Polaris Sportsman 550 XP manual

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A card containi ng important A TV safety informa tion should be attached to the owner's man ual on the next page. If you canno t locate th is card, or if it has been removed, plea se call 1-8 00-342- 3764 for assistance. W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth [...]

1 WELCOME Thank you for purch asin g a Polaris vehicl e, and welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a l[...]

2 POLARIS and POLARIS THE W A Y OUT are regist ered tradem arks of Polari s Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of pub lication. Due to constant improvements in the design and quality of production compo nents, some minor discr[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potentia l personal injury ha za rd. W ARN ING A W ARNING indicates a hazar[...]

5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate . This vehicle ha ndles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuv[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n 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 yo ur key number) and mating it wi th one of your ex isting keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchase d your new A TV , yo ur dealer instructed you on the authorized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and y our eligible f[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the ch ance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su[...]

10 SAFETY Safety W arnings Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See th e OPERA TION section of the owner ’s manual for proper operating proce dures. Operati[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and explosive u nder certain conditions. • Always exercise extreme cautio n whenever h andling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventil ated area. • Do not smoke or allow open flames or sparks in or near the area where refu- [...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e withou t wearing an approved helmet and protective eyewe ar increases the risk of a serious inj uries in the event of an accident. Always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alcohol or Drugs Operating the A TV after consu[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the A TV and co uld result in loss of control and accident or overturn. Avoid operating the A TV on pavement. A TV tires are design ed for off-road use. If it's una[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to co ntrol the ve hicle or cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Nev[...]

15 SAFETY Safety W arnings Descending Hill s Impr oper ly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hi ll s as de scri b e d in the own e r 's manual. NOTE: A special techn ique is required when braking while traveling do wn- hill. See page 59. • Always d[...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or impr operl y dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascending or descendin g a hill. See page 36. If all forward speed is lost: •[...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl ippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippe ry or loose terrain. Always u se extra cautio n on rough, slippery or loose terrain. [...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could resul t in a collision with an obstacle or person. Always follow prope r op erating procedures as outli ned in this manual. See page 63. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When i t's safe to p[...]

19 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obst acles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme c aution and always follow proper ope rating proce dures as outlin ed[...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carryin g/towing cargo improperly may cau se changes in handling, which could cause loss of contro l or an acciden t. • Never exceed the stated load capa city for this A TV . • Cargo should b e properl y distributed and securely attached. • Reduce speed when carrying ca[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A T V can result in a n accident. After any overturn or accident, have a qual ified service dealer in spect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active veh ic[...]

22 SAFETY Safety Labels and Locations W arning labels have b een placed on the ve hicle for your protec tio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the labe ls on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or g[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper tha n 25 degrees 25 ° . T o pre- vent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. S t eering becomes difficult. T o prevent loss of[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNIN G NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 T ire Pressure/Load W arning W ARNIN G Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or deat[...]

25 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING • Moving part s hazard und er belt-clutch gu ard. T o prevent serious injury , do not operate vehicle with gu ard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engi ne RPM, which can result in seriou s in jury or [...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse sp eed limit er system . T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button while th e thro ttle is open can cause loss of control, wh ich may resu lt in s[...]

27 FEA TURES AND CONTROLS Switches Engine S top Switch Move the stop switch either left or right to the OFF position to stop the engine quickly . Move the stop switch to the RUN position before attempt- ing to start the engine. The engine will not start or ru n when the switch is off. Both the main switch and the engine stop switch will shut of f a[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV with sticking or impr operly operating throttl e controls could cause an accident. N ever start or oper ate an A TV that has a sticking or improperly operating th ro ttle. Always c ontact your deal er for service before operating the vehicle. Failure to check or ma intain proper operati on [...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of brak ing, which could cause an accident. Neve r operat e th e A TV with a spongy-feeling brake lever . Always contact your dealer for service before operating the vehicl e. Squeeze the brake lever toward the handlebar to apply the fr ont and re[...]

30 FEA TURES AND CONTROLS Master Cylinde r/Br ake Fluid An over-full master cylinder may cause brake drag or b rake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygrosco pic, meaning it rapidly absorbs moisture from the[...]

31 FEA TURES AND CONTROLS Parking Brake Locking the 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 lo ck, squeeze and release the brake lever [...]

32 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could result in seri ous in jury or death. Never ba ck down a hill. Use caution when applying the a uxiliary bra ke. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may [...]

33 FEA TURES AND CONTROLS Electronic Power S teering (EPS) Electronic power steering (if equipped ) engages when the ignition key is turned to the ON positi on. EPS rema ins engaged whether the vehicl e is moving or idle. S ee page 39 for EPS W arning Indicator information . Automatic T ransmission Gear Selector The transmission gear selector is lo[...]

34 FEA TURES AND CONTROLS All Wheel Drive System The All Wheel Dr ive s ystem 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 36. 4X4 [...]

35 FEA TURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially , the vehicle's electr onic sy stem will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remai ns enabled until the 4X4 switch is turned of f. If the switch is turn ed off while the de[...]

36 FEA TURES AND CONTROLS Active Descent Cont rol (ADC) System The ADC system allows engine brak ing 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 auto matically engage when all four of the follow- ing c[...]

37 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from a gear in the transmissi on. The instrument cluster measures distance in miles/kilometers as well as hours of op eration. In addition to showing ve hicle speed, the instrument cluster also dis- plays the following items: eng[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments 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 cl uster may hav e shut of f to protect the el[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center 3. Speed Display - This area displ ays vehicle ground speed or engin e rotational speed when the correspon ding display is selected. See page 40. 4. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last seg me nt clears, a low fuel war[...]

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

41 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 reve rse override button also acts as the SELECT button when pressed and released q[...]

42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Pr ogrammable Service Interval When the ho urs of engine op eration equal the p rogrammed service interval setting, the wr ench icon will flash for 5 seconds each time the engine is started. When this featur e is enabled, it provides a convenient reminder[...]

43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diag nostic display mode is for informational p urposes only . Please see your Polaris dealer for all major repairs. The diagnostic mode is accessible on ly when the check engine warning indicator activates after the key ha[...]

44 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 cha rt (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 i[...]

45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center *Assumes unipolar configuration of stepper motor Sport sman 550 XP / XP EPS Diagnostic Codes Component Condition SPN FMI Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load* 520193 1 1 S tarter Enable Circuit Drive r Circuit Short to B+ 1321 3 All Wheel Drive Control D[...]

46 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Sport sman 850 XP / XP EPS 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 [...]

47 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Sport sman 850 XP / XP EPS 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[...]

48 FEA TURES AND CONTROLS Front Rack/Comp artment Release the front rack latches and remove the rack to gain access to the front compart- ment. T o reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches. Access the following compo- nents in the front co[...]

49 OPERA TION Failure to operate the A TV properly can resul t in a coll ision, 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 Polaris A TV is the first ten hours of[...]

50 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before ea ch use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 2 9 85 Brake fluid Ensure pr[...]

51 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op eratin g this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle . Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Never carry a passenger on this A TV . 4. Engine ex hau[...]

52 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you r ide. Find out where the de signated riding areas are by con- tacting your Polaris dealer , a local riding club or loc al officials. Help keep[...]

53 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. Tip : The starter interlock will preven t the eng ine from starting if the transmi ssion is in gear and the brake is not engaged. 4. Sit on the vehicle and move the [...]

54 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. 2. Sit upright with both feet on th e foo trests and both hand s on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check you r surroundings and determi ne your path of travel. 6. Release the parking brake. 7. Slowly depress[...]

55 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the in side tire must slip traction sl ightly . T o turn, steer in the direction of the turn[...]

56 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precau tions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before whee ls begin to lose traction. NOTICE: Seve[...]

57 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure cou ld cause loss of c ontrol or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 36. 2. Drive straight uphill. 3. [...]

58 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proc edure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down! 2. Shift body weight uph ill. 3. Keep your feet o[...]

59 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 36. 2. A void steep hills (25 ° maximum ). 3. Shift body weight uph ill. 4. Drive straight downhill. 5. Slow down. Excessive speed wh en traveling downhill can cause loss of contr[...]

60 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. S top and lock the parking brake while keeping b ody weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascendi ng or descending a hill. See page 36. 3. Leave the transmission in f[...]

61 OPERA TION Driving Through W ater Y our A TV can operate th rough water with a maximum recom- mended dep t h eq ual to the bot- tom of the footrests. Follow these precautions when operat- ing throug h water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks hav e g radual inclines. 3. A void oper[...]

62 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacle s: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamilia[...]

63 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or people behind the vehi cle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turnin g at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button [...]

64 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly ca n alter vehicl e handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these p recautions when hauling ca rgo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARG[...]

65 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A TV on warning labels and in the specifications section of this manual. Carg o weight should be evenly distributed (1/3 on th e fro nt rack and 2/3 on the rear rack) and mounted as low as possi- ble. When operating over rough or hil ly terrain, reduce speed and cargo[...]

66 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S t op the engine. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. 4. Always block the rear wh eels on the downhil l side.[...]

67 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was teste d and qual[...]

68 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic main tenance ch art. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

69 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedure s marked with a  could resu lt in component failure and cause an accid ent, wh ich ma y result in seri ous injury o r death. Always have an authorize d Po la ris dealer perform these services. Maintenance Chart Key X Perform these operations more often for ve hicles su[...]

70 MAINTENANCE Periodic Maintenance Chart Perform all services at whiche ver main tenance inter val is r eached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service  Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours C[...]

71 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) Inspect; adjust; lubr icate; replace if necessary E Throttle Body Intake Duct 50 H 6 M 500 (800) Inspect duct for proper seal- ing/air leaks Drive belt 50 H 6 M 500 (800) Ins[...]

72 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 68. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be neede[...]

73 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. See the table on page 72 for fluid recommendatio ns, capacities and plug torques. Oil may need to be changed more fre quently if Polaris oil is not used. Always use 2W -50 oil. Fo[...]

74 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 72 for flui d recommendations, capacities and plug torques. Always change th e oil and filter at t he intervals outlined in the Periodic Maintenance Chart beginni ng on page 68. Always ch ange the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. S [...]

75 MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneat h the oil filter . Using an oil filter wrench (available from your Polaris dealer), turn th e filter counter- clockwise to remove i t. 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 [...]

76 MAINTENANCE T ransmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP T rans- mission Fluid fo r this transmission. See the table on page 72 for flu id recommenda tions, capa cities an d plug torq ues . Always che ck a nd change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pag[...]

77 MAINTENANCE Front Gearcase (Dem and Drive) Fluid See the table on page 72 for flui d recommendations, capacities and plug torques. Always check and change th e demand dri ve fluid at the inter- vals outlined in the Periodic Main tenance Chart beginning on pa ge 68. See page 125 for the p art numbers of Po laris products. Use the recommende d flu[...]

78 MAINTENANCE Rear Gearcase Oil See the table on page 72 for flui d recommendations, capacities and plug torques. Always check and change the rear gearca se oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 for th e part numb ers of Polaris products. The fill plug is located on the rear of the gearc[...]

79 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 sea ling washer . T orque to specification. 5. Remove the fill plug. Add the pr oper amount of the recommend[...]

80 MAINTENANCE Active Descent Control (ADC) Fluid If your veh icle is equipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fluid an d ADC fluid). See page 77 for d emand drive fluid maintenance . Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart begin[...]

81 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[...]

82 MAINTENANCE Power S teering 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 th e recovery bottle, the radi ator f[...]

83 MAINTENANCE Cooling System Recovery Bottle Coolan t The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front storage com- partment. 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 neede[...]

84 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s 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 coo ling system has been drained for maintenance or repair . If the recove[...]

85 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handleba r . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drop s. If the fluid leve l is low and the diaphragm is not extended, a leak is li[...]

86 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) to e out. W ARNING! Severe injury or death can result from improper toe alig nment and adjustment. Do not attemp t to adjust ti e rod alignment. All tie rod adjustments should be perf[...]

87 MAINTENANCE 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 the seat. Side Panel /Footwell Removal Remove the seat before removing a side pane l. Remove the screws and rivets securing the side panel or footwell (see illustration). Plastic Rivet Hex Hea d Scre[...]

88 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or dea th . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle. Always[...]

89 MAINTENANCE Ti r e s Front Wheel Hub T ightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operati ons. All service must be performed by you r authorized Polaris dealer . Wheel Removal 1. S t op the engine. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. 4. Loosen the wheel nuts slightly . [...]

90 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parkin g brake. 3. Place the wheel on the hub with the valve stem toward the out side and rotation arrows on the tire po inting toward forward rotation (if equipped). 4. Install the wheel nuts and finger -tighten them. 5. Lower the veh icle to the grou nd. 6[...]

91 MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover screws, 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.[...]

92 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 cir- cuits that may have caused the blown fuse , then replac e the fuse. Spare fuses are provided in the fuse box. 1. Remove the front rack. 2. Remove the fuse box cover . 3[...]

93 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps pro mptly . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halogen lamp, avoi[...]

94 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in P ARK. 2. Measure the distance from the floo r to the ce[...]

95 MAINTENANCE Light s Low Beam Adjustment The low beam can be adjusted slightly upward or downward . 1. Loosen the phillips screw located at the rear of the headla mp. 2. T ilt the headlamp upward or downward. 3. T ighten the screw . Phillips Screw[...]

96 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the five (5) headlight pod screws. 2. Lift the pod cov er an d disconnect the speedometer harnesses from the speed omet er . 3. Unplug the headlamp from the wiring harness. 4. Use a sm a ll sc r ewdri ver to remove the o-rings from the headlight mounting tabs. 5. Pull the headlight hou[...]

97 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counterclockwi se and pull the harness assembly away from the headlight assembly . 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harne ss clockwise to secure the h[...]

98 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifi cations sect i on beg inn ing on p age 1 26 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs t o specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plu[...]

99 MAINTENANCE Spar k P l u g s S p ark Plug Inspection Normal S p ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator [...]

100 MAINTENANCE V ehicle Immersion If your vehicle bec om es immersed, majo r engine damag e ca n result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossi ble to take your A TV to a dealer before starting it, follow t he steps outlined below . 1. Move the A TV to dry land [...]

101 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warni ngs while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging.[...]

102 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failure ma y occur at a high speed. The PVT system ha s been precision balanced. Any modi fication will cause the system to be out of ba[...]

103 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed d[...]

104 MAINTENANCE P VT System When T o Use Low Range and High Range P VT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall th[...]

105 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t in an explosion and cause serious injury or death. When removi ng the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisono us. It contains[...]

106 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, re move the battery vent tube. 6. Lift the battery out of the A TV . Be careful not to tip a conventional ba[...]

107 MAINTENANCE Battery Battery Inst allatio n Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinde r vehicle performance. Follow the battery charging instructio ns on page 109 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery [...]

108 MAINTENANCE Battery Batter y S tor age 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 s t orag e and recha r ge as needed to mainta in a full charge. Polaris[...]

109 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prev ent damage from leak- ing or spilled ele ctrolyte during cha rging. See page 106. 2. Char ge the battery with a char ging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the spec ific grav- ity to [...]

110 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top o f batter y) 100% 12.8-13.0 vol ts None, chec k at 3 mos. from date of manufacture None required 75[...]

111 MAINTENANCE Cleaning and S torage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, inclu[...]

112 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint an d labels. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or c[...]

113 MAINTENANCE Cleaning and S torage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve 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. C l[...]

114 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S tarting the engine durin g the storage perio d will di sturb the protective film created by fogging and damage could occur . Never start the engine during the stora ge peri od. Clean the Exterior Make any necessary repa irs and then clea n the vehicle a s recommended. See page 1 1 1 [...]

115 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommende d in the Periodic Maintenance Char t beginni ng on page 6 8. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • T ransmission • Brake fluid (change eve[...]

116 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cables and lubric ate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 68. Battery Maintenance Remove the battery and recharge it as outlined on page 109. S tore the battery in a cool, dry place. S torage Area/Covers[...]

117 MAINTENANCE T ransporting the A TV 1. S t op the engine. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the A TV to the transporti ng unit securely with suitable straps or rope . Do no t attach tie straps to the front A- arm bolt pocke ts, racks or hand lebars[...]

118 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Pola ris dealer for adjustment. Throttle Cable Freeplay 1. Remove the three cover screws from the right han- dlebar control and remove the cover . 2. W ith the handlebars straight ah ead, place very light p[...]

119 ADJUSTMENTS Throttle Cable Freeplay 4. Place the transmission in P ARK. Lock the parking brake. 5. S tart 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 c orre ct gap. If gap [...]

120 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Front and Rear S prings The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counter- clockwise to increase or decrease spring tension. Accessory s prings are available through your Polaris dealer . Handlebars The handlebars ca[...]

121 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn aro und using the K-turn (see page 60). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher sp eed or us e low range more freque[...]

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

123 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recomme nded 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[...]

124 TROUBLESHOOTING Engine S top 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 Insp ect, clean and/o r replace spar[...]

125 POLARIS PRODUCTS Pa r t Number Description Engine L ubricant 2870791 Fogging Oil (12 oz./355 ml Aero sol) 2876244 PS-4 PLUS Pe rformance Synthe tic 2 W -50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Perfo rma nce Synt hetic 2W -50 4-Cycle Oil (gal ./ 3.8 l) Gearcase / T ran smission Lubricants 2877606 Synthetic S portsman XP T ransmission Fluid [...]

126 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 550 XP / XP EPS Maximum W eight Capacity 575 lbs. (261 kg) Dry W eight 732 lbs. (332 kg) (XP) 744 lbs. (337.5 kg) (XPS) Fuel Capacity 5.25 gal. (20 l) (XP) 4.5 gal. (17 l) (XP EPS) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Ca pacity 7 .1 oz. ([...]

127 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment Sportsman 550 XP / XP EPS T ransmission H/L/N/R/P 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, Rea r 3.7:1 T ires/Pressure, Front 26x8-14 A T / 7 psi (48.3 kPa) T ires/Pressure, Rear 26x10[...]

128 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 850 XP / XP EPS Maximum W eight Capacity 575 lbs. (261 kg) Dry W eight 784 lbs. (356 kg) (XP) 796 lbs. (361 kg) (XP EPS) Fuel Capacity 5.25 gal. (20 l) (XP) 4.5 gal. (17 l) (XP EPS) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Ca pacity 7 .1 oz. [...]

129 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment Sportsman 850 XP / XP EPS T ransmission H/L/N/R/P 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, Rea r 3.7:1 T ires/Pressure, Front 26x8-14 A T / 7 psi (48.3 kPa) T ires/Pressure, Rear 26x10[...]

130 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship . Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty c[...]

131 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A TIONS OF W ARRANT IES AND REMEDIE S The Polaris l imited warrant y excludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This warranty also does not cover any A [...]

132 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not al low limi- tations on[...]

133 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA - TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. D[...]

134 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally pur chased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you hav[...]

135 W ARRANTY U.S.A. EP A Emission s Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions lim it ed warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with th[...]

136 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 ser- vices performed. DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

137 MAINTENANCE LOG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

138 MAINTENANCE LOG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]