Polaris SPORTSMAN 850 2019 User manual

2019
OWNER’S MANUAL
SPORTSMAN® 850
SPORTSMAN XP® 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.

WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road
vehicle can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of California
to cause cancer and birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the engine expect as
necessary, service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
!WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
!
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.

2019 Owner’s Manual
Sportsman® 850
Sportsman XP® 1000

POLARIS®, ACE™, OUTLAW®, and SPORTSMAN® are trademarks of
POLARIS Industries Inc.
Copyright 2018 Polaris Industries Inc. All information contained within this
publication is based on the latest product information at the time of
publication. Due to constant improvements in the design and quality of
production components, some minor discrepancies may result between the
actual vehicle and the information presented in this publication. Depictions
and/or procedures in this publication are intended for reference use only. No
liability can be accepted for 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 instructions.
Printed in U.S.A.
9929560

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide
family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for
the latest news, new product introductions, upcoming events, career
opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational
products. We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience
have gone into the engineering, design, and development of your POLARIS
vehicle, making it the finest machine we’ve ever produced.
• Snowmobiles
• SPORTSMAN® All-terrain vehicles
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
• BRUTUS® work vehicles
• SLINGSHOT® three wheel
motorcycles
• RZR® sport vehicles
• GEM® vehicles
• INDIAN® motorcycles
• POLARIS POWER® generators
• POLARIS DEFENSE® combat
vehicles
• Timbersled® Snow Bikes
For safe and enjoyable 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 Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total
satisfaction. Your POLARIS dealership can perform all of your service needs
during, and after, the warranty period.
3
WELCOME

4
WELCOME

Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . 11
Features and Controls . . . . . . . . . . . . . . 27
Operation . . . . . . . . . . . . . . . . . . . . 57
Winch Guide. . . . . . . . . . . . . . . . . . . 75
Emission Control Systems . . . . . . . . . . . . . 85
Maintenance . . . . . . . . . . . . . . . . . . 87
Specifications . . . . . . . . . . . . . . . . . . 123
POLARIS Products . . . . . . . . . . . . . . . . 129
Troubleshooting . . . . . . . . . . . . . . . . . 131
Warranty . . . . . . . . . . . . . . . . . . . . 137
Maintenance Log . . . . . . . . . . . . . . . . 145
5

6

INTRODUCTION
This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your
local POLARIS dealer. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with
the vehicle.
• Never operate this vehicle without proper instruction. Take an authorized
training course. Visit www.rohva.org or call 866-267-2751.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16
and have a valid driver’s license to operate this vehicle.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the New Operator Driving Procedures outlined in this manual.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.
• Never permit a guest to operate this vehicle unless the guest has reviewed
the owner’s manual and all safety labels and has completed a safety training
7
INTRODUCTION

SAFETY SYMBOLS AND SIGNAL WORDS
The following signal words and symbols appear throughout this manual and on
your vehicle. Your safety is involved when these words and symbols are used.
Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not
avoided, COULD result in serious injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not
avoided, COULD result in minor to moderate injury.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle
damage or property damage.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
NOTICE
NOTICE provides key information by clarifying instructions.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
8
INTRODUCTION

EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per EN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as
indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many
factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
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 your existing keys. The ignition switch must be
replaced if all keys are lost.
The manufacturer’s label is located on the front right side of the vehicle behind
the radiator.
Vehicle Model Number (VIN) q
Frame VIN
Engine Serial Number w
Key Number
9
INTRODUCTION

10

SAFETY
SAFETY TRAINING
ATV safety training is a top priority for POLARIS. POLARIS strongly encourages
you and any family members who will be riding the ATV to take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer
provided information about the authorized ATV RiderCoursesm that is available
to you and your eligible family members. This training is included in the
purchase price of your ATV. You were also provided with printed materials that
explain safe operating procedures. You should review this information on a
regular basis.
If you purchased a used POLARIS ATV in the United States, you can enroll in
the ATV RiderCoursesm for a fee. Call ATV Enrollment Express at (800) 887-
2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the
United States, please contact your dealer or local law enforcement agencies for
information about safety training.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and
regulations concerning the operation of this vehicle in your area. We strongly
advise you to strictly follow the recommended maintenance program outlined in
your vehicle manual. This preventive maintenance program is designed to
ensure that all critical components on your vehicle are thoroughly inspected at
specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call
the Consumer Product Safety Commission at 1-800-638-2772, or visit
www.cpsc.gov, visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.
SAFE RIDING GEAR
Always wear helmet, eye protection, gloves, long-
sleeve shirt, long pants, over-the-ankle boots and
seat belt (if equipped) at all times. Protective gear
reduces the chance of injury.
q
Helmet
w
Eye Protection
e
Long Sleeves
r
Gloves
t
Long Pants
y
Over-the-Ankle Boots
11
SAFETY

HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear
the ECE 22.05 label. The ECE mark consists of a
circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding
this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof
helmet face shield. POLARIS recommends wearing approved Personal
Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or
CE. Make sure protective eye wear is kept clean.
GLOVES
Wear gloves for comfort and for protection from sun, cold weather and other
elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a
POLARIS vehicle with bare feet or sandals.
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
12
SAFETY

SAFETY WARNINGS
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. See the OPERATION section of the owner’s
manual for proper operating procedures.
OPERATING WITHOUT INSTRUCTION
Operating this vehicle without proper instruction increases the risk of an
accident. The operator must understand how to operate the vehicle properly in
different situations and on different types of terrain.
All operators must read and understand the owner's
manual and all warning and instruction labels before
operating the vehicle.
All operators should review the safety DVD provided
with this vehicle and take a ROHVA training course
(www.rohva.org).
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY. Operation
is prohibited for anyone under 16 years of age or
anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and both
hands on the steering wheel (if equipped) or
handlebars.
USING ALCOHOL OR DRUGS
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
13
SAFETY

FAILURE TO INSPECT BEFORE OPERATING
WARNING
Failure to inspect and verify that the vehicle is in safe operating condition
before operating increases the risk of an accident.
Always perform the pre-ride inspection before each use of your vehicle to
make sure it's in safe operating condition.
Always follow the inspection and maintenance procedures and schedules
described in this owner’s manual.
HANDLING GASOLINE
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and 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 gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
EXPOSURE TO EXHAUST
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
PROTECTIVE APPAREL
Riding in this vehicle without wearing an approved helmet and protective eye
wear increases the risk of a serious injuries in the event of an accident.
Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
OPERATING ON PAVEMENT
This vehicle's tires are designed for off-road use only, not for use on pavement.
Operating this vehicle on paved surfaces (including sidewalks, paths, parking
lots and driveways) may adversely affect the handling of the vehicle and may
increase the risk of loss of control and accident or rollover. Avoid operating the
vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and
avoid sudden turns or stops.
14
SAFETY

OPERATING ON PUBLIC ROADS
Operating this vehicle on public streets, roads or
highways could result in a collision with another
vehicle. Never operate this vehicle on any public
street, road or highway, including dirt and gravel roads
(unless designated for off-highway use).
OPERATING AT EXCESSIVE SPEEDS
Operating this vehicle at excessive speeds
increases the operator's risk of losing control.
Always operate at a speed that's appropriate for
the terrain, the visibility and operating conditions
and your skills and experience.
PHYSICAL CONTROL OF THE VEHICLE
Removing even one hand or foot can reduce ability to control the vehicle or
could cause loss of balance and ejection from the ATV.
If a person's feet are not firmly planted on the footrests, they could come into
contact with the wheels or other moving parts and lead to accident or injury.
Always keep both hands on the handlebars and both feet on the footrests of the
ATV during operation.
TURNING IMPROPERLY
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this owner’s
manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
15
SAFETY

JUMPS AND STUNTS
Exhibition driving increases the risk of an accident or
rollover. DO NOT do power slides, “donuts”, jumps or
other driving stunts. Avoid exhibition driving.
IMPROPER HILL CLIMBING
Improper hill climbing could cause loss of control or rollover. Use extreme
caution when operating on hills. Always follow proper procedures for hill climbing
as described in this owner's manual. See the New Operator Driving Procedures
section for details.
DESCENDING HILLS IMPROPERLY
Improperly descending a hill could cause loss of control or rollover. Always
follow proper procedures for traveling down hills as described in this owner’s
manual. See the New Operator Driving Procedures section for details.
CROSSING HILLSIDES
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or rollover. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow proper procedures as
described in this owner's manual. See the New Operator Driving Procedures
section for details.
16
SAFETY

STALLING WHILE CLIMBING A HILL
Stalling, rolling backwards or improperly dismounting
while climbing a hill could cause a rollover.
• Always maintain a steady speed when climbing a
hill.
• Always move the 4X4 switch to 4WDC (if equipped)
before ascending or descending a hill.
If all forward speed is lost:
• Lean forward to keep body weight uphill. A passenger should also lean uphill.
• Apply the brakes.
• Lock the parking brake when fully stopped.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. 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.
If the ATV begins rolling downhill:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. 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.
OPERATING ON STEEP HILLS
Operating on excessively steep hills could cause an overturn.
Never operate on hills too steep for the ATV or for your abilities.
• Never operate a 1-up ATV on hills steeper than 25 degrees.
17
SAFETY

OPERATING ON SLIPPERY TERRAIN
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.
Do not operate on excessively rough, slippery or loose
terrain until you've learned and practiced the skills
necessary to control the vehicle on such terrain.
Always use extra caution on rough, slippery or loose
terrain.
OPERATING IN UNFAMILIAR TERRAIN
Failure to use extra caution when operating on unfamiliar terrain could result in
an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause
loss of control or rollover.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always
be alert to changing terrain conditions.
IMPROPER TIRE MAINTENANCE
Operating this vehicle with improper tires or with
improper or uneven tire pressure could cause loss of
control or accident.
Always use the size and type of tires specified for your
vehicle.
Always maintain proper tire pressure as described in
the owner's manual and on safety labels.
OPERATING IMPROPERLY IN 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 the New Operator Driving Procedures section for details.
Before shifting into reverse gear, always check for obstacles or people behind
the vehicle. When it's safe to proceed, back slowly.
OPERATING OVER OBSTACLES
Improperly operating over obstacles could cause loss of control or rollover.
Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as large rocks and fallen trees. Always follow the proper
procedures outlined in this manual when operating over obstacles. See the New
Operator Driving Procedures section for details.
18
SAFETY