Owners Manual
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It contains important safety information. 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. Operation is an adult vehicle only. Owner's Manual for those under 16 years of age.
It contains important safety information. 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. Operation is an adult vehicle only. Owner's Manual for those under 16 years of age.
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
Page 31
... injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Vehicle damage or tipover may result causing severe injury or death. Hitch Capacity Label (All Models) TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. SAFETY Safety Labels and Locations Rack/Box Warning Tire Pressure/Load Warning Rack/Box Warning Clutch Cover Warning (under belt-clutch guard. VERTICAL WEIGHT: 150 LBS. (68...
... injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Vehicle damage or tipover may result causing severe injury or death. Hitch Capacity Label (All Models) TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. SAFETY Safety Labels and Locations Rack/Box Warning Tire Pressure/Load Warning Rack/Box Warning Clutch Cover Warning (under belt-clutch guard. VERTICAL WEIGHT: 150 LBS. (68...
Owners Manual
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... unattended, always place the transmission in PARK and lock the parking brake. Belt Life To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed. 37 When the engine is located on the right side of the vehicle. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is idling, move the lever...
... unattended, always place the transmission in PARK and lock the parking brake. Belt Life To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed. 37 When the engine is located on the right side of the vehicle. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is idling, move the lever...
Owners Manual
Page 49
... displays odometer, trip meter, engine hour meter, engine speed and programmable service hour interval. 4. The time will flash. Fuel Gauge Display - Your authorized POLARIS dealer can provide scheduled maintenance. See page 43. 5. Clock Display - See page 49 for resetting instructions. 6. Gear Display - Refuel immediately. Information Display - When the last segment clears, a low fuel warning is active. This area displays gear shifter position. If the...
... displays odometer, trip meter, engine hour meter, engine speed and programmable service hour interval. 4. The time will flash. Fuel Gauge Display - Your authorized POLARIS dealer can provide scheduled maintenance. See page 43. 5. Clock Display - See page 49 for resetting instructions. 6. Gear Display - Refuel immediately. Information Display - When the last segment clears, a low fuel warning is active. This area displays gear shifter position. If the...
Owners Manual
Page 79
... front rack and 2/3 on warning labels and in 2/3 the specifications section of 1/3 this manual. 2. NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg). 6. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 9. All 2-Up Models...
... front rack and 2/3 on warning labels and in 2/3 the specifications section of 1/3 this manual. 2. NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg). 6. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 9. All 2-Up Models...
Owners Manual
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...; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Ź Air filter, main element Ź Brake pad wear D Battery Fuel System 10 H 20 H 20 H Weekly Monthly Monthly Monthly Miles (Km) 100 (160) 200 (320) Inspect; cycle key to severe 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...
...; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Ź Air filter, main element Ź Brake pad wear D Battery Fuel System 10 H 20 H 20 H Weekly Monthly Monthly Monthly Miles (Km) 100 (160) 200 (320) Inspect; cycle key to severe 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...
Owners Manual
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... connectors subjected to pressurize fuel pump; check for wear, routing, security; replace worn parts 1000 (1600) Inspect; replace as needed 1000 (1600) Inspect for leaks at fill cap, fuel lines/rail and fuel pump; 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...
... connectors subjected to pressurize fuel pump; check for wear, routing, security; replace worn parts 1000 (1600) Inspect; replace as needed 1000 (1600) Inspect for leaks at fill cap, fuel lines/rail and fuel pump; 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...
Owners Manual
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... off during operation, which could cause a tire to specification. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. MAINTENANCE Tires Wheel Installation 1. Install the wheel nuts and finger-tighten them. 5. Loose nuts could result in PARK. 2. Lock the parking brake. 3. WARNING! Place the transmission in an accident or overturn. Lower the vehicle to specification. Wheel Type All Nut Torque 75 ft...
... off during operation, which could cause a tire to specification. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. MAINTENANCE Tires Wheel Installation 1. Install the wheel nuts and finger-tighten them. 5. Loose nuts could result in PARK. 2. Lock the parking brake. 3. WARNING! Place the transmission in an accident or overturn. Lower the vehicle to specification. Wheel Type All Nut Torque 75 ft...
Owners Manual
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... five (5) headlight pod screws. MAINTENANCE Lights Poor lighting can cause burns to skin. Pull the pod cover forward. Always make sure lights are adjusted properly for best visibility. CAUTION! Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. Install the new lamp. Headlight and taillight lenses become dirty during normal operation. Turn the lamp counter-clockwise to cool before servicing. 2. Hot...
... five (5) headlight pod screws. MAINTENANCE Lights Poor lighting can cause burns to skin. Pull the pod cover forward. Always make sure lights are adjusted properly for best visibility. CAUTION! Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. Install the new lamp. Headlight and taillight lenses become dirty during normal operation. Turn the lamp counter-clockwise to cool before servicing. 2. Hot...
Owners Manual
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... PARK. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) 2. The most intense part of the headlight pod. Measure the distance from a wall. Include rider weight on the wall at the same height. 3. Screw To adjust the beam, loosen the screw. Start the engine. Adjust the headlamp to high beam. 4. Turn the headlight switch to the desired position, then tighten the screw. 116 MAINTENANCE Lights High...
... PARK. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) 2. The most intense part of the headlight pod. Measure the distance from a wall. Include rider weight on the wall at the same height. 3. Screw To adjust the beam, loosen the screw. Start the engine. Adjust the headlamp to high beam. 4. Turn the headlight switch to the desired position, then tighten the screw. 116 MAINTENANCE Lights High...
Owners Manual
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... o-rings from the headlight mounting tabs. 5. Pod Headlight Housing Replacement (Non-SP/XP) 1. MAINTENANCE Lights Pod Headlight Housing Replacement (SP/XP Models) 1. Use a small screwdriver to install the new housing and reassemble the pod. Pull the headlight housing up from the speedometer. 3. Lift the pod cover and disconnect the speedometer harnesses from the bracket for removal. 6. Carefully pull the assembly up to install the...
... o-rings from the headlight mounting tabs. 5. Pod Headlight Housing Replacement (Non-SP/XP) 1. MAINTENANCE Lights Pod Headlight Housing Replacement (SP/XP Models) 1. Use a small screwdriver to install the new housing and reassemble the pod. Pull the headlight housing up from the speedometer. 3. Lift the pod cover and disconnect the speedometer harnesses from the bracket for removal. 6. Carefully pull the assembly up to install the...
Owners Manual
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... headlamp. 1. Test the light for proper operation. MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the headlight harness clockwise to remove it. 3. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Remove the harness connector from the headlight assembly. 2. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the back of the light assembly. 2. Harness Taillight/Brakelight Lamp Replacement Connector Lamp 119
... headlamp. 1. Test the light for proper operation. MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the headlight harness clockwise to remove it. 3. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Remove the harness connector from the headlight assembly. 2. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the back of the light assembly. 2. Harness Taillight/Brakelight Lamp Replacement Connector Lamp 119
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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...) High Lifter 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 / Gap AUTOLITE 5682 / .030 in. (0.76 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS...
...) High Lifter 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 / Gap AUTOLITE 5682 / .030 in. (0.76 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS...
Owners Manual
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... POLARIS Servicing Dealer. WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take your product to an authorized POLARIS ...perform the warranty repair. Upon residence verification, the servicing dealer will be authorized to government officials or military personnel on assignment outside of the selling dealer's authorized location as your product was originally purchased, all warranty coverage will be denied. Product importation rules vary considerably from POLARIS. however, you move to continue your warranty coverage and to Safety...
... POLARIS Servicing Dealer. WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take your product to an authorized POLARIS ...perform the warranty repair. Upon residence verification, the servicing dealer will be authorized to government officials or military personnel on assignment outside of the selling dealer's authorized location as your product was originally purchased, all warranty coverage will be denied. Product importation rules vary considerably from POLARIS. however, you move to continue your warranty coverage and to Safety...
Owners Manual
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... considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components 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...
... considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components 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...
Owners Manual
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... 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...
... 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...
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...