Polaris Sportsman 850 XP User Manual

7SAFETYSafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized

97MAINTENANCELightsLower Headlamp Replacement1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the he

98MAINTENANCESpark PlugsSpark Plug RecommendationsRefer to the specifications section beginning on page 126 for the recom-mended spark plug type and g

99MAINTENANCESpark PlugsSpark Plug InspectionNormal Spark PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion depos

100MAINTENANCEVehicle ImmersionIf your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the v

101MAINTENANCESpark ArrestorFailure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never r

102MAINTENANCEPVT SystemFailure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of th

103MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed in

104MAINTENANCEPVT SystemWhen To Use Low Range and High RangePVT DryingThere may be some instances when water is accidently ingested into the PVT syste

105MAINTENANCEBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

106MAINTENANCEBatteryBattery Removal1. Remove the seat.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery

8SAFETYSafe Riding GearAlways wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.He

107MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It

108MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure

109MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage from leak-ing or spilled electrol

110MAINTENANCEBatteryBattery Charging (Sealed Battery)Always verify battery condition before and 1-2 hours after the end of charging.State of ChargeVo

111MAINTENANCECleaning and StorageWashing the VehicleKeeping your Polaris vehicle clean will not only improve its appearance but it can also extend th

112MAINTENANCECleaning and StorageWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution.

113MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life an

114MAINTENANCECleaning and StorageStorage TipsNOTICE: Starting the engine during the storage period will disturb the protective film created by foggin

115MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance

116MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Per

9SAFETYSafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear sha

117MAINTENANCETransporting the ATV1. Stop the engine.2. Place the transmission in PARK.3. Lock the parking brake.4. Secure the fuel cap, oil cap and s

118ADJUSTMENTSThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris deal

119ADJUSTMENTSThrottle Cable Freeplay4. Place the transmission in PARK. Lock the parking brake.5. Start the engine and allow the idle to stabilize. If

120ADJUSTMENTSCamber and CasterThe camber and caster are non-adjustable.Front and Rear SpringsThe front and rear shock absorber springs are adjusted b

121TROUBLESHOOTINGDrive Belt Wear/BurnPossible Cause SolutionDriving onto a pickup or tall trailer in high rangeUse low range during loading.Starting

122TROUBLESHOOTINGEngine Doesn't Turn OverEngine Turns Over, Fails to StartEngine BackfiresPossible Cause SolutionLow battery voltage Recharge th

123TROUBLESHOOTINGEngine Pings or KnocksEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionPoor quality or low octane fuel Replace with

124TROUBLESHOOTINGEngine Stops or Loses PowerEngine OverheatingPossible Cause SolutionOut of fuel Refuel, cycle key to ON position three times for 5 s

125POLARIS PRODUCTSPart NumberDescriptionEngine Lubricant2870791 Fogging Oil (12 oz./355 ml Aerosol)2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cy

126SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman 550 XP / XP EPSMaximum Weight Capacity 575 lbs. (261 kg)Dry Weight 732 lbs. (332 kg) (XP)7

10SAFETYSafety WarningsFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serio

127SPECIFICATIONSClutching*EBS models require no helix/spring adjustmentSportsman 550 XP / XP EPSTransmission H/L/N/R/PGear Reduction, Low 5.034:1Gear

128SPECIFICATIONS* Based on EU Directive 76/432/ECSportsman 850 XP / XP EPSMaximum Weight Capacity 575 lbs. (261 kg)Dry Weight 784 lbs. (356 kg) (XP)7

129SPECIFICATIONSClutching*EBS models require no helix/spring adjustmentSportsman 850 XP / XP EPSTransmission H/L/N/R/PGear Reduction, Low 5.034:1Gear

130WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris

131WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

132WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE L

133WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

134WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

135WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

136MAINTENANCE LOGPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

11SAFETYSafety WarningsHandling GasolineGasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution wheneve

137MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

138MAINTENANCE LOGDATE MILES (KM)OR HOURSTECHNICIAN SERVICE PERFORMED / COMMENTS

12SAFETYSafety WarningsProtective ApparelRiding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a seri

13SAFETYSafety WarningsOperating on PavementOperating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely

14SAFETYSafety WarningsPhysical Control of the ATVRemoving a hand from the handlebars or feet from the footrests during operation can reduce your abil

15SAFETYSafety WarningsDescending Hills ImproperlyImproperly descending a hill could cause loss of control or overturn.• Always follow proper procedur

16SAFETYSafety WarningsStalling While Climbing a HillStalling, rolling backwards or improperly dismounting while climbing a hill could cause an overtu

3

17SAFETYSafety WarningsOperating on Slippery TerrainFailure to use extra caution when operating on excessively rough, slippery or loose terrain could

18SAFETYSafety WarningsOperating Improperly in ReverseImproperly operating in reverse could result in a collision with an obstacle or person. Always f

19SAFETYSafety WarningsOperating Over ObstaclesImproperly operating over obstacles could cause loss of control or overturn.Before operating in a new a

20SAFETYSafety WarningsImproper Cargo LoadingOverloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause

21SAFETYSafety WarningsOperating a Damaged ATVOperating a damaged ATV can result in an accident. After any overturn or accident, have a qualified serv

22SAFETYSafety Labels and LocationsWarning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label

23SAFETYSafety Labels and LocationsDiscretionary WarningWARNING• Never operate this ATV on HILLS steeper than 25 degrees 25°. To pre-vent overturn o

24SAFETYSafety Labels and Locations“No Passenger” WarningWARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE

25SAFETYSafety Labels and LocationsClutch Cover WarningWARNING• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate

26FEATURES AND CONTROLSSwitchesMode/Reverse Override SwitchThis vehicle is equipped with a reverse speed limiter system. To gain additional wheel spee

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

27FEATURES AND CONTROLSSwitchesEngine Stop SwitchMove the stop switch either left or right to the OFF position to stop the engine quickly. Move the st

28FEATURES AND CONTROLSThrottle LeverOperating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or

29FEATURES AND CONTROLSBrake LeverOperating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never oper

30FEATURES AND CONTROLSMaster Cylinder/Brake FluidAn over-full master cylinder may cause brake drag or brake lock-up, which could result in an acciden

31FEATURES AND CONTROLSParking BrakeLocking the Parking Brake1. Place the transmission in PARK.2. Squeeze and release the brake lever two or three tim

32FEATURES AND CONTROLSAuxiliary Foot BrakeAggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could resu

33FEATURES AND CONTROLSElectronic Power Steering (EPS)Electronic power steering (if equipped) engages when the ignition key is turned to the ON positi

34FEATURES AND CONTROLSAll Wheel Drive SystemThe All Wheel Drive system is controlled by the 4X4 switch.ADC 4X4 ModeWhen the switch is on ADC 4X4, the

35FEATURES AND CONTROLSAll Wheel Drive System Engaging 4X4The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle&a

36FEATURES AND CONTROLSActive Descent Control (ADC) SystemThe ADC system allows engine braking to all four wheels when the vehicle descends a hill or

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

37FEATURES AND CONTROLSInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. Th

38FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. All seg-ments will

39FEATURES AND CONTROLSInstrument ClusterRider Information Center3. Speed Display - This area displays vehicle ground speed or engine rotational speed

40FEATURES AND CONTROLSInstrument ClusterRider Information CenterSpeed Display AreaUse the MODE button to toggle through the speed display options. MO

41FEATURES AND CONTROLSInstrument ClusterRider Information CenterInformation Display AreaUse the SELECT button (SEL) to toggle through the information

42FEATURES AND CONTROLSInstrument ClusterRider Information CenterInformation Display AreaProgrammable Service IntervalWhen the hours of engine operati

43FEATURES AND CONTROLSInstrument ClusterRider Information CenterInformation Display AreaDiagnostic Display ModeThe EFI diagnostic display mode is for

44FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic Display Code DefinitionsOpen Load: There is a break in the wires that lead

45FEATURES AND CONTROLSInstrument ClusterRider Information Center*Assumes unipolar configuration of stepper motorSportsman 550 XP / XP EPS Diagnostic

46FEATURES AND CONTROLSInstrument ClusterRider Information CenterSportsman 850 XP / XP EPS Diagnostic CodesComponent Condition SPN FMIThrottle Positio

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2008 Polaris Sales Inc. All information contained with

47FEATURES AND CONTROLSInstrument ClusterRider Information CenterSportsman 850 XP / XP EPS Diagnostic CodesComponent Condition SPN FMIChassis Relay Dr

48FEATURES AND CONTROLSFront Rack/CompartmentRelease the front rack latches and remove the rack to gain access to the front compart-ment. To reinstall

49OPERATIONFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or

50OPERATIONPre-Ride ChecklistFailure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accid

51OPERATIONSafe Operation Practices1. Complete the recommended safety training before operating this vehicle. See page 7.2. Do not allow anyone under

52OPERATIONKnow Your Riding Area/Tread LightlyFamiliarize yourself with all laws and regulations concerning the opera-tion of this off-road vehicle in

53OPERATIONStarting the Engine1. Position the vehicle on a level surface outdoors or in a well-venti-lated area. 2. Place the transmission in PARK.3.

54OPERATIONDriving Procedures1. Wear a helmet and eye protection.2. Sit upright with both feet on the footrests and both hands on the handlebars.3. St

55OPERATIONTurning the VehicleYour ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the whe

56OPERATIONDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow the

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . .

57OPERATIONDriving UphillBraking and handling are greatly affected when operating in hilly ter-rain. Improper procedure could cause loss of control or

58OPERATIONDriving on a Sidehill (Sidehilling)Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Av

59OPERATIONDriving DownhillWhen driving downhill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a h

60OPERATIONTurning Around on a Hill (K-Turn)If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.1.

61OPERATIONDriving Through WaterYour ATV can operate through water with a maximum recom-mended depth equal to the bot-tom of the footrests. Follow the

62OPERATIONDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2

63OPERATIONDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always a

64OPERATIONHauling CargoOverloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or bra

65OPERATIONHauling CargoNever exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual.C

66OPERATIONParking on an InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Plac

4INTRODUCTIONThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sy

67EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

68MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, ad

69MAINTENANCEPeriodic Maintenance ChartImproperly performing the procedures marked with a  could result in component failure and cause an accident, w

70MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.X Perform these procedures more often f

71MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)QEThrottle Cable/ ETC Switch50 H

72MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 68. It

73MAINTENANCEEngine OilOil RecommendationsPolaris recommends the use of Polaris PS-4 PLUS Performance Syn-thetic 2W-50 4-cycle oil or a similar oil fo

74MAINTENANCEEngine OilOil and Filter ChangeSee the table on page 72 for fluid recommendations, capacities and plug torques. Always change the oil and

75MAINTENANCEEngine OilOil and Filter Change9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris deale

76MAINTENANCETransmission OilPolaris recommends the use of Polaris Synthetic Sportsman XP Trans-mission Fluid for this transmission. See the table on

5INTRODUCTIONFailure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a

77MAINTENANCEFront Gearcase (Demand Drive) FluidSee the table on page 72 for fluid recommendations, capacities and plug torques. Always check and chan

78MAINTENANCERear Gearcase OilSee the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the rear gearca

79MAINTENANCERear Gearcase OilOil Change1. Position the vehicle on a level surface.2. Place a drain pan under the drain hole.3. Remove the drain plug.

80MAINTENANCEActive Descent Control (ADC) FluidIf your vehicle is equipped with Active Descent Control, there are two fluid levels that must be mainta

81MAINTENANCEActive Descent Control (ADC) FluidFluid Change1. Position the vehicle on a level surface. Before performing the fluid change, allow the v

82MAINTENANCEPower Steering UnitIf your model is equipped with power steering, frequently clean the areas around and on the power steering unit to all

83MAINTENANCECooling SystemRecovery Bottle CoolantThe recovery bottle fluid level can be viewed from inside the front right wheel well. Access the rec

84MAINTENANCECooling SystemRadiator CoolantTo ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain t

85MAINTENANCEBrakesHand BrakeThe front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The

86MAINTENANCEToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4&quo

6INTRODUCTIONVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare k

87MAINTENANCESeat Removal1. Grasp one side of the seat near the rear edge.2. Pull upward abruptly to disengage the under-seat fasteners.3. Remove the

88MAINTENANCETiresOperating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle

89MAINTENANCETiresFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are critical com-ponent operations. All service mu

90MAINTENANCETiresWheel Installation1. Place the transmission in PARK.2. Lock the parking brake.3. Place the wheel on the hub with the valve stem towa

91MAINTENANCEAir Filter1. Remove the seat.2. Remove the air box cover screws, and remove the air box cover.3. Remove the filter.4. Remove the fabric t

92MAINTENANCEFuse ReplacementIf the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locat

93MAINTENANCELightsPoor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. C

94MAINTENANCELightsHigh Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustm

95MAINTENANCELightsLow Beam AdjustmentThe low beam can be adjusted slightly upward or downward.1. Loosen the phillips screw located at the rear of the

96MAINTENANCELightsHeadlight Housing Replacement1. Remove the five (5) headlight pod screws.2. Lift the pod cover and disconnect the speedometer harne