Polaris 550 manual

Owner's Manual for Maintenance and Safet y 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. Spor tsman Forest 550 Spor tsman Forest 850[...]

1 WELCOME 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. ?[...]

2 POLARIS® and SPOR TSMAN® are registered trademarks of POLARIS Industries Inc. MAXXIS® is a registered trademark of Maxxis International. Copyright 2013 POLARIS Sales 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 qualit[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Winch Guide . . . . . . . . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situat[...]

5 INTRODUCTION As the operator of the vehicle, you are responsible for your personal safety , the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Ride r esponsi[...]

6 SAFETY Failure to follow the warnings in this manu al can result in serious injury or death . This POLARIS vehicle is no t a toy and can be hazardous to operate. A collision or rollover can occur quickly , even during ro utine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before o[...]

7 SAFETY Rider Safety Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. See the OPERA TION section of the owner ’s manual for proper operating procedures. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before [...]

8 SAFETY Rider Safety Never carry a passenger on this veh icle. Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeves an d long pants. Never consume alcohol o r drugs before or while operati ng th is vehicle. Never operate at excessive speeds. Travel and turn at speeds appropri[...]

9 SAFETY Rider Safety Always inspect your vehicle before each use to verify that it's in safe o perating co ndition. See page 44. Follow the inspection and maintenance procedures outlined in this manual. Keep both hands on the handlebars. Ke ep both feet on the footrests. Always travel slowly when operati ng on unfamiliar terrain. U se extra c[...]

10 SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the pro cedures outlined i n this manual for driving on hills. See page 52. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larg er hill s. Avoid climbing hills steeper than 25°. Always move the 4X4 switch t[...]

11 SAFETY Rider Safety Always follow the pro cedures outlined i n this manual for braking if you stall or roll backwards while cli mbing a hill. Never back down a hill. See page 53. Always follow the procedures outlined in thi s manual for operating over obstacles. See p age 50. Always follow the pro cedures outlined i n this manual for operating o[...]

12 SAFETY Rider Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this vehicle through improper installation or use of accesso ri es. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and foll ow the in[...]

13 SAFETY Rider Safety Always remove the ignition key when the vehicle is not in use to prevent u nauthorized use or accidental starting. Always unlock the steering before starting the engine. See page 26. Hot components can cause serious burns and fi re. Do not touch hot exhaust system components. Always keep combustible materials away fro m the e[...]

14 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark [...]

15 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS veh icle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Prot ective Equipment (PPE) bearing markings such as VESC 8, V -8, Z8 7.1, or CE. Make sur[...]

16 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully . If a label becomes illegible or comes of f, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no char ge. The part number is p[...]

17 SAFETY Safety Labels and Locations General Alert (Multi-Lingual) Before you operate this vehicle, read th e owner ’s manual. 7173025 Reverse Override W arning/4X4 Caution W ARNING Improper use of the override b utton can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engage d. Always app[...]

18 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJUR Y or DEA TH. 7175378 Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT : 7.0 (48.3) REAR: 7.0 (48.3) MAXIMUM WEIGHT CAP ACITY 575 lbs. (261 kg) INCLUDES WEIGHT OF OPERA TOR[...]

19 SAFETY Safety Labels and Locations Clutch Cover Alert 7175826 Rack W a rning, Front and Rear W ARNING • DO NOT TOW FROM RACK OR BUMPER. V ehicle damage or tipover may result causing severe injury or death. T ow only from tow hooks or hitch. • Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg) 7175448 Clutch Cover Wa r n i n g (un[...]

20 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter system. T o gain additional wheel speed while backing, release the throttle and depress the override switch . Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or[...]

21 FEA TURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Star t the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. See page 45 for starting procedures. Engine Stop Switch The engin[...]

22 FEA TURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the e [...]

23 FEA TURES AND CONTROLS Brakes Aggressively applying the brakes when backin g down a hill may cause rear tipover . Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's ma nual and understand the operat ion of all brake systems on this vehicle. Always use cau [...]

24 FEA TURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in PA R K . 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. T o release the parking brake lock, squeeze and release the brake lever . Operating the vehi[...]

25 FEA TURES AND CONTROLS Electronic Power St eering (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 33 for EPS W arning Indicator information. Automatic T ransmission Gear Selector The transmission gear selector is located on the right s[...]

26 FEA TURES AND CONTROLS S teering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. 1. T urn the handlebars to the full left position. Tip : The handlebars may also be locked in the full right po siti on. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key . Tip : Place the steering lock keys in a sa[...]

27 FEA TURES AND CONTROLS Front Rack/Comp artment Release the front rack latches and remove the rack to gain access to the front compartment. T o reinstall the rack, hold the rack as shown in the illustration. Posi tion the front edge in the tabs, then push the rack downward and secure the latches. Access the following components in the front compa[...]

28 FEA TURES 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 ascending or descending a hill. See page 30. 4X4 Mo[...]

29 FEA TURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or of f 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 the switch is turn ed off while the deman[...]

30 FEA TURES 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 automatically engage when all four of the following condit[...]

31 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation. In addition to showing vehicle speed, the instrument cluster also displays the following items: engin[...]

32 FEA TURES AND CONTROLS Instrument Cluster 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 the instrument cluster may have shut of f to protect the electron[...]

33 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center 4. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately . Tip : If the fuel icon fails to display , an open or short [...]

34 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Spe ed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip : The reverse override switch also acts as a MODE button when held down for approximately one half second. [...]

35 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip : The reverse o verride switch also acts as the SELECT b utton when pressed and released [...]

36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Programmable Service Interval When the hours of engine oper ation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to p[...]

37 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only . Please see your POLARIS d ealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has [...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector , fuel pump, etc.), or the item has failed. Short-to-Gr ound: The wire is shorted to ground between the electronic control unit and the item listed in [...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center *Assumes unipolar configuration of ste ppe r motor SPORTSMAN Forest 550 Diagnostic Codes Component Condition SPN FMI Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load* 520193 1 1 S tarter Enable Circuit Driver Circuit Short to B+ 1321 3 All Wheel Drive Control Driver[...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor V oltage T oo High 51 3 V oltage T oo Low 51 4 Engine T emperature Sensor V oltage T oo High 1 10 3 V oltage T oo Low 1 10 4 T emperature T oo High 1 10 16 Engine Overheat Shutdown 1 10 0 I[...]

41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 Diagnostic Codes Component Condition SPN FMI Chassis Relay Driver Circuit Open/Grounded 520208 5 Driver Circuit Short to B+ 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open/Grounded 520207 5 Driver Circuit Short to B+ 5202[...]

42 OPERA TION Failure to operate the vehicle properly can result in a collision , loss of control, 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 POLA RIS vehicle is the first 20 hou[...]

43 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 79. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open are[...]

44 OPERA TION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Hand brake/lever travel Ensure proper operation 93 Foot brake Ensure prope[...]

45 OPERA TION S t arting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in P ARK. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 3. Sit on the vehicle. Move the engine stop switch to RUN. 4. Do not press the throttle while starting the[...]

46 OPERA TION Driving Procedures 1. W ear protective riding gear . See page 14. 2. Perform the pre-ride inspection. See page 44. 3. Place the transmission in P ARK. 4. Mount the vehicle from the left side. 5. Sit upright with both feet on the footrests. Keep both hands on the handlebars. 6. Star t the engine and allow it to warm up. 7. Apply the br[...]

47 OPERA TION T urning the V ehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use[...]

48 OPERA TION Driving on Slippery Surfaces Whenever driving on slippery or l oose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train ma y occur if the 4X4 is engaged while the wheels are spinni[...]

49 OPERA TION Driving Through W ater Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly . A void rocks and obstacles. 4. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, travel s[...]

50 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void hazards such as logs, rocks and low branches. Always follow the procedures outlined in thi s [...]

51 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. A void backing downhill. 3. Drive slowly . Apply the brakes lightly for stopping. 4. A void turning at sharp angles. 5. Never open the throttle suddenly . 6. Do not use the override switch unless additi[...]

52 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Drive straight uphill. 3. A void steep hills (25° maximum). 4. A void hills with slippery or loose surfaces. 5. Keep both feet on the footrests. 6. Shift body weight uphil[...]

53 OPERA TION Driving Uphill If all forwar d speed is lost: Keep your weight uphill. If the vehicle begins r olling downhill, never apply engine power . Never apply the brakes aggr essively while r olling backwar ds. 1. Apply the brakes gradually . 2. When fully stopped, lock the hydraulic parking brake. 3. Dismount on the uphill side, or on the le[...]

54 OPERA TION Driving on a Sidehill (Sidehilling) A void crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary , follow these precautions: 1. Slow down. 2. Shift body weight uphill. 3. Keep your feet on the footrests. 4. A void hills with slippery or loose surfaces. 5. A void crossing the sides of steep hills. 6. If the[...]

55 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. A void hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down. 4. Drive straight downhill. A void driving downhill at an angle, which can cau[...]

56 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 3. Lock the hydraulic parking brake. 4. Leave the transm[...]

57 OPERA TION T urning Around on a Hill (K-T urn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. 1 1. Apply the foot brake. 12. W ith the transmission still in forward, start the engine. 13. Squeeze and release the brake le ver to release the parking brake. 14. Release the foot brake and drive slowly[...]

58 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or tow ing cargo improperl y can alter vehicle handling and may cause loss of control or brake instability . Always follow thes e precautions when hauling cargo . • Read and understand the load distributio n warnin gs liste d on the vehicle warning labels. • Never exceed the state[...]

59 OPERA TION Hauling Cargo 1. Never exceed the weight capacities specified for your vehicle on warning labels and in the specifications section of 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 operating over rough or hilly terrain, reduce speed and[...]

60 OPERA TION Hauling Cargo T owing Loads T owing is approved OFF-ROAD ONL Y . See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road. • Do not tow any trailer on a grade steeper than 15°. • Always attach a towed load to the hitch point. Remove the hitch from the vehicle when not towing a trailer . • I[...]

61 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. Improper winch use can result in SEVERE INJURY or DEA TH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or special[...]

62 WINCH GUIDE Winch Safety Precautions 1 1. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. A void winching with the winch cable at an ang le to the winching vehicle’ s centerline whenever possible. 12. If winching at an angle is unavoidable, follow these precautions: A. Look at the winch dr[...]

63 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 . T ake your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable be fore each use. 23. Never winch the hook fully into the winch. This can cause damage to w[...]

64 WINCH GUIDE Winch Operation Read the W inch Safety Precautions in the preceding pages before using your winch. Tip : Consider practicing the operation a nd use of your winch befo re you actually need to use it in the field. Improper winch use can result in SEVERE INJURY or DEA TH. Always follow all winch instructions and warnings in this manual.[...]

65 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. W ARNING! Never put your fi nge rs into the hook. This could lead to SEVERE INJURY . A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip : A “tow strap” is NOT intended to stretch. A “recovery strap”[...]

66 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 as possible maximizes the winch’ s pulling capacity . Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provi[...]

67 WINCH GUIDE Winch Operation 1 1. The ONL Y time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 70. For your safety , al[...]

68 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 prevent the battery from run ning low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch[...]

69 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 . W ARNING! Use of worn or damaged ca ble could lead to sudden failure and SEVERE INJUR Y . 1. Always inspect your winch before each use. Inspect for worn or lo[...]

70 WINCH GUIDE Shock Loading W ARNING! Y our winch cable is very strong but it is NOT desig ned for dynamic, or “shock” loading. Sho ck loading may t ension a winch cable beyond its strength and cause the cable to brea k. The end of a broke n winch cable under such hig h loading can cause SEVERE INJUR Y or DEA TH to you and other bystanders. W [...]

71 WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store ener gy . This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly , never use elastic “bungie” cords for winching. 5. Never use the winch to tie down[...]

72 WINCH GUIDE Winch Maintenance and Service Safety W ARNING! Improper or lack of winch ma intena nce and service could lead to SEVERE INJUR Y or DEA TH. 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. Also inspect for worn or loose parts includi[...]

73 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. S p ark Arrester Y our POLARIS vehicle has a spark arrester that was designed for on- road and off-road operation. It is required that this spark arrester rem[...]

74 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart . Inspect, clean, lubricate, adjust a nd replace parts as necessary . When inspection reveals the ne[...]

75 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Improperly performing the p rocedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services. Perform all services at whichever ma intenance interval is r eached first. Symbol Description Ź [...]

76 MAINTENANCE Periodic Maintenance Chart Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź Brake pad wear 10 H Monthly 100 (160) Inspect periodicall[...]

77 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź Oil lines and fasteners 100 6 M 1000 (1600) Inspect for leaks and loose fittings Ź Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter Ź Demand drive fluid (normal use) 100 H 12 M 1000 (1600) Change fluid [...]

78 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. Items not listed in the chart should be lubricated at the General Lubr ication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be needed.[...]

79 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W - 50 4-cycle oil or a similar oil for this engi ne. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W - 50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 131 f[...]

80 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 78 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the int ervals outlined in the Periodic Maintenance Chart beginning on page 74. Al ways change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. Place th[...]

81 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 . 1 1. Lubricate the o-ring on the new filter with a film of fres[...]

82 MAINTENANCE T ransmission Oil See the table on page 78 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. See page 131 for the part nu mbers of POLARIS products. Maintain the oil level at the bottom of the fill plug[...]

83 MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 78 for fluid recommendations, capacities and plug torques. Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. See page 131 for the part numbers of POLARIS products. Change the front gearcase fluid ev[...]

84 MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Ac tive Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 83 for demand drive fluid maintenance. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning [...]

85 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the dif ferential). 3. Remove the reservoir cap and dia[...]

86 MAINTENANCE Rear Gearcase Oil See the table on page 78 for fluid recommendations, capacities and plug torques. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. See page 131 for the part nu mbers of POLARIS products. The fill plug is located on the rear of the gearcase[...]

87 MAINTENANCE Rear Gearcase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain hole. 3. Remove the drain plug. Allow the oil to drain completely . 4. Clean and reinstall the drain plug with a new sealing washer . T orque to specification. 5. Remove the fill plug. Add the proper amount of the recommended[...]

88 MAINTENANCE Power Steering Unit If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly . Cooling System The engine coolant level is controlled by the recovery system. Recovery system components are the recovery bottle, the radiator fill[...]

89 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 storage compartment. 1. V iew the fluid level in the bottle. 2. If the level is low , remove the front rack. 3. Remove the bot tle cap and ad d coolant as needed. [...]

90 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintains its ability to protect the engine, POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the cooling system has been drained for maintenance or repair . If the recovery[...]

91 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the r ecommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low flui d level may also mean that brake pads are worn and [...]

92 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Maintain the fluid level 6 mm below the top edge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. V iew the fluid level through the indicator window (eye) on the top of the maste[...]

93 MAINTENANCE Brake Inspections The front and rear b rakes are hydraulic disc b rakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal opera[...]

94 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/4-1/2 inch (6-12 mm) toe out. Severe injury or death can result from improper toe alignment and adjustme nt. Do not attempt to adjust tie rod alignment. All tie rod a djustments should be performed by an authorized[...]

95 MAINTENANCE S teering Assembly The steering assembly should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle. Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. Remove [...]

96 MAINTENANCE Ti r es Operating your vehicle with worn tires, i mproperly infl ated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follo w all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Alway[...]

97 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation (if equipped). 3. Install the wheel nuts and finger-tighten them. 4. Lower the vehicle to the ground. 5. T orque the wheel nuts to speci[...]

98 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 pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main filter if needed. 6. [...]

99 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. Remove the front rack. 2. Remove the fuse box cover . 3. Re[...]

100 MAINTENANCE Light s Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in P ARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall a[...]

101 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently . Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen la[...]

102 MAINTENANCE Light s Front T urn Signal Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly . Rear T urn Signal Lamp Replacement 1. Place the transmission in P ARK. 2. Rotate the turn signal socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric[...]

103 MAINTENANCE Light s T aillight/Brakelight Lamp Replacement 1. Place the transmission in PA R K . 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. T est the lamp for proper operation. 6. Reinstall all components in reverse order .[...]

104 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer . If the engine idle speed is not satisfactory , please see your POLARIS dealer for adjustment. Throttle Cable Freeplay 1. Remove the three cover screws from the right handlebar control and remove the cover . 2. W ith the handlebars straight ahead, place very light pressu[...]

105 MAINTENANCE Throttle Cable Freeplay 4. Place the transmission in P ARK. 5. Star t the engine and allow the idle to stabilize. If necessary , tap the throttle lever to ensure the idle speed settles. 6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed [...]

106 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer . Handlebars The handlebars can be[...]

107 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications section beginning on page 132 for the recommended spark plug type and gap for your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Sp ark P[...]

108 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection Normal Sp ark Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes ar e 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 [...]

109 MAINTENANCE V ehicle Immersion If your vehicle becomes immersed, major engine da mage can result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle to dry land o[...]

110 MAINTENANCE S p ark Arrester Failure to heed the following warnings whil e servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible ma terials from the area. W ear eye pr otection and leather work gloves. Do not stand behind or in fro nt of the vehicle while purgi ng.[...]

111 MAINTENANCE PVT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occu r at a high speed. The PVT system has be en precision balanced. Any modification will cause the system to be out of balanc[...]

112 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 drive belt. Similarly , if the engine speed decr[...]

113 MAINTENANCE PVT System When T o Use Low Range and High Range PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Reinstall the drain [...]

114 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an e xplosion 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. Battery electrolyte is poisonous. It contains sul[...]

115 MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable last. 4. Disconnect the battery hold-down strap. 5. On conventional batteries, remove the battery vent tube. 6. Lift the battery out of the vehicle. Be careful not to tip a conventional b[...]

116 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 1 18 before installing the battery . If your factory-installed 18 AH battery cannot maintain a char ge becau[...]

117 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full char ge. POLARIS recom[...]

118 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 1 15. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or g[...]

119 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. St ate of Charge V oltage Action Charge Time (Using constant current charger @ standa rd amps specified on to p o f batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-[...]

120 MAINTENANCE Cleaning and St orage W ashing th e V ehicle 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 han d or with a garden hose, using mild soap. Certain products, inclu[...]

121 MAINTENANCE Cleaning and St orage W ash ing the V ehicle If a high pressure water system is used for cleaning (n ot recommended), exercise extreme caution. The water may damage components and could remove paint and labels. A void directing the water stream at the following items: If an informational or graphic label becomes illegible or comes o[...]

122 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean[...]

123 MAINTENANCE Cleaning and St orage Sto r ag e Tips NOTICE: S t arting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended. See page 120. St abili[...]

124 MAINTENANCE Cleaning and St orage Sto r ag e Tips Fluid Levels Inspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 74. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • T ransmission • Brake fluid (change every two y[...]

125 MAINTENANCE Cleaning and St orage Sto r ag e Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 74. Battery Maintenance Remove the battery and recharge it as outlined on page 1 18. Store the battery in a cool, dry place. Storage Area/Covers Set [...]

126 MAINTENANCE T ransporting the V ehicle 1. Stop the engine. 2. Place the transmission in P ARK. 3. Secure the fuel cap, oil cap and seat. 4. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks or handlebars. 5. Remove the key to preve[...]

127 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 56). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher sp eed or use low range more frequently [...]

128 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Out of fuel Refuel, cy[...]

129 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly , St alls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs Insp[...]

130 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark p[...]

131 POLARIS PRODUCTS Part Number Description Engine Lub ricant 2870791 Foggi ng Oil (12 oz. Aerosol) 2876244 PS-4 Ful l Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synt h et ic 5W -5 0 4- Cycle Oil (gal./ 3. 8 l) Gearcase / T ransmission Lubricants 2878068 AGL Full Synthetic Gearcase Lu bricant & Transmission Fluid (qt./.95 l) 287[...]

132 SPECIFICA TIONS * Based on EU Directive 76/ 432/EC SPORTSMAN Forest 550 Maximum W eight Load Capacity 575 lbs. (261 kg) Dry W eight 342 kg +/- 7 % , based on configuration 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 Drive Fluid Capacity 9.3[...]

133 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN Forest 550 T ransmission and Gears High/Low/Neutral/Reverse/Parking Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.693:1 Drive Ratio, Front 3.818:1 Drive Ratio, Rear 3.7:1 T ires T ype Front Off Road Style, Deep T read Design, [...]

134 SPECIFICA TIONS * Based on EU Directive 76/ 432/EC SPORTSMAN Forest 850 Maximum W eight Load Capacity 575 lbs. (261 kg) Dry W eight 360 kg +/- 7 % , based on configuration 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 Drive Fluid Capacity 9.3[...]

135 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN Forest 850 T ransmission and Gears High/Low/Neutral/Reverse/Parking Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.367:1 Drive Ratio, Front 3.818:1 Drive Ratio, Rear 3.7:1 T ires T ype Front Off Road Style, Deep T read Design, [...]

136 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C for [...]

137 W ARRANTY LIMIT A TIONS OF W ARRANT IES 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 any parts exposed to friction surfaces, stresses, environmental conditions [...]

138 W ARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration From to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that[...]

139 W ARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER V ICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give au[...]

140 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

141 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

142 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . 20, 28 A Access, Front Compartment . . . . . . 27 Accessories . . . . . . . . . . . . . . . . . . 125 Active Descent Control Fluid . . . 84-85 Active Descen t Control System . . . . 30 ADC System . . . . . . . . . . . . . . . . . . 30 Age Restrictions . . . . . . . . . . . . . . . . . 6 Air F[...]

143 INDEX F Fluid Change ADC . . . . . . . . . . . . . . . . . . . . . . . 85 Demand Drive . . . . . . . . . . . . . . . 83 Foot Brake, Auxiliary . . . . . . . . . . . . 23 Footwell Removal . . . . . . . . . . . . . . . 95 Front Compartme nt . . . . . . . . . . . . . . 27 Front Gearcase (Demand Drive) . . . . 83 Front Rack/Compartment . . . . . . .[...]

144 INDEX S Safety Labels . . . . . . . . . . . . . . . . 16-19 Safety Tra ining . . . . . . . . . . . . . . . . . 6 Safety, Winch Main tenance . . . . . . . 72 Severe Use . . . . . . . . . . . . . . . . . . . . 74 Shock Loading the Winch . . . . . . 70-71 Side Panel Removal . . . . . . . . . . . . . 95 Sidehilling . . . . . . . . . . . . . . . . .[...]

For your nearest Polaris dealer , visit www .polaris.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Part No. 9924662 Rev 01 Printed in USA *9924662 * Before you operate this vehicle, read the owner ’ s manual[...]