2010 Polaris Sportsman Touring 850 EPS Owners Manual

2010 Polaris Sportsman Touring 850 EPS Manual

2010 Polaris Sportsman Touring 850 EPS manual content summary:

  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 1
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    the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800342-3764 for assistance.
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    The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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    - dismount passenger when conditions require make sure passenger reads and understands this label and passenger safety label READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100
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    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master
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    of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2010 SPORTSMAN 550/850 Touring EPS Owner's Manual P/N 9922090 2
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    TABLE OF CONTENTS Introduction ...4 Safety ...7 Features and Controls ...26 Operation ...52 Emission Control Systems ...75 Maintenance ...76 Troubleshooting ...131 Polaris Products...135 Specifications ...136 Declaration of Conformity ...140 Warranty ...141 Maintenance Log ...149 Index ...151 3
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 8
    on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
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    . Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV. • Never operate an ATV without proper instruction. Take a training course. • This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years
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    INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. 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
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    you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorized ATV RiderCoursesm that is available to you and follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that
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    SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Long Sleeves Eye Protection Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris
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    SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings
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    . Heed all safety warnings outlined in this section of the owner's manual. See the OPERATION section of the owner's manual for proper operating procedures. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how
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    ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual. 11
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    SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles
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    SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are
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    could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. Jumps and Stunts Attempting wheelies
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    . Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 64. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as
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    . Have a passenger dismount first, then the operator may dismount. • Turn the ATV around and remount, following the procedure described in the owner's manual. See page 66. If the ATV begins rolling backwards: • Keep operator and passenger body weight uphill. • Never apply engine power. • Never apply
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    Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 70. Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back
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    accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area
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    . • Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. • Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. • Always follow the instructions in the owner's manual for operating with a passenger. See page 60. 19
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    SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather
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    Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe
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    have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label
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    1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper ATV training or instruction General Warning • at speeds too fast for your skills or the conditions • on public and passenger safety label LOCATE AND READ OPERATOR'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175844 23
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    SAFETY Safety Labels and Locations Passenger Warning/Discretionary Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly Passenger Warning plant feet on
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    SAFETY Safety Labels and Locations Rack/Box Warning Rack/Box Warning + + Clutch Cover Warning + Rack/Box Warning WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Maximum Rack Loads: Front 120 lbs. (
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    FEATURES AND CONTROLS Switches Headlight Switch 4X4 Switch Mode/Reverse Override Switch Main Key Switch Engine Stop Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, depress the override switch. WARNING!
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    FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. Move the stop switch to the RUN position before attemptOFF RUN OFF ing to start the engine. The engine will not start or run when the switch is off. Both the
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    controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle
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    in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated
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    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
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    FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake
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    FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary
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    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. Gear
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    the seat upward. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. See pages 95-96 for passenger seat adjustment procedures. See page 95 for passenger seat removal and installation procedures. Beverage Holders This vehicle is
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    FEATURES AND CONTROLS Fuel Tank Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap and add fuel. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with
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    FEATURES AND CONTROLS Front Storage Box Open the front storage box to access the under-compartment area. 1. Release the front box cover latches and lift the cover. 2. Release the plunger latches that secure the box to the frame. 3. Close the cover and Cover Latches Plunger Latches lift the unlatched
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    FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is ADC 4X4 controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4
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    FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If
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    FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will
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    speed, the instrument cluster also displays the following items: engine speed, odometer, resettable trip meters (2), total engine hours of operation, service interval timer and indicator, gear position, fuel level, AWD status, EPS status (if equipped), high beam status, battery voltage warning
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    Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2. Information Display Area - This area displays odometer, tripmeters, engine hour meter and programmable service hour interval. 41
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    - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 46 for resetting instructions. 9. Under / Over Voltage - This warning usually indicates that the ATV is operating
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override button also acts as a MODE button when
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override button also acts as
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Odometer Mode The odometer records and displays the distance traveled by the ATV. Trip Meter Mode The trip meters record the distance traveled by the ATV on each trip if reset before each trip. To reset a trip
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    is programmed at 50 hours at the factory. Use the following procedure to change the service interval. 1. Press the SELECT button until remaining service hours display. 2. Press and hold the MODE button. 3. When the service hours flash, press and release the SELECT button to advance the hours to the
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your Polaris dealer for all major repairs. The diagnostic mode is accessible only when the check engine
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 550 Touring EPS Diagnostic Codes Component Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Condition Driver Circuit Grounded Shorted Load* Driver Circuit Short to B+ Driver
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 Touring EPS Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too High Voltage Too Low Voltage Too High Voltage Too Low Temperature Too High Engine Overheat Shutdown Voltage
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 Touring EPS Diagnostic Codes Component Chassis Relay Condition Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit
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    , accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to
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    OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 35. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 81. Add oil if necessary to maintain the level between the safe and add marks
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    OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Item Passenger seat latch Brake system/lever travel Brake
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    type of tires specified for your vehicle. Always maintain proper tire pressure. 10. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage. 11. Never operate the ATV on a frozen body of water. 12. Do not touch hot
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    OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding
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    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.
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    OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Wear protective riding gear. See page 8. Perform the pre-ride inspection. See page 54. Place the transmission in PARK. Lock the parking brake. Mount the vehicle from the left side. Sit upright with both feet on the footrests and
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    cargo. 3. Steer in the direction of the turn. 4. Keep both feet on the footrests. 5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
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    OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you have at least two hours of driving
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    OPERATION Driving with a Passenger 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 64. 13. A passenger should
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    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. Engage 4X4 before
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    OPERATION Driving Uphill 15° Maximum 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. Always move the 4X4 switch to ADC 4X4 before ascending or descending a
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    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. Slow down. 2.
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    OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Always descend a hill with the transmission in
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    OPERATION Turning 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. 8 ft. (2.4 m) 66
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    OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board,
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    if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 110, then see
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    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. Travel slowly and use
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    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning
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    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. 71
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    with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when
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    OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning 2/3 labels and in the specifications sec1/3 tion of this manual. 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. 2. When
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    OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed
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    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 Polaris vehicle
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    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed
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    maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services. Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Steering Front suspension
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    MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar X Air filter, E main element X Engine oil change X Brake pad wear Q Remarks Miles (Km) 500 (800) 100 (160) 200 (320) 250 (400) 250 (400) 250 (400) 500 (800) 500 (800) 500 (800) 500 (800) Inspect
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    Q Brake fluid X ADC fluid Q Spark arrestor E Q Valve clearance Q Toe adjustment Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these
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    MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 76. Items not listed in the chart should
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    MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 80 for fluid recommendations, capacities and plug torques. Oil may need to be changed more frequently if Polaris
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    MAINTENANCE Engine Oil Oil and Filter Change See the table on page 80 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 76. Always change the oil filter whenever changing oil. 550
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    MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath 550 850 the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counter-clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11.
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    MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic SPORTSMAN XP Transmission Fluid for this transmission. See the table on page 80 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic
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    MAINTENANCE Transmission Oil Oil Change 1. Remove the footwell. 2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. 3. Clean and reinstall the drain plug. Torque to specification. 4. Remove the fill plug. Add the proper amount of the recommended oil. 5.
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    MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 80 for fluid recommendations, capacities and plug torques. Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 76. See page 135 for the part numbers of
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    MAINTENANCE Rear Gearcase Oil See the table on page 80 for fluid recommendations, capacities and plug torques. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 76. See page 135 for the part numbers of Polaris products. The
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    MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 86 for demand drive fluid maintenance. Check and change the ADC fluid at the intervals outlined in
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    MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level Bleeder surface. Before performing the Screw fluid change, allow the vehicle Cap to sit for at least 30 minutes. Bleeder 2. Thoroughly clean the areas Valve Screw around and on the ADC reservoir and
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    of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are
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    MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. See page 36. 1. View the fluid level in the bottle. 2. If the level is low, remove the bottle cap and add
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    MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 97
    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 selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 98
    1/8" (0-3 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. 94
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 99
    MAINTENANCE Seats Passenger Seat Removal 1. Pull the latch at the rear of the seat. 2. Pivot the rear of the seat upward and remove the front legs of the seat base from the frame. 3. To reinstall the seat, position the front legs of the seat base under the frame. Pivot the rear of the seat downward
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 100
    Seats Passenger Seat Suspension 1. Remove the passenger seat. 2. Remove the fastener retaining the passenger seat shock to the passenger seat support. 3. Pivot the seat support upward to access the lower shock fastener. Remove the lower shock fastener. 4. Remove the shock from the vehicle. If
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 101
    MAINTENANCE Side Panel/Footwell Removal 1. Remove the seat before removing a side panel. 2. Remove the fasteners securing the side panel or footwell to remove it. Plastic Rivet Hex Head Screw Plastic Rivet 97
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 102
    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. Refer to the specifications section
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 103
    Wheel Removal 1. 2. 3. 4. Stop the engine. Place the transmission in PARK. Lock the parking brake. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 5. Elevate the side of the vehicle by placing a suitable stand under the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 104
    ) Cast Aluminum Steel 45 ft. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. lbs. (102 Nm) 45 ft. lbs. (61 Nm) 100
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 105
    MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover screws, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type prefilter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filter.
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 106
    MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. 1. Access the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 107
    the pod cover and disconnect the speedometer harnesses from the speedometer. CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 3. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 4. Turn the lamp counter-clockwise
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 108
    MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 25 ft.
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 109
    MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw. Phillips Screw 105
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 110
    MAINTENANCE Lights Headlight Housing Replacement 1. Remove the five (5) headlight pod screws. 2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 3. Unplug the headlamp from the wiring harness. 4. Use a small screwdriver to remove the o-rings from the headlight
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 111
    MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 112
    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 136 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
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 113
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel. Wet
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 114
    . Reinstall the plugs or install new plugs. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 8. If water has been ingested into the PVT, follow the procedure on page
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 115
    of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Use the following procedure to periodically purge
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 116
    PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury safe: • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 117
    MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 118
    There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the repeat the process. 7. Take the vehicle to your dealer for service as soon as possible. 114
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 119
    MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 120
    MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. Remove the passenger seat and the seat pivot bolt. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Disconnect the battery hold-down strap. On conventional batteries, remove the battery vent
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 121
    has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 119 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 122
    MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 123
    charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 124
    MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 125
    the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. Be sure the handlebars do
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 126
    MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay 1. Remove the four cover screws from the right handlebar control and remove the cover. 2. With the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 127
    setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your Polaris dealer for service. 7. With the engine running, turn the handlebars fully to the left and right. Tap the throttle lever at each turn, verifying that idle RPM
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 128
    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose,
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 129
    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 • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 130
    and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 131
    . See page 124. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. 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
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 132
    any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 133
    See pages 118-119 for storage and charging procedures. Store the battery in a cool, dry place. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 134
    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 and oil cap. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 135
    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 136
    TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.8 VDC Check all connections
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 137
    TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 138
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 139
    POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2877606 2873602 2873603 2877922 2877923 2871653 2872276 2870465 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 140
    SPECIFICATIONS SPORTSMAN 550 Touring EPS 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 772 lbs. (350 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weight 150 lbs. (68 kg) (Rear rack capacity and tongue weight
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 141
    SPECIFICATIONS SPORTSMAN 550 Touring EPS Lubrication System Transmission Type Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tire Type/Pressure, Front Tire Type/Pressure, Rear Brakes, Front/Rear Brake, Auxiliary
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 142
    SPECIFICATIONS SPORTSMAN 850 Touring EPS 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 798 lbs. (362 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weight 150 lbs. (55 kg) (Rear rack capacity and tongue weight
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 143
    SPECIFICATIONS SPORTSMAN 850 Touring EPS Lubrication System Transmission Type Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tire Type/Pressure, Front Tire Type/Pressure, Rear Brakes, Front/Rear Brake, Auxiliary
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 144
    DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 145
    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain (if
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 146
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 147
    WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment,
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 148
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 149
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 150
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 151
    WARRANTY 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
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 152
    responsible for performing the scheduled maintenance identified in the owner's manual. Polaris may deny warranty claims for failures that have been recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 153
    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 149
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 154
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 150
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 155
    INDEX 0-9 4X4 Switch ...26, 37 C Clutching (550) ...137 Clutching (850) ...139 Cold Weather Operation ...57 Consumer Product Safety ...7 Coolant Bottle ...91 Coolant, Radiator ...92 Cooling System...90-92 Corrosion Removal, Chrome ...126 Crankcase Emission Control System 75 A Accessories ...129
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 156
    Replacement 107 Taillight/Brakelight/Worklight 107 Low Beam Adjustment ...105 Low Range Use ...114 Lower Headlamp Replacement ...107 Lubrication Guide ...80 G Gasoline Handling ...11 Gear Selector ...33 Gearcase Oil, Front ...86 Gearcase Oil, Rear ...87 Gloves ...9 M Maintenance Chart...76
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 157
    Damaged ATV ...21 Operating on Pavement...13 Operating on Public Roads ...13 Operating on Steep Hills...16 Operating Over Obstacles...18 Operating Without Instruction . 10 Physical Control of the ATV . . 14 Physical Skills...21 Poor Visibility...20 P Parking Brake ...31 Parking on an Incline ...71
  • 2010 Polaris Sportsman Touring 850 EPS | Owners Manual - Page 158
    INDEX S Safety Warnings...10-21 Protective Apparel ...12 Reverse Operation ...17 Skidding or Sliding ...18 Slippery Terrain ...17 Stalling While Climbing a Hill 16 Turning Improperly ...14 Unauthorized Use ...21 Unfamiliar Terrain ...17 Using Alcohol or Drugs...12 Seat Adjustments, Passenger ...95
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