Polaris 850 XP manual

[...]

3[...]

A card containing impo rtant A TV safety informatio n should be attached to the owner's manual on the next page. If you cannot locate this car d, or if it has be en removed, pl ease call 1-800- 342- 3764 for assistan ce. 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 purchasin g a Polaris vehicl e, an d welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line o f 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 TH E W A Y OUT are registered t rademarks 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 publication. Due to constant improvements in the design and quality of production components, some minor discrep[...]

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 throughout th is manual and on your vehicle. Y ou r safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard. W ARNING A W ARNING indicates a hazardous[...]

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in thi s manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicle s, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuver[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your k ey number) and mating it with one of your existing keys. The ignition switch[...]

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

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance 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 goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi 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 T V pro perly can re sult in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manual. See the OPERA TION section of the owner ’s manual for proper operating proce dures. Operatin[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution w henever handling g asoline. • 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 vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous 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 lots and driveways) may adversely affect 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 designed for o ff-road use. If it's unavo[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the footrests during operatio n can reduce your abili ty to control th e 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 Improper ly Improperly descending a hill could cause loss of control or overtu rn. • Always follow proper procedures for travel- ing down hi ll s as de scri b ed in the owner's manual. NOTE: A special technique i s required when braking while traveling down- hill. See page 59. • Always descend a[...]

16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, rolling backwards or impr operl y dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed whe n climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascending or descending 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 operati ng on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain. Always use ex tra caution on roug h, slippery or loose terrain. Op[...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a coll ision with an obstacle or person. Always follow proper operating procedures as outlined 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 proc[...]

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 obstacles. A void ope rating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operati ng proce dures as outlined [...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carryin g/towing cargo improperly may cause chang es in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this A TV . • Cargo should be p roperly distributed and securely attached. • Reduce speed when carrying cargo [...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a dama ged A TV can resu lt in an accident. After any overturn or accident, have a qualifi ed service dealer inspect the entire ma chine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active vehicle[...]

22 SAFETY Safety Labels and Locations W arn ing labels have been plac ed on the vehicle for your protectio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or grap[...]

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 teering becomes difficult. T o prevent loss of [...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNIN G NEVER ride as a passenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 Tire Pressure/Load W arning W ARNIN G Improper tire pressure or overlo ading can cause lo ss of co ntrol. Loss of control can result in severe injury or death[...]

25 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o p revent serious injury , do not operate vehicle wi th guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, whi ch can result in serious injury or dea[...]

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

27 FEA TURES AND CONTROLS Switches Engine Stop 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 al[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV with sticking or impr o perly ope rating throttle controls could cause an accident. Never start or oper ate an A TV that has a sticking or improperly operating throttle . Always c ontact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of t[...]

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. Never operat e the A TV with a sp ongy-feeling brake lever . Always contact your dealer for service before operating the vehicl e. Squeeze the brake lever toward the handlebar to ap ply the front and rear[...]

30 FEA TURES AND CONTROLS Master Cylinde r/Brake Fluid An over-full master cyl inder may cause brake drag or brake lock-up, which co uld 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 hygroscopic, 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 auxiliary brake whe n backin g down a hill may cause rear tipover , which could result in seri ous injury or death. Ne ver back down a hill. Use caution when ap plying the auxiliary b rake. Do not aggressively a pply the auxiliary brake when going forward. The rear wheels may [...]

33 FEA TURES AND CONTROLS Electronic Power St eering (EPS) Electronic power steering (if equipped ) engages when the ignition key is turned to the ON position. EPS rema ins engaged whether the vehicle is moving or idle. See page 39 for EPS W arning Indicator information. Automatic T ransmission Gear Selector The transmission gear selector is locate[...]

34 FEA TURES AND CONTROLS All Wheel Drive System The All Wheel Dr ive sy stem 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 movin g. Initially , the vehicle's electronic sy stem will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turn ed of f while the dem[...]

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 operation. In addition to showing vehicle speed, the instrument cluster also dis- plays the following items: engin[...]

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 cluster ma y have shut of f to protect the ele[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center 3. Speed Display - This area displays vehicle ground speed 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 las t seg ment clears, a low fuel warni[...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Spe ed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip : The reverse override 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 overri de 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 Programmable Service Interval When the hours of engine operation equ al the programmed 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 to[...]

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

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 chart (inj ector , fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in [...]

45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center *Assumes unipolar configuration of ste ppe r 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[...]

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 H igh 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 collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for yo ur 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 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 prop[...]

51 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before operatin g this vehicle. See page 7. 2. Do not allow anyone und er 16 year s of a ge to operate this vehicle . Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle. 3. Never carry a passenger on this A TV . 4. Engine exhaus[...]

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 ride. Fin d out where the de signated riding areas are by con- tacting your Polaris dealer , a local rid ing club or local officials. Help keep[...]

53 OPERA TION S tarting 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 brake. 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 engi[...]

54 OPERA TION Driving Procedures 1. W ea r a helmet and eye protection. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path o f 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 slightly . 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 freezing weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before whee ls begin to lose traction. NOTICE: Severe [...]

57 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 switch to ADC 4 X4 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 reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down! 2. Shift body weight uphill. 3. Keep your feet o[...]

59 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4 X4 before ascending or descending a hill. See page 36. 2. A void steep hills (25 ° maximum ). 3. Shift body weight uphill. 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 uphil l. 2. Always move the 4X4 switch to ADC 4 X4 before ascending 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 through water with a maximum recom- mended depth eq ua l to the bot- tom of the footrests. Follow these precautions when operat- ing through wa ter: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have grad ual inclines. 3. A void operati[...]

62 OPERA TION Driving Over Obst acles Follow these precautions whe n 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 unfamilia[...]

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

64 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo imp roperly can alte r vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. N[...]

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. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possi- ble. When operating over rough or hilly terrain, reduce speed and cargo wei[...]

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 brake. 4. Always block the rear wheels on the do wnhill side.[...]

67 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect 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 tested and qualif[...]

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

69 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could result in component failure and cause an accident, wh ich may result in se rious injury or death. Always have an authorized Pola ris de aler perform these services. Maintenance Chart Key X Perform these operations more often for vehic les subject[...]

70 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main te nanc e interval is r eac hed 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 [...]

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 (8 00) Ins[...]

72 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art 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 the int ervals outlined in the Periodic Maintenance Ch art beginning on page 68. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Sta[...]

75 MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter . Using an oil filter wrench (available from your Polaris dealer), turn th e filter counter- clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 1 1. Lubricate the o-ring on the new filter with a film of fr[...]

76 MAINTENANCE T ransmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP T rans- mission Fluid for this tr ansmission. See the table on page 7 2 for fluid recommendations , capacities and plug torques. Always check a nd change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginn ing 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 an d change th e demand drive fluid at the inter- vals outlined in the Periodic Mai n ten ance Chart beginning on pa ge 68. See page 125 for the part nu mbers of Polaris products. Use the recommended 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 gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 for the p art numbers of Polaris pro d ucts. 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 sealing washe r . 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 vehicl e is equipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fl uid and ADC fluid). See page 77 for dema nd drive fluid maintena nce. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Ch art 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 AD C reservoir and bleeder valves (one on each side of the dif ferential). 3. Remove the reservoir cap and di[...]

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

83 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front storage com- partment. 1. V iew the fluid level in the bottle. 2. If the level is low , remove the front rack. 3. Remove the bottle cap and ad d 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 handlebar . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drops. If the fluid le ve l is low and the diaphragm is not extended, a leak is lik[...]

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) toe out. W ARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adju st tie rod alignment. All tie rod a djustments should be perfor[...]

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/Footwe ll Removal Remove the seat before remo vin g a side panel. Remove the screws and rivets securing the side panel or footwell (see illustration). Plastic Rivet Hex Head Scr [...]

88 MAINTENANCE Ti r es Operating your A TV with worn tires, impr operly i nflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al ways [...]

89 MAINTENANCE Ti r es Front Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer . Wheel Removal 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Loosen the wheel nuts slightly . W ARNI[...]

90 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside 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 vehicle to the ground. 6. T or[...]

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 bo x 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 replace burn ed out lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlight Lamp Replacement When servicing a halogen lamp, av oi[...]

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 do wnward. 1. Loosen the phillips screw located at the rear of the headlamp . 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 cover and disconnect the speedometer harnesses from the speedom eter . 3. Unplug the headlamp from the wiring harness. 4. Use a sma ll scr ew dri ver 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 counterclockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp 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 Sp ark Plug Recommendatio ns Refer to the specifications sect ion beg inn ing on pa ge 1 26 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.[...]

99 MAINTENANCE Spar k P l u g s Sp ark Plug Insp ection Normal Sp 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 t[...]

100 MAINTENANCE V ehicle Immersion If your vehicle becomes imm ersed, major engine da mage can 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 the steps outlined below . 1. Move the A TV to dry land or a[...]

101 MAINTENANCE S p ark Arrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. N[...]

102 MAINTENANCE P VT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balan[...]

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 PVT Drying There may be some instances when 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 the [...]

105 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains su[...]

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 can 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 Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge 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 dam age from leak- ing or spilled electroly t e du ring charging. See page 106. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to rais e 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 Time (Using constant cu rrent charger @ standard amps specifie d on top of batt ery) 100% 12.8-13.0 vol ts None, check at 3 mos. from date of manufacture None required 75%-[...]

111 MAINTENANCE Cleaning and St orage 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 comp onents. NOTICE: High water pressure may damage comp onents. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, inclu[...]

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

113 MAINTENANCE Cleaning and St orage 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. Cle[...]

114 MAINTENANCE Cleaning and St orage Sto r ag e Tips NOTICE: S tarting the engine durin g the storage period will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and then clean the vehic le as recommended. See page 1 11. St abil[...]

115 MAINTENANCE Cleaning and St orage Sto r ag e Tips Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommended in the Periodic Maintenance Char t beginning on page 68. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • T ransmission • Brake fluid (change every tw[...]

116 MAINTENANCE Cleaning and St orage Sto r ag e Tips Inspect and Lubricate Inspect all cables and lubricate all a reas of the vehicle as recommende d in the Periodic Maintenance Chart beginning on page 68. Battery Maintenance Remove the battery and rechar ge it as outlined on page 109. S tore the battery in a cool, dry place. Storage Area/Covers S[...]

117 MAINTENANCE T ransporting the A TV 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parking 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 pockets, rack s or handlebars. 6.[...]

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 ahead , place very light p[...]

119 ADJUSTMENTS Throttle Cable Freeplay 4. Place the transmission in P ARK. Lock the parking brake. 5. Start 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 corre ct gap. If gap is[...]

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

121 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 60). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher sp eed or us e low range more frequently[...]

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

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

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

125 POLARIS PRODUCTS Pa rt Number Description Engine Lubr icant 2870791 Fogging Oil (1 2 oz./355 ml Aeroso l) 2876244 PS-4 PLUS Performance Syn the tic 2W-50 4-Cycl e Oil (qt./. 95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cyc le Oil (gal./3.8 l) Gearcase / T ransmission Lubricants 2877606 Synthetic S portsman XP T ransmission Fluid (q t./[...]

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. (2[...]

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, Rear 3.7:1 T i res/Pressure, Front 26x8-14 A T / 7 psi (48.3 kPa) T i res/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, Rear 3.7:1 T i res/Pressure, Front 26x8-14 A T / 7 psi (48.3 kPa) T i res/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 co[...]

131 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND RE MEDIES The Polaris limi ted warranty 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 TV[...]

132 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT N OT LIMITED TO THE IMPLIED W ARRANTIES O F 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 EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not al low limi- tations on h[...]

133 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 LO CA - TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dea[...]

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

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 limited 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 the [...]

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 (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / C OMMENTS[...]

137 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / C OMMENTS[...]

138 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SER VICE PERFORMED / C OMMENTS[...]