Polaris 2009 Sportsman XP 850 User manual

GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION 1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL: 2009 SPORTSMAN XP 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL: 2009 SPORTSMAN XP 850 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
DETAILED: 2009 SPORTSMAN XP 850 / XP 850 EPS. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
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1.2
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
EH085OLE.............................................................Twin Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start
Vehicle Identification Number (VIN)
Vehicle and Engine Serial Number Locations
Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and
the engine serial number.
The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1).
The engine serial number can be found on top of the engine located on the valve cover (see Figure 1-2).
}
Machine Model Number Identification
}
}
Year Designation
Basic Chassis
Designation Engine Designation
Emissions &
Model Option
A 0 9 Z N 8 5 A L
}
4 X A Z N 8 5 A * 9 P 0 0 0 0 0 0
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Descriptor Vehicle Identifier
}
Check Digit
Model
Yea r
Body Style
Plant No
Individual Serial Number
* This could be either
a number or a letter
Powertrain
Emissions
VIN
Figure 1-1
Engine Serial
Number
Figure 1-2
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1.3
GENERAL INFORMATION
1
VEHICLE INFORMATION
Publication Numbers
NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key
and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch
assembly is necessary.
Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools
maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris
product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or
on-line at http://polaris.spx.com/.
YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN
2009 SPORTSMAN XP 850 A09ZN85AL, AQ,
AS, AT, AX, FL
9921973
9922173 (INT’L)
9921857
9922081 (INT’L)
2009 SPORTSMAN XP 850 EPS A09ZX85AG, AL,
AQ, AR, AS, AX, FS
9921973
9922173 (INT’L)
9921977
9922085 (INT’L)
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
Key Series
Number
KEY COVER
P/N 5533534
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1.4
GENERAL INFORMATION
SPECIFICATIONS
MODEL: 2009 SPORTSMAN XP 850
MODEL NUMBER:. . . . . . . . . A09ZN85AL, AQ, AS, AT, AX, FL
ENGINE MODEL:. . . . . . . . . . EH085OLE
MODEL: 2009 SPORTSMAN XP 850 EPS
MODEL NUMBER:. . . . . . . . . A09ZX85AG, AL, AQ, AR, AS, AX, FS
ENGINE MODEL:. . . . . . . . . . EH085OLE
* Data based on EU Directive 76/432/EEC
Category Dimension
Length 83.25 in. / 211.5 cm
Width 47.6 in. / 121 cm
Height 50.75 in. / 129 cm
Wheel Base 53 in. / 135 cm
Ground Clearance 11.6 in. / 29.5 cm
Turning Radius 84 in. / 213 cm (unloaded)
Dry Weight 784 lbs. / 356 kg
Front Rack Capacity 120 lbs. / 54 kg
Rear Rack Capacity 240 lbs. / 109 kg
Max. Weight Capacity 575 lbs. / 261 kg
Towing Capacity 1500 lbs. / 680 kg
Unbraked Trailer
Towing Capacity (EU)* 1913.6 lbs. / 868 kg
Hitch Tongue Weight 150 lbs. / 68 kg
Category Dimension
Length 83.25 in. / 211.5 cm
Width 47.6 in. / 121 cm
Height 50.75 in. / 129 cm
Wheel Base 53 in. / 135 cm
Ground Clearance 11.6 in. / 29.5 cm
Turning Radius 84 in. / 213 cm (unloaded)
Dry Weight 796 lbs. / 361 kg
Front Rack Capacity 120 lbs. / 54 kg
Rear Rack Capacity 240 lbs. / 109 kg
Max. Weight Capacity 575 lbs. / 261 kg
Towing Capacity 1500 lbs. / 680 kg
Unbraked Trailer
Towing Capacity (EU)* 1913.6 lbs. / 868 kg
Hitch Tongue Weight 150 lbs. / 68 kg
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1.5
GENERAL INFORMATION
1
2009 SPORTSMAN XP 850 / XP 850 EPS
XP MODELS: A09ZN85AL,AQ,AS,AT,AX,FL
XP EPS MODELS: A09ZX85AG,AL,AQ,AR,AS,AX,FS
ENGINE MODEL: EH085OLE
CLUTCH CHART
Engine
Platform Domestic Twin Cylinder, 4-Cycle
Engine Model Number EH085OLE011
Engine Displacement 850 cc
Number of Cylinders 2
Bore & Stroke (mm) 87 x 71.5 mm
Compression Ratio 11.0:1
Compression Pressure 210 - 250 psi
Engine Idle Speed 1200 ±50 RPM
Cooling System / Cap. Liquid Cooled / 2 qt. (1.9 l)
Overheat Warning Instrument Cluster Indicator
Lubrication Pressurized Wet Sump
Engine Oil Requirement PS-4 Plus / 2 qt. (1.9 l)
Exhaust System Stainless Steel Dual Header Pipe
w/ Dual Outlet Silencer
Fuel System
Fuel System Type Bosch Multi-Port Sequential
Electronic Fuel Injection
Throttle Body / Size Mikuni Dual Bore / 40 mm
Fuel Delivery Electronic Fuel Pump
(in tank)
Fuel Pressure 43 psi
Fuel Capacity XP: 5.25 gal. (20 l)
XP EPS: 4.5 gal. (17 l)
Fuel Requirements 87 Octane (minimum)
Electrical
Alternator Output 475 W @ 1200 RPM / Peak 575 W
Voltage Regulator 3-Phase / 32 Amp
Head Lights Pod: 12V / 50 Watts
Bumper: 12V / 50 Watts x 2
Brake Light 12V / 27 Watts
Tail Light 12V / 7 Watts
Starting System Electric
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 6° ± 5° BTDC @ 1200 RPM
Spark plug / Gap REA8MCL / .035 in. (.90 mm)
Battery / Model / AH / CCA Deka / ETX30L / 30 AH / 365
Instrumentation Multifunction Instrument Cluster
DC Outlet Standard
Relays
(Located in Relay/Fuse Box)
Chassis / Start Solenoid / Fan /
EFI / Bumper Lights
Circuit Breaker Fan Motor: 20A
Fuses
(Located in Relay/Fuse Box)
Lights: 20A / Drive: 20A /
Accessory: 20A / EFI: 20A /
Unswitched: 10A / EPS: 30A
Drivetrain
Transmission Type Automatic PVT
In-Line H-L-N-R-P
Transmission
Fluid Type / Fluid Capacity
Synthetic Sportsman XP
Transmission Fluid /
32 oz. (946 ml)
Front Gearcase
Fluid Type / Fluid Capacity
Premium LT Demand Drive
Fluid / 9.3 oz. (275 ml)
Front Gearcase
ADC Reservoir Fluid Type
Premium ADC
Front Drive Fluid
Rear Gearcase
Fluid Type / Fluid Capacity
ATV Angle Drive Fluid /
7.1 oz. (210 ml)
Clutch Type PVT w/EBS
Belt 3211123
Steering / Suspension
Toe Out 0-1/16 in. (0-.159 mm)
Front Suspension Dual A-arm
Front Travel 9.2 in. / 23.4 cm
Rear Suspension Dual A-arm w/Rolled IRS
Rear Travel 10.2 in. / 25.9 cm
Shock Preload Adjustment
Front / Rear Cam Adjustable
Wheels / Brakes
Front Wheel Size / Bolt Pattern
Tire Model / Size
14 x 6 / 4-156
Carlisle Terrathon / 26 x 8 - 14
Rear Wheel Size / Bolt Pattern
Tire Model / Size
14 x 8 / 4-156
Carlisle Terrathon / 26 x 10 - 14
Tire Air Pressure Front: 7 psi (48 kPa)
Rear: 5 psi (34.5 kPa)
Brakes - Front & Rear Single Control
Hydraulic 4-Wheel Disc
Brake Fluid Polaris DOT 4 Brake Fluid
Altitude Shift
Weight
Drive
Spring
Driven
Spring
Meters
(Feet)
0-1800
(0-6000)
24-63
5632215
Red / Wht
7043349
Red / Wht
3235621
1800-3700
(6000 - 12000)
24-60
5632216
Red / Wht
7043349
Red / Wht
3235621
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1.6
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
°C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C
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1.7
GENERAL INFORMATION
1
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the
steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque
values of fasteners before using standard torque.
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1.8
GENERAL INFORMATION
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
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1.9
GENERAL INFORMATION
1
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to
close and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm²: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in²: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
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NOTES
GENERAL INFORMATION
1.10
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MAINTENANCE
2.1
CHAPTER 2
MAINTENANCE 2
PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2
MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
MAINTENANCE QUICK REFERENCE, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . .2.7
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 2.9
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9
FUEL FILTERS / VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
THROTTLE OPERATION / ETC SWITCH / THROTTLE CABLE ADJUSTMENT . . . . . 2.10
AIR FILTER / PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
ENGINE OIL LEVEL / OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
ENGINE BREATHER HOSE / BREATHER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .2.13
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
COMPRESSION AND LEAKDOWN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
EXHAUST SILENCER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE MOUNT FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
FRONT GEARCASE ADC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLING SYSTEM HOSES / COOLANT STRENGTH / COOLANT TYPE . . . . . . . . .2.22
PVT / FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
PVT DRYING / DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
WHEEL AND HUB TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TIRE PRESSURE / TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
ENGINE / CHASSIS GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
POWER STEERING UNIT (EPS MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
TIE ROD END / STEERING INSPECTION / TOE ALIGNMENT . . . . . . . . . . . . . . . . . .2.29
TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
SUSPENSION INSPECTION / SUSPENSION SPRING PRE-LOAD ADJUSTMENT . .2.30
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BRAKE FLUID / BRAKE PAD / HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . .2.31
AUXILIARY BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
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2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenanceintervalsinthe followingchartare based uponaverageriding conditionsandanaveragevehicle speed ofapproximately
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, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.
Break-In Period
The break-in period consists of the first 20 hours of operation. Careful treatment of a new engine and drive components will result
in more efficient performance and longer life for these components.
• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 20 hours or one month.
• See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures markedcould result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
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2.3
MAINTENANCE
2
Maintenance Intervals
Item
Maintenance Interval
(whichever comes first) Remarks
Hours Calendar Miles
(KM)
Steering - Pre-Ride -
Inspect and make adjustments as needed.
See Pre-Ride Checklist later in this chapter.
Front Suspension - Pre-Ride -
Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
Brake Fluid Level - Pre-Ride -
Brake Lever Travel - Pre-Ride -
Brake System - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
Engine Oil Level - Pre-Ride -

EAir Filter, Pre-filter - Daily - Inspect;clean often
Coolant - Daily - Check level daily, change coolant every two
years
ADC Fluid - Daily - Check level daily, add as needed
Power Steering Unit
(if equipped) - Daily - Inspect daily, clean often
Head Lights / Tail Lights - Daily - Check operation; apply dielectric grease if
replacing

EAir Filter (main element) - Weekly - Inspect; replace as needed

Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test

EEngine Oil Change
(Break-in Period) 20 H 1 M - Performabreak-inoilchangeatonemonthor
20 hours, whichever comes first
Front Gearcase Fluid 25 H Monthly 250 (400) Inspect level
Rear Gearcase Fluid 25 H Monthly 250 (400) Inspect level
Transmission Fluid 25 H Monthly 250 (400) Inspect level
Perform these procedures more often for vehicles subjected to severe use.
EEmission Control System Service (California)
Have an authorized Polaris dealer perform these services.
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2.4
MAINTENANCE
Item
Maintenance Interval
(whichever comes first) Remarks
Hours Calendar Miles
(KM)
General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

EThrottle Cable / ETC Switch 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if
necessary
EThrottle Body Intake
Duct 50 H 6 M 500 (800) Inspect ducts for proper sealing / air leaks
Drive belt 50 H 6 M 500 (800) Inspect; replace as needed
Cooling System 50 H 6 M 500 (800) Inspect coolant strength seasonally;
pressure test system yearly
Radiator 50 H 6 M 500 (800) Inspect; clean external surfaces
Cooling Hoses 50 H 6 M 500 (800) Inspect for leaks
Engine Oil Change 100 H 6 M 1000 (1600) Perform a break-in oil change at 20 hours or
after one month of operation; change more
frequently during cold weather operation
Oil Filter Change 100 H 6 M 1000 (1600) Replace with oil change
Front Gearcase Fluid - 12 M 1000 (1600) Change Fluid
Rear Gearcase Fluid - 12 M 1000 (1600) Change Fluid
Transmission Fluid - 12 M 1000 (1600) Change Fluid

EFuel System 100 H 12 M 1000 (1600) Check for leaks at tank cap, fuel lines, fuel
pump; replace lines every two years
Engine Mounts 100 H 12 M 1000 (1600) Inspect
Exhaust Pipe / Silencer 100 H 12 M 1000 (1600) Inspect

ESpark Plug 100 H 12 M 1000 (1600) Inspect; replace as needed
Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to
water, mud, etc.
Clutches
(Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
Brake Fluid 200 H 24 M 2000 (3200) Change every two years
ADC Fluid 200 H 24 M 2000 (3200) Change every two years
Spark Arrestor
(if applicable) 300 H 36 M 3000 (4800) Clean out; or remove clean out plug

EValve Clearance 1000H - 10000 (16000) Inspect; adjust
Toe Adjustment - Inspect periodically; adjust as needed
Headlight Aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
EEmission Control System Service (California)
Have an authorized Polaris dealer perform these services.
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2.5
MAINTENANCE
2
Grease Lubrication Points
There are grease fittings on each upper and lower front and rear A-arms, each rear bearing carrier, and on the front propshaft yoke.
Apply a maximum of 3 pumps of grease at each of these areas.
Item Recommended Lube Method Frequency
Front Propshaft Yoke
PolarisPremium U-Joint Grease Grease fittings (3 pumps maximum)
every 500 miles (800 km).
Grease before long periods
of storage, and after
pressure washing or
submerging the ATV.
Front & Rear A-Arms
Rear Bearing Carrier
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2.6
MAINTENANCE
Maintenance Quick Reference
* More often under severe use, such as operated in water or under severe loads.
III. # Item Lube Rec. Method Frequency*
1Engine Oil PolarisPS-4PLUS2W-50
Performance Synthetic Add oil to proper level on dipstick
Change after 1st month or first
20 hours of operation, 100
hours thereafter; Change more
often (25 hours) in severe duty
conditions or short trip cold
weather operation
2 Transmission Synthetic Sportsman XP
Transmission Fluid Add fluid until it is visible at the fill hole threads Check level every 25 hours; change fluid yearly
3 Engine Coolant Polaris 60/40 Coolant Maintain coolant level in
coolant reservoir bottle. Check level daily, change coolant every 2 years
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2.7
MAINTENANCE
2
Maintenance Quick Reference, Continued.....
*More often under severe use, such as operated in water or under severe loads.
III. # Item Lube Rec. Method Frequency*
4FrontGearcase
ADC Reservoir Polaris Premium ADC Front Drive Fluid Maintain fluid level in ADC Reservoir to indicated level Check level every 25 hours; change fluid every two years
5 Front Gearcase Polaris Premium LT
Demand Drive Fluid Add fluid until it is visible at the fill hole threads Check level every 25 hours; change fluid yearly or 1000 mi.
6 Rear Gearcase Polaris ATV Angle Drive
Fluid (ADF) Add fluid until it is visible at the fill hole threads Check level every 25 hours; change fluid yearly
7 Brake Fluid Polaris DOT 4 Brake Fluid Maintain fluid level in both master cylinder reservoirs to
indicated levels
Check level during pre-ride
inspection; change fluid every
two years
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2.8
MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS
PolarisLubricants,Maintenanceand Service
Products
NOTE: Each item can be purchased separately at
your local Polaris dealer.
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
Part No. Description
Engine / Transmission Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244 PS-4PLUS2W-50PerformanceSynthetic
4-Cycle Engine Oil (Quart)
2876245 PS-4PLUS2W-50PerformanceSynthetic
4-Cycle Engine Oil (Gallon)
Gearcase Lubricants
2877606 Synthetic Sportsman XP
Transmission Fluid (Quart)
2876251 Premium LT Demand Drive Fluid
(Quart) (12 count)
2872277 Premium Demand Drive Hub Fluid
(2.5 Gallon) (2 count)
2876160 ATV Angle Drive Fluid
(Quart) (12 count)
2872276 ATV Angle Drive Fluid
(2.5 Gallon) (2 Count)
2870465 Pump for Gallon Jug
Coolant
2871534 60/40 Coolant (Quart) (12 count)
2871323 60/40 Coolant (Gallon) (6 count)
Grease / Specialized Lubricants
2871312 Grease Gun Kit
2871322 Premium All Season Grease
(3 oz. cartridge) (24 Count)
2871423 Premium All Season Grease
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
Additives/ Sealants/ThreadLockingAgents/ Misc.
2870585 Loctite™ Primer N, Aerosol, 25 g
2871956 Loctite™ Thread Sealant 565
(50 ml.) (6 Count)
2871949 Loctite™ Threadlock 242
(50 ml.) (10 Count)
2871950 Loctite™ Threadlock 242
(6 ml.) (12 Count)
2871951 Loctite™ Threadlock 262
(50 ml.) (10 Count)
2871952 Loctite™ Threadlock 262
(6 ml.) (12 Count)
2871953 Loctite™ Threadlock 271
(6 ml.) (12 Count)
2871954 Loctite™ Threadlock 271
(36 ml.) (6 Count)
2870584 Loctite™ 680-Retaining Compound
(10 ml.)
2870587 Loctite™ 518 Gasket Eliminator / Flange
Sealant (50 ml.) (10 Count)
2871326 Premium Carbon Clean
(12 oz.) (12 Count)
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2872189 DOT 4 Brake Fluid (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)
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2.9
MAINTENANCE
2
GENERAL VEHICLE INSPECTION
AND MAINTENANCE
Pre-ride / Daily Inspection
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance.
• Tires - check condition and tire pressure
• Fuel and oil - fill both to their proper level; do not
overfill
• All brakes - check operation (includes auxiliary brake)
• Throttle - check for free operation
• Headlight / Taillight / Brakelight - check operation of
all indicator lights and switches
• Engine stop switch (key switch) - check for proper
function
• Wheels - check for loose wheel nuts
• Air cleaner element - check for dirt or water; clean or
replace
• Steering - check for free operation, noting any unusual
looseness in any area
• Loose parts - visually inspect vehicle for any damaged
or loose nuts, bolts or other fasteners
• Engine coolant - check for proper level at the recovery
bottle
Frame, Nuts, Bolts, Fasteners
Periodically inspect the torque of all fasteners in accordance
with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Controls
Check handlebar controls for proper operation, positioning and
adjustment.
FUEL SYSTEM AND AIR INTAKE
Fuel System
• Always stop the engine and refuel outdoors or in a well
ventilated area.
• Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where gasoline
is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
• If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
• Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result loss
of consciousness or death in a short time.
• Never drain the fuel when the engine is hot. Severe
burns may result.
Fuel Lines
1. Check fuel lines for signs of wear, deterioration, damage,
or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured with
cable ties where applicable.
3. Replace all fuel lines every two years.
WARNING
Gasoline is extremely flammable and explosive
under certain conditions.
CAUTION
Make sure lines are not kinked or pinched
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2.10
MAINTENANCE
Fuel Filters
Therearetwo fuel filterslocatedwithin thefuel pumpassembly.
The fuel pump is non-serviceable. If the internal fuel pump
filters require service, the fuel pump and fuel tank must be
replaced as an assembly.
NOTE: See the “Electronic Parts Catalog” for more
information. For all other information related to the EFI
System, refer to Chapter 3.
Vent Line
1. Check the vent line from the fuel tank for signs of wear,
deterioration, damage or leakage. Replace the line every
two years.
2. Verify vent line is routed properly and secured with an
appropriate number of cable ties.
Throttle Operation
Check for smooth throttle opening and closing in all handlebar
positions. Throttle lever operation should be smooth and lever
must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, no adjustment is required.
5. Replace the throttle cable if worn, kinked, or damaged.
Electronic Throttle Control Switch (ETC) /
Throttle Cable Adjustment
NOTE:SportsmanXPrequiresanew adjustmentprocedure.
1. Slide the boot back far enough to expose the inline cable
adjuster sleeve and loosen the adjuster locknut.
2. Remove the (4) screws and cover from the RH control.
3. With handlebars centered and wheels pointing forward,
slowly turn the adjuster sleeve counter-clockwise (out) just
until the gap is removed between the throttle arm and the
throttle arm stop (see illustration below).
NOTE: While moving the adjuster sleeve, “flip” the
throttle lever slightly to remove slack in the cable.
4. Turn the cable adjuster sleeve clockwise (in) 1.5 - 2 turns;
tighten locknut and reinstall boot. After this adjustment
there should be .079-.118” (2-3 mm) gap between throttle
arm and throttle arm stop.
5. Reinstall the RH control cover and ensure the O-ring is
properly in place. Securely tighten the (4) screws.
6. Place the vehicle in PARK and start the engine. Turn the
handlebars from full left to full right while listening for any
change in engine speed. If engine speed changes, loosen
the locknut and turn the adjuster sleeve clockwise (in) an
additional 1/2 turn and repeat this step.
CAUTION
Make sure lines are not kinked or pinched
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