Polaris SPORTSMAN 850 HIGH LIFTER EDITION 2020 Owner's Manual
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Polaris SPORTSMAN 850 HIGH LIFTER EDITION 2020 Owner's Manual

Polaris SPORTSMAN 850 HIGH LIFTER EDITION 2020 Owner's Manual

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SPORTSMAN® 850
HIGH LIFTER EDITION
SPORTSMAN® XP 1000
HIGH LIFTER EDITION
Owner's Manual
For Maintenance and Safety
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.

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Summary of Contents for Polaris SPORTSMAN 850 HIGH LIFTER EDITION 2020

  • Page 1 SPORTSMAN® 850 HIGH LIFTER EDITION SPORTSMAN® XP 1000 HIGH LIFTER EDITION Owner's Manual For Maintenance and Safety 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.
  • Page 3 2020 Owner’s Manual Sportsman® 850 High Lifter Edition Sportsman XP® 1000 High Lifter Edition...
  • Page 4 POLARIS®, ACE™, OUTLAW®, SPORTSMAN®, and SCRAMBLER® are trademarks of POLARIS Industries Inc. Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this 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 ....113 POLARIS Products ....119 Troubleshooting ....121 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 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 13: 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 14 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 15 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 16 SAFETY 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. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 17 SAFETY OPERATING ON PAVEMENT This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover.
  • Page 18 SAFETY TURNING IMPROPERLY CAUTION Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.
  • Page 19 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 a 1-up ATV on hills steeper than 25 degrees. STALLING WHILE CLIMBING A HILL Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover.
  • Page 20 SAFETY 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 control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the vehicle on such terrain.
  • Page 21 SAFETY OPERATING OVER OBSTACLES Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.
  • Page 22 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 23 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.
  • Page 24 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 Discretionary Warning...
  • Page 25 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 PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper training or instruction •...
  • Page 26 SAFETY TIRE PRESSURE/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: 7.0 psi (48.3 kPa) •...
  • Page 27 SAFETY AGE 16 WARNING The Age 16 warning is located on the left-hand wheel well. WARNING Operating this vehicle if you are under the age of 16 increases the chances of severe injury or death to operator. NEVER operate this vehicle if you are under age 16. CLUTCH COVER WARNING WARNING •...

  • Page 29: 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 Drive Line Switch Engine Stop Switch Throttle Lever Switch Winch Switch (if equipped) Mode/Reverse Override Switch...
  • Page 30 FEATURES AND CONTROLS 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. Turn the key to the OFF position to stop the engine. Electrical circuits are off. Turn the key the RUN position to activate electrical components.
  • Page 31 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 32 FEATURES AND CONTROLS HEADLIGHT SWITCH Use the headlight switch to turn the lights on and off. The key must be in the ON position and the engine stop switch must be in the RUN position. MODE/REVERSE OVERRIDE SWITCH WARNING Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death.
  • Page 33 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 34 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 35 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 36 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 37 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 38 FEATURES AND CONTROLS ELECTRONIC POWER STEERING (EPS) Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See the Instrument Cluster section for EPS Warning Indicator information.
  • Page 39 POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.
  • Page 40 FEATURES AND CONTROLS ALL WHEEL DRIVE SYSTEM The All Wheel Drive system is controlled by the Drive Line switch. 4X4 MODE When the switch is on 4X4, the ATV is four-wheel drive, and the 4X4 indicator icon in the instrument cluster display will be visible. When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction.
  • Page 41 If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, your POLARIS dealer can provide proper diagnosis.
  • Page 42 FEATURES AND CONTROLS Gear Indicator This indicator displays gear shifter position. H: High Gear L: Low Gear N: Neutral R: Reverse Gear P: Park –: Gear Signal Error (or shifter between gears) Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank.
  • Page 43 FEATURES AND CONTROLS DISPLAY UNITS (STANDARD/METRIC) The display can be changed to display either standard or metric units of measurement. The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button.
  • Page 44 FEATURES AND CONTROLS CLOCK MODE The clock must be reset any time the battery has been disconnected or discharged. To set the clock time, do the following: 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 45 DIAGNOSTIC DISPLAY MODE The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer or qualified person can provide for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
  • Page 46 This indicator illuminates briefly when the key is Steering (EPS) turned to the ON position. If the light remains on, the Warning (if EPS system is inoperative. See your POLARIS equipped) dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

  • Page 47: Operation

    OPERATION OPERATION NEW OPERATOR DRIVING PROCEDURES 1. Wear protective riding gear. See the Safe Riding Gear section. 2. Perform the pre-ride inspection. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6.
  • Page 48 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 49 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 50 OPERATION DRIVING ON SLIPPERY SURFACES Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.
  • Page 51 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 52 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 53 OPERATION DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills. Maximum incline is 25° 3.
  • Page 54 OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Avoid steep hills. Maximum incline is 25° 3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.
  • Page 55 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 56 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 57 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 58 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 59 OPERATION BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. PVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance.
  • Page 60 OPERATION ITEM REMARKS PAGE Engine stop switch Ensure proper operation page 29 Air filter, pre-filter Inspect, clean page 91 Headlamp Check operation page 27 Brake light/taillight Check operation Wear approved helmet, Riding gear goggles, and protective page 11 clothing Winch (if equipped) Inspect cable and switch page 63 Grass and leaves...
  • Page 61 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 62 OPERATION 3. Turn the engine off. 4. Engage the parking brake (if equipped). 5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 6. Remove the ignition key to prevent unauthorized use. HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter...
  • Page 63 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 65: 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 66 WINCH GUIDE 9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load. 10.
  • Page 67 WINCH GUIDE 19. Never use the winch for lifting or transporting people. 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Your dealer can provide service on your winch if this occurs. 22.
  • Page 68 WINCH GUIDE 1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly.
  • Page 69 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. • If possible, keep the winch cable aligned with the centerline of the winching vehicle.
  • Page 70 WINCH GUIDE 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
  • Page 71 WINCH GUIDE b. Align the winch cable as close as possible to the winching vehicle’s centerline. c. Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following instructions in this manual. d. Re-engage the clutch on the winch. e.
  • Page 72 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 73 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 74 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 75: 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 77: 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 MAINTENANCE OIL CHANGE 1. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. 2. Clean and reinstall the drain plug. Torque to specification. 3. Remove the fill plug. Add the proper amount of the recommended oil. 4.
  • Page 86 REAR GEARCASE OIL Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart. See page 119 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 87 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 88 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 89 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 90 MAINTENANCE 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. 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.
  • Page 91 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 92 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 93 MAINTENANCE AIR FILTER INSTALLATION 1. Remove the seat and 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. Reinstall the pre-filter over the main filter. Install a new main filter if needed. 5.
  • Page 94 MAINTENANCE LIGHTS CAUTION Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. HEADLAMP ADJUSTMENT The headlamps can be adjusted slightly upward or downward by rotating the...
  • Page 95 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 96 MAINTENANCE SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
  • Page 97 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 98 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 99 • 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 100 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 101 (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 102 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 about once a month to make up for normal self- discharge.
  • Page 103 MAINTENANCE BATTERY CHARGING The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 104 MAINTENANCE BATTERY CHARGING (SEALED BATTERY) Always verify battery condition before and 1-2 hours after the end of charging. CHARGE TIME (USING CONSTANT CURRENT CHARGER @ STATE OF CHARGE VOLTAGE ACTION STANDARD AMPS SPECIFIED ON TOP OF BATTERY) 100% 12.8-13.0 volts None, check at 3 mos.
  • Page 105 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 106 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 107 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 108 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 109 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 110 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the pod. 2. Loosen the four handlebar bolts.
  • Page 111 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 112 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 113 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 114 MAINTENANCE TRANSPORTING THE ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seats. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.

  • Page 115: Specifications

    SPECIFICATIONS SPECIFICATIONS SPORTSMAN® 850 HIGH LIFTER SPORTSMAN 850 HIGH LIFTER Maximum Weight Capacity 275 lbs. (125 kg) (includes operator, cargo and accessories) Dry Weight 888.32 lbs. (403 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts.
  • Page 116 Spark Plug Type / Gap REA6MC / .035 in. (0.9 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 7.4" (19 cm) travel Rear Suspension Progressive rate with 6.7" (17 cm) travel...
  • Page 117 SPECIFICATIONS CLUTCHING DRIVEN SHIFT DRIVE ALTITUDE CLUTCH HELIX WEIGHT CLUTCH SPRING 64-66FR BA 0-1800 24-70 Red/Black Black/White (0-6000) PN 5633136 PN 7044263 PN 7044511 PN 3235971 Meters (Feet) 1800-3700 (6000-12000) SPORTSMAN XP 1000 HIGH LIFTER SPORTSMAN XP 1000 Maximum Weight Capacity 275 lbs.
  • Page 118 Spark Plug Type / Gap AUTOLITE 5682 / .030 in. (0.76 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Dual a-arm with 7.4" (19 cm) travel Rear Suspension Progressive rate with 6.7" (17 cm) travel...
  • Page 119 SPECIFICATIONS SPORTSMAN XP 1000 Brake, Parking Hydraulic lock, all wheel Headlight 2 Single Beams on Bumper (50 watt) Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital/Analog CLUTCHING DRIVEN SHIFT DRIVE ALTITUDE CLUTCH HELIX WEIGHT CLUTCH SPRING 64-66FR BA 0-1800 24-70 Red/Black...

  • Page 121: 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 123: 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 124 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.8 VDC 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...
  • Page 125 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre-filter Inspect and clean (with soapy water) or replace Other mechanical failure...

  • Page 127: 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 128 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 129 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 130 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 131 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 132 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 133 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 134 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 135: 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 137 2X4 Mode ....... . 38 4X4 Mode ....... . 38 Descending Hills Improperly .
  • Page 138 Failure to Inspect Before Jumps and Stunts ..... . 16 Operating ....... 14 Fan Shroud .
  • Page 139 Starting the Engine ....58 Polaris Products ..... . . 119 Steering Assembly.
  • Page 140 Unauthorized Use of the Vehicle . . . 21 Vehicle Break-in Period....56 Vehicle Identification Numbers ..10 Vehicle Immersion ..... 96 Warning Symbols .
  • Page 142 SCAN CODE FOR PRODUCT 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 Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No.

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