Polaris Sportsman Touring 850 2021 Owner's Manual
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Polaris Sportsman Touring 850 2021 Owner's Manual

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2021
For Maintenance and Safety
OWNER'S
MANUAL
Sportsman Touring 850
Sportsman Touring XP 1000
Read this manual carefully. It contains important safety
information. This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
WARNING

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  • Page 1 2021 For Maintenance and Safety OWNER’S MANUAL Sportsman Touring 850 Sportsman Touring XP 1000 WARNING Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR® code with your smartphone. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it...
  • Page 3 2021 Owner’s Manual Sportsman Touring 850 Sportsman Touring XP 1000...
  • Page 4 N.A. Duro® is a registered trademark of HWA Fong Rubber (USA) Inc. DBA Duro Tire & Wheel Corp. BOSCH® is registered to Robert Bosch GmbH. Unless noted, trademarks are the property of Polaris Industries, Inc. Copyright 2020 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 WELCOME...

  • Page 7: Table Of Contents

    Specifications ....133 POLARIS Products ....139 Troubleshooting ....141 Warranty .

  • Page 9: Introduction

    WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.
  • Page 10 INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
  • Page 11 INTRODUCTION EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
  • Page 12 MANUFACTURER B1 Gauge Bluetooth WT12 Silicon Labs Hereby, Polaris Industries Inc. declares that the above radio equipment is in compliance with EU Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address:...
  • Page 13 Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 15: Safety

    You should review this information on a regular basis. If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887- 2887 or visit www.atvsafety.org.
  • Page 16 HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
  • Page 17 SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.
  • Page 18 SAFETY USING ALCOHOL OR DRUGS Never consume alcohol or drugs before or while operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
  • Page 19 SAFETY EXPOSURE TO EXHAUST CAUTION 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. Operate this vehicle only outdoors or in well-ventilated areas. PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eye wear...
  • Page 20 SAFETY OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience. PHYSICAL CONTROL OF THE VEHICLE Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.
  • Page 21 SAFETY JUMPS AND STUNTS Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills.
  • Page 22 SAFETY STALLING WHILE CLIMBING A HILL Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. • Always maintain a steady speed when climbing a hill. • Always engage ADC mode (if equipped) before ascending or descending a hill. If ADC mode is not equipped, apply AWD mode before ascending or descending a hill.
  • Page 23 SAFETY OPERATING ON STEEP HILLS Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the ATV or for your abilities. Never operate this ATV on hills steeper than 25 degrees. OPERATING ON SLIPPERY TERRAIN Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of...
  • Page 24 SAFETY IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
  • Page 25 SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
  • Page 26 SAFETY IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. • Never exceed the stated load capacity for this vehicle. •...
  • Page 27 SAFETY HOT EXHAUST SYSTEMS WARNING 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.
  • Page 28 SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.
  • Page 29 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. General Warning Clutch Warning (Under Seat)
  • Page 30 SAFETY GENERAL WARNING WARNING Improper use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: •...
  • Page 31 SAFETY PASSENGER SAFETY WARNING WARNING To reduce the risk of SEVERE INJURY or DEATH: • NEVER CARRY MORE THAN ONE PASSENGER • NEVER RIDE AFTER USING DRUGS OR ALCOHOL • NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.
  • Page 32 SAFETY RACK/BOX WARNING WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg) TIRE PRESSURE/LOAD WARNING WARNING Improper tire pressure or overloading can cause loss of control.

  • Page 33: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS SWITCHES NOTE Image below is for reference only. Your model may differ slightly. Ignition Switch Headlight Switch Engine Stop Switch Drive Line Switch Mode/Reverse Override Switch Auxiliary Outlet IGNITION SWITCH/LIGHT SWITCH Use the ignition switch to start the engine. The key can be removed from the switch when it is in the OFF position.
  • Page 34 FEATURES AND CONTROLS AWD MODE SWITCH (IF EQUIPPED) The AWD switch controls the All Wheel Drive (AWD) system. Use this switch to engage AWD or 2X4. The vehicle automatically engages AWD when operating in reverse if the drive mode is set to AWD. ENGINE STOP SWITCH Move the stop switch either left or...
  • Page 35 Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise.
  • Page 36 Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your POLARIS dealer or other qualified service facility for proper diagnosis and repairs.
  • Page 37 FEATURES AND CONTROLS MASTER CYLINDER/BRAKE FLUID WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 38 FEATURES AND CONTROLS PARKING BRAKE LOCKING THE PARKING BRAKE WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating. 1. Place the transmission in PARK. 2.
  • Page 39 FEATURES AND CONTROLS AUXILIARY FOOT BRAKE WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
  • Page 40 FEATURES AND CONTROLS AUTOMATIC TRANSMISSION GEAR SELECTOR The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.
  • Page 41 FEATURES AND CONTROLS FUEL CAP NOTICE Never use fuel blends with more than 10% ethanol. Engine damage could occur. 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 minimum pump octane number of 87=(R+ M)/2 octane.
  • Page 42 FEATURES AND CONTROLS FRONT COMPARTMENT REMOVAL Remove the front compartment from the vehicle to access the coolant bottle, radiator cap, fuse box, and battery. To remove the front compartment, do the following: 1. Unlock both front rack latches (previous page), and open the front rack.
  • Page 43 POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.
  • Page 44 FEATURES AND CONTROLS ALL WHEEL DRIVE SYSTEM The All Wheel Drive system is controlled by the Drive Line switch. ADC 4X4 MODE When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 45 FEATURES AND CONTROLS ACTIVE DESCENT CONTROL (ADC) SYSTEM The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. ENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically engage when all four of the following conditions occur:...
  • Page 46 FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE Features vary by model. Your ATV is equipped with one of three available gauge variants, (1) a standard gauge (no Bluetooth® functionality), (2) a Bluetooth®-equipped gauge, and (3) a no-button gauge. If your gauge is equipped with Bluetooth®, the Bluetooth® icon will briefly display in the upper right corner of the gauge at start-up.
  • Page 47 All segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the Service preset service interval has been reached. Your POLARIS Indicator dealer can provide scheduled maintenance. See page 56 for more information.
  • Page 48 EPS Warning (if This indicator illuminates when a fault equipped) has occurred in the EPS system. Your authorized POLARIS dealer can assist. EPS operation is possible with key on/ engine off for up to 5 minutes. Engine Hot This lamp illuminates to indicate an overheated engine.
  • Page 49 FEATURES AND CONTROLS INDICATOR ICON FUNCTION Chassis Fault If applicable. Performance On models equipped with a low speed Limited limiter, indicator light will remain on when low speed limiter is active. Lamp illuminates when Geofencing or max speed is enabled. Lamp remains off when Geofencing and max speed settings are disabled.
  • Page 50 FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 DISPLAY AREA 2 FUNCTION Odometer The vehicle’s odometer reading will be displayed. Engine The vehicle Engine Temperature will be displayed. Temperature Trip 1 The vehicle Trip 1 mileage will be displayed.
  • Page 51 FEATURES AND CONTROLS OPTIONS MENU Press and hold the MODE button to enter the Options Menu. OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Units - Distance Select MPH or KPH Units - Temp Select between °F and °C Clock Select between 12H or 24H, and set...
  • Page 52 FEATURES AND CONTROLS DIAGNOSTIC CODE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. To access the Diagnostic Code Screen, do the following: 1. Press and hold the MODE button to enter the Options Menu.
  • Page 53 FEATURES AND CONTROLS NOTICE When the gauge is displaying a fault code, the warning telltale (check engine or EPS) will blink to indicate which controller set the fault code. 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
  • Page 54 FEATURES AND CONTROLS UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 55 FEATURES AND CONTROLS CLOCK (IF EQUIPPED) 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 56 FEATURES AND CONTROLS BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Color” from the Options Menu by pressing the MODE button.
  • Page 57 FEATURES AND CONTROLS BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Level” from the Options Menu by pressing the MODE button.
  • Page 58 FEATURES AND CONTROLS SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 59 2. Access the options menu on the vehicle’s digital gauge and select BT PAIR. The Bluetooth® icon will begin to blink. 3. Find and select Polaris Gauge on your phone’s Bluetooth® menu or prompt. Pairing should occur momentarily. Pairing mode will continue for up to 90 seconds or if you exit the BT PAIR menu.

  • Page 61: Operation

    VEHICLE BREAK-IN PERIOD The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
  • Page 62 OPERATION ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See the Oil Check section for reference. Add the recommended oil as needed to maintain the oil level in the safe operating range.
  • Page 63 OPERATION PRE-RIDE CHECKLIST Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. ITEM REMARKS PAGE page 34...
  • Page 64 OPERATION SAFE OPERATION PRACTICES 1. Complete the recommended safety training before operating this vehicle. Visit www.atvsafety.org for safety courses and riding tips. See page 13 for details. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
  • Page 65 Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
  • Page 66 OPERATION NOTICE Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. COLD WEATHER OPERATION If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase.
  • Page 67 OPERATION TURNING THE VEHICLE Both rear wheels drive equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2.
  • Page 68 OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 69 OPERATION DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.
  • Page 70 OPERATION DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or rollover. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill.
  • Page 71 OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. Never operate in TURF mode while operating on a hill or other irregular terrain. 2.
  • Page 72 OPERATION DRIVING ON A SIDEHILL (SIDEHILLING) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.
  • Page 73 If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section of this manual, and take the vehicle in for service at the first opportunity.
  • Page 74 OPERATION DRIVING IN REVERSE Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.
  • Page 75 OPERATION PARKING ON AN INCLINE Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
  • Page 76 OPERATION STOPPING THE ENGINE 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the key to the OFF position. 4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.
  • Page 77 OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 78 ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use.
  • Page 79 OPERATION MAXIMUM TOWING CAPACITIES Do not exceed maximum towing capacities. Avoid towing on inclines. 850 MODELS XP 1000 MODELS Maximum Towed Load 1500 lbs. (680 kg) 1500 lbs. (680 kg) (Level Ground) Maximum Vertical Hitch 150 lbs. (68 kg) 150 lbs. (68 kg) Weight...

  • Page 81: Winch Guide

    WINCH GUIDE WINCH GUIDE WINCH SAFETY These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 82 WINCH GUIDE 12. If winching at an angle is unavoidable, follow these precautions: a. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
  • Page 83 WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 84 Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer.
  • Page 85 WINCH GUIDE • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead. • If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation.
  • Page 86 WINCH GUIDE c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. d.
  • Page 87 WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 88 Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
  • Page 89 WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 90 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

  • Page 91: Emission Control Systems

    EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.

  • Page 93: Maintenance

    PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
  • Page 94 DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized Polaris dealer or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log.
  • Page 95 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) ITEM HOURS CALENDAR REMARKS Air Filter (main Weekly Inspect; replace as needed element) Monthly Inspect periodically Brake Pad Wear 10 H (160) Battery Monthly Check terminals; clean; test 20 H (320) Turn key on to pressurize fuel pump, Fuel System Monthly 20 H...
  • Page 96 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) ITEM HOURS CALENDAR REMARKS Rear gearcase oil Change fluid 100 H 12 M (1000) Change fluid Transmission oil 100 H 12 M (1000) Cycle key to pressurize fuel pump; Fuel System check for leaks at fill cap, fuel lines/ 100 H 12 M (1000)
  • Page 97 U-Joint Grease fittings (3 pumps maximum) every 500 miles, before long Shaft Yoke Grease periods of storage, or after pressure washing or submerging. A-Arms, POLARIS All- Grease fittings after extreme use or if suspension becomes Front and Season squeaky. Rear...
  • Page 98 POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 99 MAINTENANCE OIL LEVEL Check the oil level when the engine is cold. Never check the oil with the engine running. 1. Position the vehicle on a level surface. 2. Access the oil dipstick and fill tube from the left side of the ATV .
  • Page 100 9. Remove the oil filter cover plate by loosening the three screws holding into place. 10. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counter- clockwise to remove it.
  • Page 101 MAINTENANCE 11. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 13.
  • Page 102 MAINTENANCE TRANSMISSION OIL Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. See the Fluid Recommendation table for capacities and plug torques. Maintain the oil level at the bottom of the fill plug hole .
  • Page 103 • ADC is the primary mode of all-wheel-drive operation If the front gearcase is making excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service.
  • Page 104 REAR GEARCASE OIL Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart. See page 139 for the part numbers of POLARIS products. The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.
  • Page 105 Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See...
  • Page 106 3. Using a funnel, slowly add coolant through the radiator filler neck. 4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
  • Page 107 MAINTENANCE BRAKES HAND BRAKE The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops.
  • Page 108 MAINTENANCE SEAT REMOVAL 1. Locate the seat removal latch in the center of the seat’s rear. 2. Pull on the latch handle to disengage the seat from the vehicle’s frame. 3. Remove the seat. TIRES WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.
  • Page 109 MAINTENANCE 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. Your authorized dealer can assist. 5.
  • Page 110 1/4–1/2 inch (6–12 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service.
  • Page 111 MAINTENANCE AIR FILTER INSTALLATION 1. Remove the seat, the air box cover strap, and remove the air box cover. 2. Remove the filter. 3. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 4.
  • Page 112 MAINTENANCE HEADLIGHT LAMP REPLACEMENT When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin 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. CAUTION Hot components can cause burns to skin.
  • Page 113 MAINTENANCE 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall . Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 114 MAINTENANCE 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. Apply dielectric grease to the socket and install the new lamp. 4. Reinstall the harness connector 5.
  • Page 115 Refer to the specifications section for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. PLUG CONDITION TORQUE SPECIFICATION New Spark Plug...
  • Page 116 Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
  • Page 117 MAINTENANCE SPARK ARRESTER WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.
  • Page 118 • See your POLARIS dealer, or other qualified person, for service and repair assistance. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 119 MAINTENANCE The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.). WHEN TO USE LOW RANGE AND HIGH RANGE CONDITION RANGE TO USE Operating at speeds less than 7 MPH...
  • Page 120 (black) cable last. Your ATV is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.
  • Page 121 Check battery voltage each month during storage and recharge as needed to maintain a full charge. POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging once a month using the battery tender port .
  • Page 122 MAINTENANCE The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. WARNING An overheated battery may explode, causing severe injury or death.
  • Page 123 It is important to identify the type of battery installed in the vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life. All Polaris ORV models include either a Conventional battery or a Low Maintenance battery. CONVENTIONAL BATTERY •...
  • Page 124 LEAD ACID CONVENTIONAL / DRY SHIPPED AGM BATTERY BEST PRACTICES Some Polaris ORV models include either a Lead Acid Conventional battery or a Dry Shipped Absorbed Glass Mat (AGM) battery. See the Service Manual for procedures on how to activate, charge, maintain, and test a Lead Acid Conventional or Dry Shipped AGM battery.
  • Page 125 CHARGING • Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP (PN 2830438) charger, which can be ordered through your normal parts channel. • Nominal voltage is 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.
  • Page 126 LOW MAINTENANCE BATTERY BEST PRACTICES Some Polaris ORV models include either a Lead Acid or Absorbed Glass Mat (AGM) Low Maintenance battery. See the Service Manual for procedures on how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.
  • Page 127 AGM LOW MAINTENANCE BATTERIES CHARGING • Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP (PN 2830438) charger, which can be ordered through your normal parts channel. • Nominal voltage is 12.6–12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.
  • Page 128 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.
  • Page 129 THROTTLE BODY/IDLE RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service facility for adjustment. THROTTLE CABLE FREEPLAY 1. Remove the four cover screws from the right handlebar control and remove the cover.
  • Page 130 6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your POLARIS dealer or other qualified service facility for service.
  • Page 131 POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS •...
  • Page 132 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.
  • Page 133 STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 135: Specifications

    SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPORTSMAN TOURING 850 Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories) Dry Weight 820 lbs. (372 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 7.1 oz.
  • Page 136 Spark Plug Type / Gap REA6MC / .035 in. (0.9 mm) Lubrication System Pressurized Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm) travel...
  • Page 137 SPECIFICATIONS CLUTCHING DRIVE DRIVEN SHIFT ALTITUDE CLUTCH CLUTCH HELIX WEIGHT SPRING SPRING 0-1800 23-58 Black/White (0-6000) PN 5632218 42-140 64-66FR 0516_140/ Meters (Feet) BA45 Purple 1800-3700 PN 3235971 PN 7043805 24-56 PN 7044511 (6000-12000) PN 5632394 SPECIFICATIONS SPORTSMAN TOURING XP 1000 Maximum Weight Capacity 575 lbs.
  • Page 138 Spark Plug Type / Gap AUTOLITE® 5682 / .030 in. (0.76 mm) Lubrication System Pressurized Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm) travel...
  • Page 139 SPECIFICATIONS SPORTSMAN TOURING XP 1000 Brake, Parking Hydraulic lock, all wheel Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt) Taillights 12v/7 watts Brake Light 12v/7 watts Instrument Cluster Digital CLUTCHING DRIVE DRIVEN SHIFT ALTITUDE CLUTCH...

  • Page 141: Polaris Products

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

  • Page 143: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground Drive at a higher speed or use low range more frequently. speed (3-7 MPH) Warm the engine at least 5 minutes.
  • Page 144 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel...
  • Page 145 TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or Set gap to specs or replace plug heat range ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug...
  • Page 146 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent Inspect and replace line Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your authorized dealer can assist wires...
  • Page 147 TROUBLESHOOTING DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground:The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • Page 148 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Injector 1 (MAG) (SDI Driver Circuit Open/ Part Load) Grounded Driver Circuit Short to Driver Circuit Grounded Ignition Coil Primary Driver Circuit Short to 1268 Driver 1 (MAG) Fuel Pump Driver Driver Circuit Open/ 1347 Circuit Grounded Driver Circuit Short to...
  • Page 149 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Driver Circuit 520208 Grounded All Wheel Drive Driver Circuit Open/ 520207 Control Grounded Driver Circuit Short to 520207 Driver Circuit 520207 Grounded System Power Voltage Too High Voltage Too Low Throttle Safety Signal Voltage Too High 520194 Voltage Too Low 520194...
  • Page 150 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Abnormal Rate Of Change Received Network Data In Error System Power Data Valid But Above Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Engine Speed...
  • Page 151 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY EPAS Inverter Data Valid But Above Temperature Normal Operational 520225 Range - Most Severe Level Data Valid But Above Normal Operating 520225 Range - Moderately Severe Level EPAS Data Erratic, Communications Intermittent Or 520226 Receive Data Error Incorrect...

  • Page 153: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.
  • Page 154 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 155 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 156 IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 157 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
  • Page 158 U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 159 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...
  • Page 160 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

  • Page 161: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 163 2X4 Mode ....... . 42 Crankcase Emission Control 4X4 Mode ....... . 42 System .
  • Page 164 Extreme Use Battery ....41 Inspect and Lubricate ....130 Eye Protection .
  • Page 165 Starting the Engine ....63 Polaris Products ..... . 139 Steering Assembly.
  • Page 166 Storage Area ......131 Wheel Removal..... . . 107 Storage Compartment .
  • Page 168 • make sure passenger reads and understands this label and passenger safety label SCAN CODE FOR PRDUCT AND SAFETY INFORMATION. FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Inc. Part No. 9931376 Rev 01...

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