Polaris Sportsman 9922452 manual

P antone 426C 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. Owner's Manual for Maintenance and Safet y Spor tsman 550 XP Spor tsman 550 XP EPS Spor tsman 850 XP Spor tsman 850 XP EPS[...]

A card containi ng important A TV safety information shou ld be attached to the owner's man ual on the next page. If you cannot locate th is card, or if it has been remove d, please 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 d[...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

P antone 426C W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without pr oper training or instruction. S at speeds too fast for your skills or the conditions. S on public r oads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and incr ease risk of losi[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, 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[...]

2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered trademarks of Pol aris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. 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 potential persona l injury hazard. W ARNING A W ARNING indicates a hazardou[...]

5 INTRODUCTION Failure to hee d the warnin gs and safety precaution s contained in this manu al can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle handl es 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 matin g it with one of yo ur existing keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family members who will be riding the A T V to take a training course. If you purchased a new Polaris A TV in the United S tates, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available t[...]

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 chan ce 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 Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Safety W arnings Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See the OPERA TION section of the owner ’ s manual fo r proper operating procedures. Operating[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme cautio n whenever hand ling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- el[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e without wearing an approved helmet and protective eyewe ar increases the risk of a serious injuries 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 consumi[...]

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 could result in loss of control and accident or overturn. Avoid operating the A TV on p avement. 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 contro l the vehicle or cause loss of balance and ejection from the A TV . If the operator's foo t is not firmly planted on the footrest, it could also contact the rear wheels. Nev[...]

15 SAFETY Safety W arnings Descending Hill s Impr operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as describ ed in the owne r's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 59. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, roll ing backwards or improperly 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 te rrain 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 caution on rough, slippery or loose terrain. [...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow prope r operating 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 . W hen it's safe to pro[...]

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 caution and always follow proper ope rating proce dures as outlin ed [...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load cap acity for this A TV . • Cargo should b e properly di stributed and se curely attached. • Reduce speed when carrying carg[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A TV can result in an accident. After any overturn or accident, have a qual ified service dealer insp ect 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 icle[...]

22 SAFETY Safety Labels and Locations W arning labels hav e been placed on the vehicle for your protection . Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the la bels on your vehicle , always read and follow the instructio ns of the labels on the vehicle. If an informational or gr[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 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 teering becomes difficult. T o prevent loss of c[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING 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 ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or death.[...]

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 seriou s injury , do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engi ne RPM, which can result in serious in jury or d[...]

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

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 off al[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th 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 rottle. Always c ontact your dealer for service before operating the vehicle. Failure to check or ma intain proper operation o [...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Neve r operat e the A TV with a spong y-feeling brake lever . Always contact your dealer for service before ope rating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear[...]

30 FEA TURES AND CONTROLS Master Cylinde r/Br ake Fluid An over-full master cylinder may cause brake drag or brake l ock-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 , w hich could result in seri ous injury or death. Never ba ck down a hill. Use caution when applying the auxili ary brake. Do n ot aggressively apply the auxiliary brake when going forward. The rear wheels may s[...]

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 vehicle i s moving or idle. S ee page 39 for EPS W arning Indicator information. Automatic T ransmission Gear Selector The transmission gear selector is loc[...]

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 of f while the vehic le is moving. Initially , the vehicl e's electronic 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 of f while the[...]

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 vehicle speed, the instrument cluster also dis- plays the following items: engi[...]

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 have sh ut 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 sp eed or engine 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 ment 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 reverse 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 reverse override button also acts as the SELECT button when pressed and released qu[...]

42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Pr ogrammable Service Interval When the ho urs of engine operatio n equal the programmed serv ice 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 fo r informational purposes 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 pu mp, 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 / X P EPS Diagnostic Codes Component Condition SPN FMI Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load* 520193 1 1 S t arter Enable Circuit Drive r Circuit Short to B+ 1321 3 All Wheel Drive Control[...]

46 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Sport sman 850 XP / X P 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 olt age 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 [...]

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

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 components in the front comp[...]

49 OPERA TION Failure to operate the A TV properly can result in a collision, loss of co ntrol, 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 T V before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 29 85 Brake fluid Ensure pro[...]

51 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating 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 haust[...]

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 d e signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or local officials. Help kee[...]

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 parking br ake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. Sit on the vehicle and move the en[...]

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 hands 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 determine your path of travel. 6. Release the parking brake. 7. Slowly depress t[...]

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 precautions: 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: Sever[...]

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

58 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure 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 ascending 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 contro[...]

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 body weight up hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 36. 3. Leave the transmission in fo[...]

61 OPERA TION Driving Through W ater Y our A TV can operate throu gh water with a maximum recom- mended dep th equal 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 gradual inclines. 3. A void operati[...]

62 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. 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 unfamiliar[...]

63 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sh arp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unl[...]

64 OPERA TION Hauling Cargo Overloading the vehi cle or carrying o r to wing cargo improperl y can alter vehicl e handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these p recautions when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO.[...]

65 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A T V on warning labels and in the specifications section of this manual. Carg o weight sh ould be evenly distributed (1/3 on th e front 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 carg[...]

66 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking br ake. 4. Always block the rear wh eels on the downhill 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 chart . Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

69 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could resu lt in component failure and cause an accid ent, wh ich may resu lt in serious injury or death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more often for ve hicles subjec[...]

70 MAINTENANCE Periodic Maintenance Chart Perform all services at whiche ver main tenance interval 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 Ca[...]

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; lubricate; 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) Insp[...]

72 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintena nce Chart beginning 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 beginning on page 68. Al ways change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. S t[...]

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 fluid recommenda tions, capacities an d plug torques. Alw ays check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68.[...]

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 drive fluid at th e inter- vals outlined in the Periodic Main tenance Chart begin ning on page 68. See page 125 for the p art numbers of Polari s 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 numbers of Po laris 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 eq uipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fluid and ADC fluid). See page 77 for d emand drive fluid main tenance. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Char t begi[...]

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 add coolant as needed[...]

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 alignment is 0" to 1/8" (0-3 mm). W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attemp t to adjust tie rod alignment. All tie rod adjustments should be performed by an a[...]

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 panel. Remove the screws and rivets securing the side panel or footwell (see illustration). Plastic Rivet Hex Hea d Screw[...]

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 perfo rmed by your authorized Polaris dealer . Wheel Removal 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking br ake. 4. Loosen the wheel nuts slightly . W[...]

90 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking br ake. 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 ground. 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 replace 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 promptly . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halogen lamp, avoid[...]

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 and disconnect the speedometer harnesses from the speed ometer . 3. Unplug the headlamp from the wiring harness. 4. Use a sm all screwdrive r to remove the o-rings from the headlight mounting tabs. 5. Pull the headlight housing [...]

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 harness clockwise to secure the he[...]

98 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifi cations section beginning on page 126 for the recom- mended spark plug type and gap for your v ehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S p[...]

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 omes immersed, major en gine damage can resu lt 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 or[...]

101 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings 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 a rea. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. N[...]

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 its strength so that a failure ma y occur at a high speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of bala[...]

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 result in an explosion and cause serious injury or death. When removing 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 s[...]

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 allation 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 hinder 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 in[...]

108 MAINTENANCE Battery Batter y 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 s torage and recha r ge as needed to mainta in a full charge. Polaris re[...]

109 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 106. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific 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 battery) 100% 12.8-13.0 vol t s None, check at 3 mos. from date of manufacture None required 75%[...]

111 MAINTENANCE Cleaning and S torage W ash ing the 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 hand or with a g arden hose, using mild soap. Certain products, inclu[...]

112 MAINTENANCE Cleaning and S torage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (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 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 stora ge period. Clean the Exterior Make any necessary repa irs and then clean the vehicle as recomme nded. See page 1 1 1. S t[...]

115 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommende d in the Periodic Maintenance Char t beginni ng on page 68. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • T ra nsmission • Brake fluid (change ever[...]

116 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cables a nd lubricate 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 o utlined 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 top the engine. 2. Place the transmission in P ARK. 3. Lock the parking br ake. 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 handleb ars. [...]

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 Polaris 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 pr[...]

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 stabiliz e. 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 around using the K-turn (see page 60). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequent[...]

122 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to S t 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 recommende d 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 (1 2 oz./355 ml Aero sol) 2876244 PS-4 PLUS Performance Syn the tic 2 W -50 4 -Cycle Oil (q t./.95 l ) 2876245 PS-4 PLUS Per formance Synthe tic 2W -50 4-Cycle Oil (ga l./3.8 l) Gearcase / T ransmission Lubricants 2877606 Synthetic SPOR TSMAN XP T ransmission Fluid[...]

126 SPECIFICA TIONS * Based on EU Directive 76/432/EC **A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation. Sportsman 550 XP / XP EPS Maximum W eigh t Capacity 575 lbs. (261 kg) Dry W eight 730 lbs. (331 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 [...]

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 eigh t Capacity 575 lbs. (261 kg) Dry W eight 767 lbs. (348 kg) (XP) 781 lbs. (354 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 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

131 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, 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[...]

132 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIE S AND REMEDIES The Polaris l imited warranty exc ludes 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 o r improper handling. This warranty also does not cover any A T[...]

133 W ARRANTY LIMIT A TIONS OF W ARRANTIE S AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfect ions caused by external stress, heat, col d or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensat i[...]

134 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not allow limi- tations on h[...]

135 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that hav e received authorization for export from Polaris Industries. Deal[...]

136 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 ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was [...]

137 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited warrant y is in additi on to the Polaris sta ndard limited warran ty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.S. Environ[...]

138 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SET FOR TH IN TH IS LIMITED W ARRANTY A RE THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O[...]

139 MAINTENANCE LOG Present this section of your ma nual 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 (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

140 MAINTENANCE LOG 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 . . . . . . . . . . . . . . . . 26, 34 A Access, Front Compartm ent . . . . . . 48 Accessories . . . . . . . . . . . . . . . . . . 116 Active Descent Control Fluid . . . 80-81 Active D escent C ontrol System . . . . 36 ADC System . . . . . . . . . . . . . . . . . . 36 Air Filt er . . . . . . . . . . . . . . . . . . . . . 91[...]

143 INDEX F Fluid ADC . . . . . . . . . . . . . . . . . . 80-81 Brake . . . . . . . . . . . . . . . . . . . . . 30 Deman d Drive . . . . . . . . . . . . . . 77 Engine Oil . . . . . . . . . . . . . . 73-75 Transm ission . . . . . . . . . . . . . . . 76 Fluid Change ADC . . . . . . . . . . . . . . . . . . . . . 81 Deman d Drive . . . . . . . . . . . [...]

144 INDEX R Rack/Compart ment, Front . . . . . . . . 48 Reverse Ope ration . . . . . . . . . . . . . . 63 Reverse Override Swi tch . . . . . . . . . 26 Rider Information Center . . . . . . . 38-47 Riding Area . . . . . . . . . . . . . . . . . . . 52 Riding Gear . . . . . . . . . . . . . . . . . . . 8-9 S Safe O peration Practices . . . . . . . . . [...]