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2016 Polaris Sportsman XP 1000 Owners Manual

2016 Polaris Sportsman XP 1000 Manual

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2016 Polaris Sportsman XP 1000 | Owners Manual - Page 1
and Safety Sportsman 850 Sportsman 850 SP Sportsman Touring 850 Sportsman Touring 850 SP Sportsman XP 1000 Sportsman XP Touring 1000 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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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 1-800-342-3764 for assistance. For
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2016 Owner's Manual Sportsman® 850 Sportsman® 850 SP Sportsman® Touring 850 Sportsman® Touring 850 SP Sportsman® XP 1000 Sportsman® XP Touring 1000 1
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omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original
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TABLE OF CONTENTS Introduction ...4 Safety ...9 Features and Controls ...30 Operation ...56 Winch Guide ...79 Emission Control Systems ...91 Maintenance ...92 Troubleshooting ...139 POLARIS Products...143 Specifications ...144 Warranty ...152 Maintenance Log ...160 Index ...162 3
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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 can be performed by a factory certified Master
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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. DANGER A DANGER indicates a hazardous situation that, if not avoided, will 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 European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as
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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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of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. FOR
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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 Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established
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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. 13
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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 68. 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 70. 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 74. 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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ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Over Obstacles Improperly operating over obstacles an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but
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ATV. • Cargo should be properly distributed and securely attached. • 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. See pages 76-78. • Always follow the
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fall through the ice. Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo, together with any other vehicles in your party. Variances in snow depth and
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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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SAFETY Safety Labels and Locations Passenger Warning (2-Up Models) General Warning Age 16 Warning Discretionary Warning Reverse Override Warning AWD Caution Reverse Override Warning/AWD Caution (All Models) WARNING Improper use of override button can lead to loss of control resulting in severe
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SAFETY Safety Labels and Locations Passenger Warning (2-Up Models) 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 plant feet on footrests and securely grasp
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NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper training or instruction • at speeds too fast for your skills or the conditions • on public roads - a seriously affect handling and control LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 26
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THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper ATV training or instruction • at speeds too fast for your skills or the conditions • on public roads - a label and passenger safety label LOCATE AND READ OPERATOR'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 27
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SAFETY Safety Labels and Locations Tire Pressure/Load Warning (1-Up Models) 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) • Maximum weight
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 31
SAFETY Safety Labels and Locations Rack/Box Warning Tire Pressure/Load Warning Rack/Box Warning Clutch Cover Warning (under seat) Hitch Capacity Label Rack/Box Warning (All Models) WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow
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FEATURES AND CONTROLS Switches Headlight Switch 2x4 4X4 Switch Mode/Reverse Override Switch Engine Stop Switch Main Key Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress
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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 OFF RUN OFF attempting to start the engine. The engine will not start or run when the switch is off. Both the
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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. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever
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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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 36
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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 37
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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 38
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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 39
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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 40
FEATURES AND CONTROLS Front Compartment Battery Brake Fluid Reservoir (auxiliary foot brake) Coolant Bottle Cap Radiator Cap Electrical/Fuse/Relay Front Rack (1-Up Models) Release the front rack latches and remove the rack to gain access to the front compartment. To reinstall the rack, hold the
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FEATURES AND CONTROLS Front Compartment Front Storage Box (Touring) 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 lift the unlatched
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 42
FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 45 for EPS Warning Indicator information. Extreme Use Battery An optional extreme use
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FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is 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 before
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 44
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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 45
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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 46
FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 47
FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps Lamp Indicates Vehicle Speed Over Temperature Condition When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. This lamp flashes to indicate
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FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 49
press the MODE button. The time will display for 5-10 seconds. See page 49 for resetting instructions. 6. Service Reminder Display - A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 49 for
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FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 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. This feature does not contain a vehicle
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FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display. 2. Press and hold the
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release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval. Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer can provide for all major repairs
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FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays Number (SPN) Number (0-9) only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not
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FEATURES AND CONTROLS Instrument Cluster 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 electronic control unit and
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FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Ignition Coil Primary Driver 1 (MAG) Ignition Coil Primary Driver 2 (PTO) Fuel Pump Driver Circuit Condition Driver Circuit Short to B+ Driver Circuit Short to B+ Driver Circuit Open/Grounded
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FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition EPS Models Only Vehicle Speed Sensor Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Abnormal Rate Of Change Received Network
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FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition EPS Models Only EPAS Inverter Temperature Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Above Normal Operating Range - Moderately Severe Level EPAS
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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 20 hours of operation. No single action on your part
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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 97. 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 Brake system/lever travel Brake fluid Auxiliary brake
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, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable). 6. Operate this vehicle off-road only. Never water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo,
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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 wellventilated 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 10. Perform the pre-ride inspection. See page 58. 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 carry a passenger on a 1-up ATV. Never carry more than one passenger on a 2-up ATV. 2. Do not carry a passenger on a 2-up ATV until you have at least two hours of driving experience with the vehicle. 3. Never allow anyone under 12 years of age to ride as a
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OPERATION Driving with a Passenger 11. Do not cross a hillside with a passenger on board. See page 68. 12. Make sure the passenger understands the importance of "active riding." When hillclimbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver
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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 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 hill. See
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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 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 43. 3. Avoid steep hills. Maximum incline is: • 15° (2-Up Models) • 25°
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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) 70
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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 43. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board,
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or fast-flowing water. NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 92. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all
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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. 75
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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 1. Never exceed the weight capacities specified for your ATV on warning labels and in 2/3 the specifications section of 1/3 this manual. 2. 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. 3. 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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WINCH GUIDE 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. Your
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WINCH GUIDE Winch Safety Precautions 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching
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WINCH GUIDE Winch Safety Precautions 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. Always inspect your winch and winch cable before each use. 23. Never winch the hook
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GUIDE result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to . 2. Never operate a winch or a vehicle in need of repair or service. 3. Always apply your vehicle's park brake and/or park mechanism to hold
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WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A.
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WINCH GUIDE Winch Operation 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
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WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be '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. Slowly winch in the slack in the winch cable
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WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle's engine run while operating the winch to
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WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
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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
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WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery
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WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable.
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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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for performing the scheduled maintenance identified in this owner's manual. Careful periodic maintenance will help keep your vehicle in 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
2016 Polaris Sportsman XP 1000 | Owners Manual - Page 95
failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Steering Front suspension Rear
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H 50 H 6M 6M Ź Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. 94
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MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Ź Oil lines and fasteners Ź Engine oil change Ź Demand drive fluid (normal use) Ź Rear gearcase oil Ź Transmission oil D Fuel system 100 H 100 H 100 H 100 H 100 H 100 H 6M 6M 12 M 12 M 12 M 12 M
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MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 92. Items not listed in the chart should
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MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W50 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 5W50 oil. Follow the manufacturer's recommendations for ambient
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MAINTENANCE Engine Oil Oil and Filter Change See the table on page 96 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 92. Always change the oil filter whenever changing oil. Drain
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MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate the
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MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 92. See the table on page 96 for fluid recommendations, capacities and plug torques. See page 143 for the part numbers of POLARIS products. Maintain
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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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excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service. Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the
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MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 92. See the table on page 96 for fluid recommendations, capacities and plug torques. See page 143 for the part numbers of POLARIS products. The
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ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer or other qualified service facility before operating the vehicle. Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system
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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 39. 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, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. Any time the cooling system has been drained for maintenance or repair,
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use spray lubricants or other petroleum-based products. If you discover any damage (cracks, excessive corrosion, warping) see your dealer for service before operating. Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the
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not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer or other qualified service facility. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3. Tie a length of string String between
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MAINTENANCE Side Panel/Footwell Removal 1. Remove the seat before removing a side panel. 2. To remove a side panel or footwell, remove the fasteners securing it to the frame. Lift the right side panel upward while removing it to clear the shifter knob Touring Shown Plastic Rivet Hex Head Screw
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MAINTENANCE Seat Removal (1-Up Models) 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. Remove the seat. Seat Removal (Touring) To remove the operator's seat, grasp one side of the seat near the rear edge. Pull upward abruptly to
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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original PARK. Lock the parking brake. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist. 5.
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ensure that all nuts are torqued to specification. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Wheel Type All Nut Torque 75 ft-lbs (102 Nm) 112
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MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover strap, 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.
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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
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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. 2. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 3. Turn the lamp counter-clockwise
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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.
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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 117
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MAINTENANCE Lights Headlight Housing Replacement (SP/XP Models) 1. Remove the seven (7) headlight pod screws. 2. Pull the pod cover forward. 3. Unplug the headlamp from the wiring harness. Headlight 4. Use a small Housing screwdriver to remove the o-rings from the headlight mounting tabs. 5. Pull
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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
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MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 146 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
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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
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immersed, major engine damage can result if the machine is not thoroughly inspected. 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. 1. Move
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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 arrester while the system is hot. Allow components to cool sufficiently before proceeding. Use the following procedure to periodically purge
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PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury vent system when replacing the belt. • 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
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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
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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. repeat the process. 7. Your vehicle requires service as soon as possible, which your POLARIS dealer can provide. 126
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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
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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 129 before installing the battery. An optional extreme use battery may be available for your model. If the performance of the factory
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. Stop 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. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage
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MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% Charge Time Voltage 12.8-13.0 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge given, check in
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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
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RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service facility for adjustment. Throttle Cable Freeplay 1. Remove the four cover screws from the right handlebar control and remove the cover. 2. With the
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), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your POLARIS dealer or other qualified service facility 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
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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,
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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
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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
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See pages 128-129 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
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MAINTENANCE Cleaning and Storage Accessories Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV
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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
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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
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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
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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
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POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878920 2878919 2878068 2878069 2877922 2877923 2870465 2880514 2880513 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 Full Synthetic
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SPECIFICATIONS SPORTSMAN 850 / 850 SP Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories) Dry Weight 759 lbs. (344.3 kg) (850) 767 lbs. (347.9 kg) (850 SP) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase
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SPECIFICATIONS SPORTSMAN 850 / SPORTSMAN 850 SP Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light
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SPECIFICATIONS SPORTSMAN Touring 850 SP Maximum Weight Capacity 575 lbs. (261 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
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SPECIFICATIONS SPORTSMAN Touring 850 SP 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
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SPECIFICATIONS SPORTSMAN XP 1000 Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories) Dry Weight 767 lbs. (347.9 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 7.1 oz. (210 ml) Demand
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SPECIFICATIONS SPORTSMAN XP 1000 Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster
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SPECIFICATIONS SPORTSMAN XP Touring 1000 Maximum Weight Capacity 575 lbs. (261 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
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SPECIFICATIONS SPORTSMAN XP Touring 1000 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
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BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. Warranty Coverage And Exclusions
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WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or
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WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES
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must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the Country where your product
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where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country
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extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension. This emissions limited warranty covers
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are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a
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WARRANTY California Residents Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50-state models available for sale in California are identified by the letter "B" in the ninth position of the model
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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 160
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MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 161
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INDEX 0-9 4X4 Switch ...30, 41 C Cold Weather Operation ...61 Compartment, Front...38-39 Consumer Product Safety ...9 Coolant Bottle ...105 Coolant, Radiator...106 Cooling System ...104-106 Crankcase Emission Control System. 91 A Access, Front Compartment ...38 Accessories ...138 Active Descent
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Replacement . 119 Taillight/Brakelight/Worklight . 119 Low Beam Adjustment ...117 Low Range Use...126 Lower Headlamp Replacement...119 Lubrication Guide ...96 M Maintenance Chart ...92-95 Master Cylinder ...34 Metric Display ...48 Mode Switch ...30 Modifications ...11 N Noise Emission Control
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W Warning Symbols ...5 Washing the Vehicle ...134-135 Wheel Installation ...112 Wheel Nut Torque Specifications . . 112 Wheel Removal ...111 Winch Cable Care ...87 Winch Maintenance/Service Safety. . 90 Winch Operation ...82-86 Winch Safety Precautions ...79-81 Winch Shock Loading ...88-89 164
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carrying a passenger - dismount passenger when conditions require. S make sure passenger reads and understands all safety labels. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc