Owners Manual
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Operation is an adult vehicle only. This is prohibited for Maintenance and Safety Sportsman® 850 Sportsman® 850 SP Sportsman® 850 High Lifter Sportsman® Touring 850 Sportsman® Touring 850 SP Sportsman® XP 1000 Sportsman® XP Touring 1000 Sportsman® XP 1000 High Lifter Read this manual carefully. Owner's Manual for those under 16 years of age. It contains important safety information.
Operation is an adult vehicle only. This is prohibited for Maintenance and Safety Sportsman® 850 Sportsman® 850 SP Sportsman® 850 High Lifter Sportsman® Touring 850 Sportsman® Touring 850 SP Sportsman® XP 1000 Sportsman® XP Touring 1000 Sportsman® XP 1000 High Lifter Read this manual carefully. Owner's Manual for those under 16 years of age. It contains important safety information.
Owners Manual
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2016 Owner's Manual Sportsman® 850 Sportsman® 850 High Lifter Sportsman® 850 SP Sportsman® Touring 850 Sportsman® Touring 850 SP Sportsman® XP 1000 Sportsman® XP 1000 High Lifter Sportsman® XP Touring 1000 1
2016 Owner's Manual Sportsman® 850 Sportsman® 850 High Lifter Sportsman® 850 SP Sportsman® Touring 850 Sportsman® Touring 850 SP Sportsman® XP 1000 Sportsman® XP 1000 High Lifter Sportsman® XP Touring 1000 1
Owners Manual
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... Locations Rack/Box Warning Tire Pressure/Load Warning Rack/Box Warning Clutch Cover Warning (under belt-clutch guard. Tow only from tow hooks or hitch. • Maximum Rack Loads: Front 0 lbs. (0 kg) Rear 75 lbs. (34 kg) Clutch Cover Warning (All Models) WARNING • Moving parts hazard under seat) Hitch Capacity Label Rack/Box Warning (All Models Except High Lifter) WARNING • DO NOT TOW FROM RACK OR BUMPER. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. VERTICAL WEIGHT: 150...
... Locations Rack/Box Warning Tire Pressure/Load Warning Rack/Box Warning Clutch Cover Warning (under belt-clutch guard. Tow only from tow hooks or hitch. • Maximum Rack Loads: Front 0 lbs. (0 kg) Rear 75 lbs. (34 kg) Clutch Cover Warning (All Models) WARNING • Moving parts hazard under seat) Hitch Capacity Label Rack/Box Warning (All Models Except High Lifter) WARNING • DO NOT TOW FROM RACK OR BUMPER. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. VERTICAL WEIGHT: 150...
Owners Manual
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... than seven miles per hour for extended periods and when operating uphill at a slow speed. 37 When the engine is left unattended, always place the transmission in PARK and lock the parking brake. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is moving could cause transmission damage. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is located...
... than seven miles per hour for extended periods and when operating uphill at a slow speed. 37 When the engine is left unattended, always place the transmission in PARK and lock the parking brake. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is moving could cause transmission damage. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is located...
Owners Manual
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... on the rear rack) and mounted as low as possible. 3. On models equipped with a front rack/box and a rear rack, cargo weight should be affected. 77 Balance, handling and control may be evenly distributed (1/3 on the front rack and 2/3 on warning labels and in 2/3 the specifications section of 1/3 this manual. 2. All 2-Up Models: NEVER exceed 50 MPH (80 km/h) while carrying a passenger. 5. All Models Except High Lifter: NEVER exceed...
... on the rear rack) and mounted as low as possible. 3. On models equipped with a front rack/box and a rear rack, cargo weight should be affected. 77 Balance, handling and control may be evenly distributed (1/3 on the front rack and 2/3 on warning labels and in 2/3 the specifications section of 1/3 this manual. 2. All 2-Up Models: NEVER exceed 50 MPH (80 km/h) while carrying a passenger. 5. All Models Except High Lifter: NEVER exceed...
Owners Manual
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Avoid towing on hitch) must not exceed the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on inclines. 850 SP Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 1500 lbs. (680 kg) 150 lbs. (68 kg) XP 1000 1500 lbs. (680 kg) 150 lbs. (68 kg) 78 NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in...
Avoid towing on hitch) must not exceed the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on inclines. 850 SP Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 1500 lbs. (680 kg) 150 lbs. (68 kg) XP 1000 1500 lbs. (680 kg) 150 lbs. (68 kg) 78 NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in...
Owners Manual
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Break-in oil level check Break-in oil level check Break-in oil and filter change Ź Demand drive fluid (extreme use) Ź Demand drive fluid Ź Rear gearcase oil Ź Transmission oil Ź General lubrication Shift linkage D Steering Ź Front suspension Ź Rear suspension D Throttle Cable/ Throttle Release Switch Throttle Body Intake Duct Drive belt Cooling system Ź Radiator Ź Cooling hoses 25 H 25 H 1M 1M 250 (400) 25 H 25 H 25 H 50 H 50 H 50 H 50 H 50 H 50 H 1M 1M 1M 3M...
Break-in oil level check Break-in oil level check Break-in oil and filter change Ź Demand drive fluid (extreme use) Ź Demand drive fluid Ź Rear gearcase oil Ź Transmission oil Ź General lubrication Shift linkage D Steering Ź Front suspension Ź Rear suspension D Throttle Cable/ Throttle Release Switch Throttle Body Intake Duct Drive belt Cooling system Ź Radiator Ź Cooling hoses 25 H 25 H 1M 1M 250 (400) 25 H 25 H 25 H 50 H 50 H 50 H 50 H 50 H 50 H 1M 1M 1M 3M...
Owners Manual
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... to pressurize fuel pump; replace worn parts 1000 (1600) Inspect; replace as needed Remarks Ź Engine mounts Exhaust muffler/ pipe D Spark plug Ź Wiring 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M D Clutches (drive and driven) D Front wheel bearings D Brake fluid Suspension bushings Spark arrester Ź Coolant D Valve clearance D Toe adjustment Headlight aim 100 H 100 H 200 H 250 H 300 H 1000 H 12 M 12 M 24 M 24 M 36 M 60 M - 95 replace if necessary 3000 (4800) Clean out 10000 (16000) Replace coolant Inspect...
... to pressurize fuel pump; replace worn parts 1000 (1600) Inspect; replace as needed Remarks Ź Engine mounts Exhaust muffler/ pipe D Spark plug Ź Wiring 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M D Clutches (drive and driven) D Front wheel bearings D Brake fluid Suspension bushings Spark arrester Ź Coolant D Valve clearance D Toe adjustment Headlight aim 100 H 100 H 200 H 250 H 300 H 1000 H 12 M 12 M 24 M 24 M 36 M 60 M - 95 replace if necessary 3000 (4800) Clean out 10000 (16000) Replace coolant Inspect...
Owners Manual
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...) 112 Lower the vehicle to come off during operation, which could cause a tire to the ground. 6. WARNING! Place the transmission in an accident or overturn. Loose nuts could result in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Lock the parking brake. 3. Wheel Nut Torque Specifications Check the wheel nut...
...) 112 Lower the vehicle to come off during operation, which could cause a tire to the ground. 6. WARNING! Place the transmission in an accident or overturn. Loose nuts could result in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Lock the parking brake. 3. Wheel Nut Torque Specifications Check the wheel nut...
Owners Manual
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.... 5. Install the new lamp. Pull the pod cover forward. Non-SP/XP: Remove the five (5) headlight pod screws. Turn the lamp counter-clockwise to remove it with bare fingers. Always make sure lights are adjusted properly for best visibility. Oil from the speedometer. Lift the pod cover and disconnect the speedometer harnesses from your skin leaves a residue, causing a hot...
.... 5. Install the new lamp. Pull the pod cover forward. Non-SP/XP: Remove the five (5) headlight pod screws. Turn the lamp counter-clockwise to remove it with bare fingers. Always make sure lights are adjusted properly for best visibility. Oil from the speedometer. Lift the pod cover and disconnect the speedometer harnesses from your skin leaves a residue, causing a hot...
Owners Manual
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... the center of the headlight pod. The adjustment screw is located on Adjustment the right side of the headlight and make the adjustment. 1. Start the engine. Include rider weight on the wall. Adjust the headlamp to high beam. 4. Observe the headlight aim on the seat when measuring. 5. Screw To adjust the beam, loosen the screw. MAINTENANCE Lights High Beam Adjustment (Headlight Pod) The headlight...
... the center of the headlight pod. The adjustment screw is located on Adjustment the right side of the headlight and make the adjustment. 1. Start the engine. Include rider weight on the wall. Adjust the headlamp to high beam. 4. Observe the headlight aim on the seat when measuring. 5. Screw To adjust the beam, loosen the screw. MAINTENANCE Lights High Beam Adjustment (Headlight Pod) The headlight...
Owners Manual
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SPECIFICATIONS SPORTSMAN 850 / 850 SP Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius (unloaded) Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Ignition Timing Idle RPM Throttle Body/Size Spark ...
SPECIFICATIONS SPORTSMAN 850 / 850 SP Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius (unloaded) Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Ignition Timing Idle RPM Throttle Body/Size Spark ...
Owners Manual
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SPECIFICATIONS SPORTSMAN XP 1000 Maximum Weight Capacity 575 lbs. (261 kg) XP 1000 275 lbs. (125 kg) High Lifter (includes operator, cargo and accessories) Dry Weight 767 lbs. (348 kg) XP 1000 974 lbs. (442 kg) High Lifter 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. (210 ml) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 37 oz. (1100 ml) Front Rack/Storage Box Capacity 120 lbs. (54 kg) XP 1000 0 lbs. (0 kg) High Lifter Rear Rack Capacity 240 lbs. (109...
SPECIFICATIONS SPORTSMAN XP 1000 Maximum Weight Capacity 575 lbs. (261 kg) XP 1000 275 lbs. (125 kg) High Lifter (includes operator, cargo and accessories) Dry Weight 767 lbs. (348 kg) XP 1000 974 lbs. (442 kg) High Lifter 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. (210 ml) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 37 oz. (1100 ml) Front Rack/Storage Box Capacity 120 lbs. (54 kg) XP 1000 0 lbs. (0 kg) High Lifter Rear Rack Capacity 240 lbs. (109...
Owners Manual
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... SPORTSMAN XP 1000 Front Suspension Rear Suspension Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight (Pod Models) Headlight (Bumper) Taillights Brake Light Instrument Cluster XP 1000: Dual a-arm with 9.2" (23 cm) travel High Lifter: Dual a-arm with 7.4" (19 cm) travel XP 1000: Progressive rate with 10.2" (26 cm) travel High Lifter: Progressive rate with 6.7" (17 cm) travel H/L/N/R/P 5.034:1 (XP 1000) 6.5:1 (High Lifter...
... SPORTSMAN XP 1000 Front Suspension Rear Suspension Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight (Pod Models) Headlight (Bumper) Taillights Brake Light Instrument Cluster XP 1000: Dual a-arm with 9.2" (23 cm) travel High Lifter: Dual a-arm with 7.4" (19 cm) travel XP 1000: Progressive rate with 10.2" (26 cm) travel High Lifter: Progressive rate with 6.7" (17 cm) travel H/L/N/R/P 5.034:1 (XP 1000) 6.5:1 (High Lifter...
Owners Manual
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... l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Fluid Capacity 37 oz. (1100 ml) Rear Gearcase Fluid Capacity 7.1 oz. (210 ml) Engine EHO952LE Displacement 952 cc Bore x Stroke 90.5 x 74 Alternator Output 475w @1200 RPM/Peak 630w Compression Ratio 11:1 Starting System Electric Ignition System Electronic Fuel Injection Ignition Timing 6° +/- 5° BTDC @ 1200 RPM, Engine warm Idle RPM 1200 +/- 50 Throttle Body/Size Mikuni Dual Bore/42 mm Spark Plug Type...
... l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Fluid Capacity 37 oz. (1100 ml) Rear Gearcase Fluid Capacity 7.1 oz. (210 ml) Engine EHO952LE Displacement 952 cc Bore x Stroke 90.5 x 74 Alternator Output 475w @1200 RPM/Peak 630w Compression Ratio 11:1 Starting System Electric Ignition System Electronic Fuel Injection Ignition Timing 6° +/- 5° BTDC @ 1200 RPM, Engine warm Idle RPM 1200 +/- 50 Throttle Body/Size Mikuni Dual Bore/42 mm Spark Plug Type...
Owners Manual
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...SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. When requesting warranty service you move to continue your product to perform warranty service. If you move to POLARIS in order to perform the warranty repair... POLARIS Customer Assistance and the customs department of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that sells the same line as proof of your vehicle....
...SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. When requesting warranty service you move to continue your product to perform warranty service. If you move to POLARIS in order to perform the warranty repair... POLARIS Customer Assistance and the customs department of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that sells the same line as proof of your vehicle....
Owners Manual
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... for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the terms of the vehicle owner. This emissions limited warranty does not cover components whose only purpose is extended for at the time it is first purchased...
... for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the terms of the vehicle owner. This emissions limited warranty does not cover components whose only purpose is extended for at the time it is first purchased...
Owners Manual
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...-138 Clutching 850 High Lifter ...145 850/850 SP ...145 Touring 850 SP ...147 XP 1000 ...149 XP 1000 High Lifter ...149 XP Touring 1000 ...151 Cold Weather Operation ...61 Compartment, Front...38-39 Consumer Product Safety ...9 Coolant Bottle ...105 Coolant, Radiator...106 Cooling System ...104-106 Crankcase Emission Control System 91 F Fan Shroud (High Lifter)...38 Fluid Brake...34 Demand Drive...102 Engine Oil ...97-99 Front Gearcase ...102 Rear Gearcase Oil ...103 Transmission...100-101 Fluid Change Demand Drive...102 Engine Oil...
...-138 Clutching 850 High Lifter ...145 850/850 SP ...145 Touring 850 SP ...147 XP 1000 ...149 XP 1000 High Lifter ...149 XP Touring 1000 ...151 Cold Weather Operation ...61 Compartment, Front...38-39 Consumer Product Safety ...9 Coolant Bottle ...105 Coolant, Radiator...106 Cooling System ...104-106 Crankcase Emission Control System 91 F Fan Shroud (High Lifter)...38 Fluid Brake...34 Demand Drive...102 Engine Oil ...97-99 Front Gearcase ...102 Rear Gearcase Oil ...103 Transmission...100-101 Fluid Change Demand Drive...102 Engine Oil...
Owners Manual
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...) ...105 Coolant (Radiator) ...106 Demand Drive ...102 Engine Oil ...97 Rear Gearcase ...103 Transmission ...100 Foot Brake, Auxiliary ...36 Footwell Removal...109 Front Box (Touring) ...39 Front Compartment...38-39 Front Gearcase Fluid...102 Front Rack (1-Up, if equipped)...39 Fuel Recommendations...35 Fuel Safety ...13 Fuel Tank Cap...35 Fuse Replacement ...114 L Lights ...115-119 Headlight Housing Replacement 118 Headlight Lamp ...115 High Beam, Adjust (Pod)...116 Low Beam, Adjust (Bumper)...117 Lower Headlamp Replacement...
...) ...105 Coolant (Radiator) ...106 Demand Drive ...102 Engine Oil ...97 Rear Gearcase ...103 Transmission ...100 Foot Brake, Auxiliary ...36 Footwell Removal...109 Front Box (Touring) ...39 Front Compartment...38-39 Front Gearcase Fluid...102 Front Rack (1-Up, if equipped)...39 Fuel Recommendations...35 Fuel Safety ...13 Fuel Tank Cap...35 Fuse Replacement ...114 L Lights ...115-119 Headlight Housing Replacement 118 Headlight Lamp ...115 High Beam, Adjust (Pod)...116 Low Beam, Adjust (Bumper)...117 Lower Headlamp Replacement...
Owners Manual
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... Vehicle ...63 S Safe Operation Practices ...59 Safety Labels ...23-29 Safety Training ...9 Safety Warnings...12-22 Safety, Winch Maintenance...90 Seat Removal (1-Up Models) ...110 Seat Removal (Touring) ...110 Severe Use ...92 Shock Loading the Winch ...88-89 Shroud, Fan (High Lifter) ...38 Side Panel Removal...109 Sidehilling ...68 Signal Words ...5 Spark Arrester ...123 Spark Plug Inspection ...120-121 Spark Plug Recommendations...120 Spark Plugs ...120-121 Speedometer ...44 Spring Adjustment, Rear Shock . . 131 Starting the Engine ...61 Steering Assembly...
... Vehicle ...63 S Safe Operation Practices ...59 Safety Labels ...23-29 Safety Training ...9 Safety Warnings...12-22 Safety, Winch Maintenance...90 Seat Removal (1-Up Models) ...110 Seat Removal (Touring) ...110 Severe Use ...92 Shock Loading the Winch ...88-89 Shroud, Fan (High Lifter) ...38 Side Panel Removal...109 Sidehilling ...68 Signal Words ...5 Spark Arrester ...123 Spark Plug Inspection ...120-121 Spark Plug Recommendations...120 Spark Plugs ...120-121 Speedometer ...44 Spring Adjustment, Rear Shock . . 131 Starting the Engine ...61 Steering Assembly...