Polaris Sportsman 9922581 manual

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

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

P antone 426 C For your nearest Polaris dealer , visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 U.S.A. Part No. 9922581 Rev 02 Printed in U.S.A.[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly pro duce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® Always follow the instructions and recommendations in[...]

2 POLARIS, THE W A Y OUT and SPOR TS MAN ar e registered tradem arks of Polaris 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 disc[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 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 As the operator of the vehicle, yo u are responsible for your perso nal safety , the safety of others (including your passenger), and the protec- tion of our environment. Rea d and understand your owner's manual, which includes valuable information ab out all aspects of your ve hicle, includi ng safe operating procedures. Ride r[...]

6 SAFETY Failure to follow the warni ngs in this manual can result in se rious injury or death. This Polaris vehi cle is not a toy and can be hazardous to operate. A collision or rollover can occur q uickly , even during routine maneuvers, if you fail to take proper precaution s. Read and understand your owner's manu al and all warni ngs befor[...]

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

8 SAFETY Rider Safety Never carry a passenger on thi s vehicle. Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gl oves, boots, long sleeves and long pant s. Never consume alcoho l or drugs before or while opera ting this vehicle . Never operate at excessive speeds. T ravel and turn at speeds approp[...]

9 SAFETY Rider Safety Always inspect your vehicle before each use to veri fy that i t's in safe operat ing condi tion. See page 44. Follow the inspection and maintenance procedures outli ned in this manual. Keep both h ands on the ha ndlebars. Keep both feet on the footrests. Always travel slowly when ope rating on unfamiliar terra in. Use ext[...]

10 SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outl ined in thi s manual for driving on hi lls. See page 52. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting la rger hills. Avoid climbing hills ste eper than 25 ° . Always move the 4X4 switc[...]

11 SAFETY Rider Safety Always follow the procedures outl ined in thi s manual for braki ng if you stall or roll backwards while climbing a hi ll. Never back down a hill. See page 53. Always follow the procedures outl ined in this manual for operating over obstacles. See p age 50. Always follow the procedures outl ined in thi s manual for operating [...]

12 SAFETY Rider Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this vehicle through improp er inst allatio n or use of accessories. Never exceed the stated load cap acity fo r your vehicle. Cargo must be p roperly distributed and securely attached. Reduce speed and follow the[...]

13 SAFETY Rider Safety Always remove the ignition key when the vehicle is n ot in use to prevent unauthorized use or accidental st arting. Always unlock the steering before starting the engine. See page 26. Hot components can cause serious burn s and fire. Do not touch ho t exhaust system components. Always keep combustible materia ls away from the[...]

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

15 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 [...]

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

17 SAFETY Safety Labels and Locations General Alert (Multi-Lingual) Before you operate this vehicle, rea d the owner ’s manual. 7173025 Reverse Override W arning/4X4 Caution W ARNING Improper use of the ove rride button can lead to loss of c ontrol resulting in se vere injury or death. Do not activate overri d e while throttle is engaged. Always [...]

18 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 Alert TIRE PRESSURE IN PSI (KPa): Front: 7.0 psi (48.3 kPa) Rear: 5.0 psi (34.5 kPa) MAXIMUM WEIGHT CAP ACITY 575 lbs. (261 kg) INCLUDES W[...]

19 SAFETY Safety Labels and Locations Clutch Cover Alert 7175826 Rack W a rning, Front and Rear W ARNING • DO NOT TO W FROM RACK OR BUMPER. V ehicle dama ge or tipover may result causing severe injury or deat h. T ow only from tow hooks or hitch. • Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg) 7175448 Hitch Cap acity Label TRAI[...]

20 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 switch. Pressing the override switch while the throttle is o pen can cause loss of control, which may result in serious injury o[...]

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

22 FEA TURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving. Throttle Lever Failure to check or ma intain proper operation o f the throttle system can resul t in an accident if the thrott le lever sticks during opera tion. Check the lever for proper operation b efore starting [...]

23 FEA TURES AND CONTROLS Brakes Aggressively applying the brakes whe n backing down a hill may cause rear tipover . Aggressively ap plying the brakes while moving forward may ca use the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all bra ke systems on this vehicle. Alwa ys use ca[...]

24 FEA TURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in PA R K . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and release the brake lever . Operating the vehi[...]

25 FEA TURES AND CONTROLS Electronic Power 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 33 for EPS W arning Indicator info rmation. Automatic T ransmission Gear Selector The transmission gear selector is lo[...]

26 FEA TURES AND CONTROLS Steering Lock Lock the steering to prevent unauthor ized use or theft of the vehicle. 1. T urn the handlebars to the full l eft position. Tip : The handleba rs may also be locked in the full left position. 2. Insert the stee ring lock key an d turn it clockwise. 3. Remove the key . Tip : Place the steering lock keys in a s[...]

27 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[...]

28 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 30. 4X4 [...]

29 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 vehicle'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 [...]

30 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[...]

31 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the 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: e[...]

32 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[...]

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

34 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 switch also acts as a MODE button when held down for approximately one half second.[...]

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

36 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area 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[...]

37 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[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the 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[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center *Assumes unipolar configuration of stepper motor SPORTSMAN 550 XP 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 emper ature Sensor V oltage T oo High 1 10 3 V oltage T oo Low 1 10 4 T emperature T oo [...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 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 emper ature Sensor V oltage T oo High 1 10 3 V oltage T oo Low 1 10 4 T emperature T oo High 1 10 16 Engine Overheat Shutdown 1 [...]

41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 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+[...]

42 OPERA TION Failure to ope rate the vehicle prop erly can result in a coll ision, loss of control, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in p eriod for your new Polaris vehicle is the first ten [...]

43 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 67. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en ar[...]

44 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Hand brake/lever travel Ensure proper operation 81 Foot brake Ensure pr[...]

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

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

47 OPERA TION T urning the V ehicle 1. Before turning, activate a turn signal to alert others of your intentions . Activate the left signal befo re a left turn. Activate the right signal before a right turn. 2. S teer in the direction of the turn, leaning your up per body to the insid e of the turn while supporting your weight on the outer footrest[...]

48 OPERA TION Driving on Slippery Surfaces Whenever driving o n slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before whee ls begin to lose traction. NOTICE: Severe damage to drive trai n may occur if the 4X4 is engaged while the wheels are spinn[...]

49 OPERA TION Driving Through W ater Follow these procedures when driving thro ugh water: 1. Check water de pth and cur- rent before crossing. 2. Choose a crossing where both banks hav e gradual inclines. 3. Drive slowly . A void rocks and obstacles. 4. A void operating in water deeper than the bottom of the footrests. If it's unavoid- able, t[...]

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

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

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

53 OPERA TION Driving Uphill If all forwar d speed is lost: Keep your weight uphill. If the vehicle begins r olling downhill, never apply engine power . Never apply the brakes aggr essively while r o lling backwar ds. 1. Apply the brakes gradu ally . 2. When fully stopped, loc k the hydraulic parking br ake. 3. Dismount on the uphill side, or on th[...]

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

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

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

57 OPERA TION T u rning Around on a Hill (K-T urn) 9. Lock the hydrau lic parking brake. 10. Remount from the uphill side . Keep your weight uphill. 1 1. Apply the foot brake. 12. W ith the transmission still in forward, start the engine. 13. Squeez e and release the brake le ver to release the pa rking brake. 14. Relea se the foot brake and drive [...]

58 OPERA TION Hauling Cargo Overloading the vehi cle or carrying o r to wing ca rgo improperly can alter vehicl e handling and may cause loss of control or brake instability . Always follow the se precautions when hauli ng cargo. • Read and understand the load distribut ion warnings listed on the vehicle warning labels. • Never exceed the state[...]

59 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your vehicle on warn ing 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 c[...]

60 OPERA TION Parking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Always block the rear wh eels on the downhill side.[...]

61 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requirements. S p ark Arrestor Y our Polaris vehicle has a spark arrestor that was de signed for on-road and of f-road operation. It is required that this spark arrestor r[...]

62 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 [...]

63 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[...]

64 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[...]

65 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[...]

66 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 62. 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 needed[...]

67 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 66 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[...]

68 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 66 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 62. Al ways change the oil filter whenever changing oil. 1. Position the vehicle on a level su rface. Place[...]

69 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 [...]

70 MAINTENANCE T ransmission Oil Polaris recommends the use of Polaris Synthetic SPOR TSMAN XP T r ansmission Fluid for this transmis sion. See the table on page 66 for fluid recommendations, capacities an d plug torques. Alwa ys check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. [...]

71 MAINTENANCE Front Gearcase (Dem and Drive) Fluid See the table on page 66 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 62. See page 1 19 for the part numbers of Polaris products. Use the recommende d flui[...]

72 MAINTENANCE Rear Gearcase Oil See the table on page 66 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 62. See page 1 19 for the part numbers of Pola ris products. The fill plug is located on the rear of the gearc[...]

73 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[...]

74 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 71 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[...]

75 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[...]

76 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[...]

77 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[...]

78 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to prot ect 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 recov[...]

79 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at th e recommended lev el. Do not overfil l. The brakes should feel firm when they're applied. Spongy or weak brakes may i ndicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are wo rn a[...]

80 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handleba r . Maintain the fluid level 6 mm below t he top edge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. V iew the fluid level through the indicator wind ow (eye) on the top of the ma[...]

81 MAINTENANCE Brake Inspections The front and rear brakes are hydraulic disc bra kes, activated by apply- ing the foot brake . The handlebar brake is also hydraulic. Both brake systems are self-a djusting. Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under normal [...]

82 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe a lignment is 0" to 1/8" (0-3 mm) toe out. Severe injury or death can result from improper toe alig nm ent and adjustment. Do not attemp t to adjust tie rod alignment. Al l tie rod adjustments should be performed by an [...]

83 MAINTENANCE S teering Assembly The steering assembly should be check ed periodically for loose nuts an d bolts. If loose nuts and bolts are foun d, see your Polaris dealer for ser- vice before operatin g the vehicle. Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. R[...]

84 MAINTENANCE Ti r e s Operating your veh icle with worn tires, improperl y inflated ti res, 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. Al[...]

85 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in P ARK. 2. Place the wheel on the hub with th e valve stem toward the outside and rotation arrows on the tire po inting toward forward rotation (if equipped). 3. Install the wheel nuts and finger -tighten them. 4. Lower the veh icle to the ground. 5. T orque the wheel nuts to s[...]

86 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.[...]

87 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if y ou 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[...]

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

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

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

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

92 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , plea se 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[...]

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

94 MAINTENANCE 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 can[...]

95 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the sp ecifications section beginn ing on page 120 for the recom- mended spark plug type and gap for your v ehicle. T o rque spark plug s to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. [...]

96 MAINTENANCE Spar k P l u g s S p ark Plug Inspection 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 ra nge for the engine and the service. The tip should not be flaky and wh ite. A white insulator [...]

97 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, majo r engine damage ca n result if the machine is not thorou ghly inspected. T ake the vehicle to your dealer before starting the engine. If it's impo ssible to take your vehicle to a dealer before starting it, fo llow the steps outlined below . 1. Move the vehicle to d ry l[...]

98 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 comb ustible materials fro m the area. W ear eye prot ection and leather work gloves. Do not stand behind or in front of the vehicle while purging. [...]

99 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 modification will cause the system to be out of balanc[...]

100 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[...]

101 MAINTENANCE P VT System When T o Use Low Ra nge and High Range P VT Drying There may be some instance s 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 t[...]

102 MAINTENANCE Battery Improperly connecting or discon necting battery cables can result in an explosion and cause serious injury or death. When removing the battery , alw ays 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 [...]

103 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 batter y out of the vehicl e. Be careful not to tip a conven- tio[...]

104 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 106 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the ba ttery i[...]

105 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 maintain a full charge. Polaris rec[...]

106 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 charging. See page 1 03. 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 1.[...]

107 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 ts None, check at 3 mos. from date of manufacture None required 75%-[...]

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

109 MAINTENANCE Cleaning and S torage W ash ing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The w ate r may damage components and could remove paint an d labels. A v oid direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or[...]

110 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[...]

111 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 coul d 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 108. S t [...]

112 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the following fluid levels. Ch ange fluids as recommended in the Periodic Maintenance Char t beginni ng on page 62. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • T ra nsmission • Brake fluid (change every [...]

113 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 62. Battery Maintenance Remove the battery and recharge it as o utlined on page 106. S tore the battery in a cool, dry place. S torage Area/Cover[...]

114 MAINTENANCE T ransporting the V e hicle 1. S top the engine. 2. Place the transmission in P ARK. 3. Secure the fuel cap, oil cap and seat. 4. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do no t attach tie straps to the front A- arm bolt pocke ts, racks or handleb ars. 5. Remove the key to [...]

115 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 56). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequent[...]

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

117 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St 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 [...]

118 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[...]

119 POLARIS PRODUCTS Pa r t Number Description Engine L ubricant 2870791 Fogging Oi l (12 oz./355 ml Aerosol) 2876244 PS-4 PLUS Performan ce Synthe ti c 2W-50 4-Cycle Oil (qt./.95 l ) 2876245 PS-4 PLUS Per formance Synthe tic 2W -50 4-Cycle Oi l (gal./3.8 l) Gearcase / T ransmission Lubricants 2877606 Synthetic SPOR TSMAN XP T ransmission Fluid (qt[...]

120 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC SPORTSMAN 550 XP Maximum W eight Capacity 575 lbs. (261 kg) Dry W eight 732 lbs. (332 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Ca pacity 7.1 oz. (210 ml) Demand Drive Fluid Capacity 9.3 oz. (275 ml) T ransmission Oil[...]

121 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN 550 XP 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 2 6x10-14 A T [...]

122 SPECIFICA TIONS * Based on EU Directiv e 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.[...]

123 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 2 6x1[...]

124 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polar is 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 [...]

125 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of th e Polaris vehicle against defects in material or workma nshi p. This warranty covers the parts and labor char ges for repair or replacement of defective parts which are cove r ed by this warranty . T[...]

126 W A RRANTY 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 or improper handling. This wa rranty also does not c over any v[...]

127 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND RE MEDIES 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[...]

128 W A RRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EX PRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some state s do not allow lim i- tations on [...]

129 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[...]

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

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

132 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . 20, 28 A Access, Front Compartm ent . . . . . . 27 Accessories . . . . . . . . . . . . . . . . . . 113 Active Descent Control Fluid . . . 74-75 Active D escent C ontrol System . . . . 30 ADC System . . . . . . . . . . . . . . . . . . 30 Age Restrict ions. . . . . . . . . . . . . . . . . 6 Air[...]

133 INDEX F Fluid ADC Fluid. . . . . . . . . . . . . . 74-75 Brake Fluid . . . . . . . . . . . . . 79-80 Deman d Drive Fluid . . . . . . . . . 71 Engine Oil . . . . . . . . . . . . . . . . 67 Fluid Change ADC Fl uid . . . . . . . . . . . . . . . . . 75 Deman d Drive Fluid . . . . . . . . . 71 Engine Oil . . . . . . . . . . . . . . 68-69 Foot Brake,[...]

134 INDEX R Rack/Compart ment, Front . . . . . . . . 27 Reverse Ope ration . . . . . . . . . . . . . . 51 Reverse Override Swi tch . . . . . . . . . 20 Rider Information Center . . . . . . . 32-41 Rider Safety . . . . . . . . . . . . . . . . . . 7-13 Riding Gear . . . . . . . . . . . . . . . . . 14-15 S Safety Labels . . . . . . . . . . . . . . . 1[...]