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 loos ened for maintenance service Wheel Type Nut Type Nut Torque Aluminum ...

Page 99: ...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 Screws ...

Page 100: ...have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Remove the front rack 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 Reinstall the front rack Fuse Box SPORTSMAN 550 EPS SPORTSMAN 850 XP EPS SPORTSMAN 550 SPORTSMAN 850 XP ...

Page 101: ...in leaves a residue 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 speedom eter harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 3 Unplug the headlamp from the wiring harness Be sure ...

Page 102: ...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 103: ...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 104: ...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 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 ...

Page 105: ... the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the head lamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light assembly 2 Turn the lamp counterclockwise to remove it 3 Install the new lamp 4 Reinstall the harness connector 5 Test the light for proper opera tion Harness Tai...

Page 106: ...n after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 103 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 counterclockwise to remove it 3 Rev...

Page 107: ...ngine 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 no...

Page 108: ... is present dry the air box and replace the filter with a new filter 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 proce dure NOTICE Serious damage can occur after immersion if fluids are not changed promptly See your dealer as recomme...

Page 109: ...purge accumulated 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 car bon 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 ...

Page 110: ...loads on components The PVT system rotates at high speeds creating large 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 See your dealer as outlined in the owner s manu...

Page 111: ...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 112: ...PARK 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 trans mission to the lowest available 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 Con...

Page 113: ... of the adjuster 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...

Page 114: ...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 the throttle arm...

Page 115: ...ease see your POLARIS 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...

Page 116: ...n of the battery 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 termi nals with diele...

Page 117: ...are properly routed Cables should be safely tucked away at the front and rear of the battery 8 Install the front rack Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintai...

Page 118: ...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 119: ...mps 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 least 20 ...

Page 120: ...s to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den 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 121: ...r 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 122: ...ntenance Chart beginning on page 73 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for...

Page 123: ...ARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 95 2 Clean the air box Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 73 Battery Maintenance...

Page 124: ...ps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for...

Page 125: ... Shift the 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 contro...

Page 126: ...ark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap...

Page 127: ...inked 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 Electronic throttle control 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 Kin...

Page 128: ...oose ignition connections 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 Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen a...

Page 129: ...7 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lu...

Page 130: ... weight not to exceed 240 lbs 109 kg Hitch Towing Rating 1500 lbs 680 4 kg Unbraked Trailer Towing Capacity 1786 lbs 810 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 ES550PLE Displacement 549 7 cc Bore x Stroke 96 6 x 75 Alternator Output 49...

Page 131: ...gle 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 LCD LED Digital Analog EPS Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6...

Page 132: ...owing 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 1 S...

Page 133: ...le 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 LCD LED XP Digital Analog XP EPS Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 180...

Page 134: ...PORTSMAN 400 2008 2009 2010 2011 ___MH50__ SPORTSMAN 500 HO 2008 2009 2010 2011 ___DH50__ SPORTSMAN 500 HO TOURING 2010 2011 ___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009 2010 2011 ___TN55__ ___TX55__ SPORTSMAN 550 X2 2010 2011 ___DN55__ ___DX55__ SPORTSMAN 550 TOURING 2010 2011 ___MN76__ SPORTSMAN 800 2008 2009 2010 2011 ___CL76__ ___CF76__ SPORTSMAN 800 6X6 2009 2010 2011 ___ZN85__ ___ZX85__ SPORTS...

Page 135: ...gh a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not ...

Page 136: ... parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effectiv...

Page 137: ...repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT...

Page 138: ...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 If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engin...

Page 139: ...m any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence...

Page 140: ...ou receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assig...

Page 141: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followi...

Page 142: ...d by a defect in material or workman ship 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 altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or...

Page 143: ... 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 ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 144: ...140 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 145: ...141 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 146: ...ant Radiator 88 Cooling System 86 88 Crankcase Emission Control System 71 D Demand Drive Fluid 81 Diagnostic Codes 550 EPS 48 49 Diagnostic Codes 850 XP EPS 50 51 Disengaging Active Descent Control 33 Display Units Standard Metric 38 45 Drive Belt Wear Burn 121 Drivetrain Break In 53 Driving Downhill 63 Driving in Reverse 67 Driving on a Sidehill 62 Driving on Slippery Surfaces 60 Driving Over Obs...

Page 147: ... Replacement 97 Headlight Switch 24 Helmet 8 High Beam Adjustment 98 High Range Use 108 I Idle RPM Adjustment 110 Immersion 104 Indicator Lamps 35 Instrument Cluster 34 51 K Key Switch 25 K Turn 64 L Lights 97 101 Headlight Housing 100 Headlight Lamp 97 High Beam Adjustment 98 Low Beam Adjustment 99 Lower Headlamp 101 Taillight Brakelight 101 Low Beam Adjustment 99 Low Range Use 108 Lower Headlamp...

Page 148: ... Arrestor 105 Spark Plug Inspection 102 103 Spark Plug Recommendations 102 Spark Plugs 102 103 Speedometer 34 Spring Adjustment Shock 109 Starting the Engine 57 S Steering Assembly 86 90 Storage 116 119 Storage Tips 118 119 Switches 4X4 Switch 24 32 Engine Stop Switch 25 Headlight Switch 24 Main Key Switch 25 Mode Switch 24 Reverse Override Switch 24 Stop Switch 25 T Taillight 101 Throttle Body Ad...

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Polaris Sportsman 850 XP, Owner'S Manual

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