2015-2017 Polaris Sportsman 850 ATVs OEM Service & Repair Manual

FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer ® technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'. Publication Printed January 2017 (PN 9927652 R01) 2015-2017 Sportsman/Scrambler 850/1000 Service Manual

SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE NOTE provides key information by clarifying instructions. IMPORTANT IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX: 2015 – 2017 SPORTSMAN / SCRAMBLER REV RELEASE DATE CHANGES R01 01/24/2017 Initial release R02

2015-2017 Sportsman/Scrambler 850/1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10: BODY / FRAME CHAPTER 11: ELECTRICAL

1 1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ............................................................................. 1.2 MODEL NUMBER DESIGNATION (2015 +) ............................................................ 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION............................................ 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS ............................................... 1.3 REFERENCE INFORMATION ........................................................................... 1.4 REPLACEMENT KEYS ................................................................................ 1.4 PUBLICATION NUMBERS ............................................................................. 1.5 SPECIAL TOOLS ...................................................................................... 1.6 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........................................................ 1.7 VEHICLE SPECIFICATIONS ............................................................................ 1.8 2015 SPORTSMAN 850 ............................................................................... 1.8 2015 SPORTSMAN 850 SP ........................................................................... 1.10 2015 SPORTSMAN 850 TOURING ................................................................... 1.12 2015 SPORTSMAN 1000 XP.......................................................................... 1.14 2015 SPORTSMAN 1000 XP TOURING............................................................... 1.16 2015 SCRAMBLER 850............................................................................... 1.18 2015 SCRAMBLER 1000 XP HO ...................................................................... 1.20 2016 SPORTSMAN 850 .............................................................................. 1.22 2016 SPORTSMAN 850 SP ........................................................................... 1.24 2016 SPORTSMAN 850 TOURING ................................................................... 1.26 2016 SPORTSMAN 1000 XP.......................................................................... 1.28 2016 SPORTSMAN 1000 XP TOURING............................................................... 1.30 2016 SCRAMBLER 850............................................................................... 1.32 2016 SCRAMBLER 1000 XP HO ...................................................................... 1.34 2016 SPORTSMAN XP 850 HIGH LIFTER ............................................................ 1.36 2016 SPORTSMAN XP 1000 HIGH LIFTER ........................................................... 1.38 2017 SPORTSMAN 850 .............................................................................. 1.40 2017 SPORTSMAN 850 SP ........................................................................... 1.42 2017 SPORTSMAN 850 TOURING ................................................................... 1.44 2017 SPORTSMAN 1000 XP.......................................................................... 1.46 2017 SPORTSMAN 1000 XP TOURING............................................................... 1.48 2017 SCRAMBLER 850............................................................................... 1.50 2017 SCRAMBLER 1000 XP HO ...................................................................... 1.52 2017 SPORTSMAN XP 850 HIGH LIFTER ............................................................ 1.54 2017 SPORTSMAN XP 1000 HIGH LIFTER ........................................................... 1.56 MISC. SPECIFICATIONS AND CHARTS .............................................................. 1.58 CONVERSION TABLE ................................................................................ 1.58 STANDARD BOLT TORQUE SPECIFICATION ........................................................ 1.59 METRIC BOLT TORQUE SPECIFICATION ............................................................ 1.59 SAE TAP / DRILL SIZES .............................................................................. 1.60 METRIC TAP / DRILL SIZES .......................................................................... 1.60 DECIMAL EQUIVALENTS ............................................................................ 1.61

1.2 VEHICLE IDENTIFICATION MODEL NUMBER DESIGNATION (2015 +) Example: R15RUE57AC GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION 1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th** R 1 5 R U E 5 7 A C * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration. VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION Example: 4XAKA09A0F3000000 WORLD MFG. ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR * MFG. LOCATION INDIVIDUAL SERIAL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 G 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017 GENERAL INFORMATION

1.3 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 the rear portion of the engine located on the valve cover (see Figure 1-2). NOTE Sportsman shown GENERAL INFORMATION 1

1.4 REFERENCE INFORMATION 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. (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141. SERIES# PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION

2015-2017 Polaris Sportsman 850 ATVs OEM Service & Repair Manual

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2015-2017 Polaris Sportsman 850 ATVs OEM Service & Repair Manual

Models covered:

What’s Inside the Polaris Sportsman 850 Service Manual

General Information & Model Specifications

Maintenance Schedules & Routine Service

Engine Mechanical & Cooling System Service

Fuel, Induction & EFI System

PVT Transmission & Drive System

Final Drive & Differential Components

Suspension & Steering System

Brake System

Body, Frame & Structural Components

Electrical & Charging System

Complete Wiring Diagrams

Why This Manual Helps

Format & Compatibility

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