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1. 3 Start the engine Quickly squeeze and release the throttle lever several times to purge car B bon from the system 5 If carbon comes out of the exhaust cover or plug the Clean Out Plug exhaust outlet s Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrester to cool 10 Reinstall the arrester clean out plug and remove the exhaust outlet cover or plug 117 MAINTENANCE PVT System A WARNING 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 high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance pr
2. im U Lamp Indicates Condition When standard mode is selected speed displavs in Vehicle miles per hour Speed z When metric mode is selected speed displays in kilometers per hour E Over This lamp flashes to indicate an overheated engine If eodem Temperature the indicator stops flashing but remains illuminated the overheating condition remains and the system will automatically reduce engine power N EPS Warning This indicator illuminates when the key is turned to the ON position and goes off when the engine is started If the light remains on after starting the engine the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in NI neutral and the ignition kev is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam EA Check Engine This indicator appears if an EFl related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result See vour dealer 35 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge 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 may have shut off to protect the electronic speedome
3. 83 Override Switch 0 000 24 P Parking Brake esee 29 Parking on an Incline 63 Periodic Maintenance Chart 84 87 Polaris Product List 137 Polishing the Vehicle 129 Power Steering 3l Power Steering Unit Cleaning 98 Pre Ride Checklist 54 PVT Break In 66e 53 PVT Drying eoe rS 120 PVT System 118 120 R Rack Compartment Front 52 Reverse Operation 67 Reverse Override Switch 24 Rider Information Center 36 41 Riding Area 00 00 56 Riding Ge r L iskala 8 9 S Safe Operation Practices 55 Safety Labels 20 23 No Passenger Warning 22 Age 16 Warning 21 Clutch Cover Warning 23 Discretionary Warning 21 General Warning 20 Hitch Capacity Label 23 Rack Warning Front and Rear 23 Reverse Override Warning 21 Tire Pressure Load Warning 22 156 S Safety Training 0000000 T Safety Warnings 10 19 Safety Winch Maintenance 82 Severe Use cese t s 84 Shock Loading the Winch 80 81 Side Panel Removal 103 Sidel llitig npe 62 Signal Words 4 Spark Arrester 0 0000 117 Spark Plug Inspection 114 115 Spark Plug Recommendations 114 Spark Plugs 114 115 Speedometer gt oye cy emen 34 Spring Adjustment Shock
4. Idle RPM 1200 50 Throttle Body Size Mikuni Dual Bore 42 mm Spark Plug Type Gap REA6MC 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT POLARIS Variable Transmis sion Front Suspension Dual a arm with 9 2 23 cm travel Rear Suspension Progressive rate with 10 2 26 cm travel Based on EU Directive 76 432 EC 140 SPECIFICATIONS SPORTSMAN XP 850 H O 850 H O EPS Transmission 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 371 Tires Pressure Front MAXXIS AT 26x8 14 7 psi 48 3 kPa Tires Pressure Rear MAXXIS AT 26x10 14 7 psi 48 3 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital LCD LED XP Digital Analog XP EPS Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 24 63 Red White Red White 105 165 BA3 Feet 0 6000 PN 5632215 PN 7043349 PN 3235088 PN 3235092 1800 3700 24 60 Red White Red White 105 165 BA3 6000 12000
5. 121 Starting the Engine 57 Steering Assemblv 98 102 SLOTAge cive e m er RR 128 131 Storage Tips 130 131 Switches 6 24 25 4X4 Switch L 24 32 Engine Stop Switch 25 Headlight Switch 24 Main Key Switch 25 Mode Switch 24 Reverse Override Switch 24 Stop Switch 25 T Taillight iin kms 113 Throttle Body Adjustment 122 Throttle Cable Freeplay 122 123 Throttle Lever 0000 000 26 Tire Tread Depth 104 Tires sissa tagna Re rm 104 106 Wheel Installation 106 Wheel Nut Torque 106 Wheel Removal 105 Toe Alignment 102 Towing Capacities 70 Towing Loads suus 70 Trail Etiquette 2 66 cece ee eee 56 Train g s gels asc hee t ESAE 7 Transmission Gear Selector 25 Transmission Oil 92 T Transporting the ATV 132 Tread Lightly 22a od ais nue ale 56 Turning Around on aHill 64 Turning the Vehicle 59 V Vehicle Identification Numbers 6 Vehicle Immersion 116 WwW Warning Symbols 4 Washing the Vehicle 128 129 Wheel Hub Tightening 105 Wheel Installation 106 Wheel Nut Torque Specifications 106 Wheel Removal 105 Winch Cable Care 79 Winch Mainte
6. If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately OPERATION 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 33 2 Avoid steep hills 25 maximum 3 Shift body weight uphill 4 Drive straight downhill 5 Slow down Excessive speed when traveling downhill can cause loss of control 6 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake u 4 Always block the rear ul wheels on the downhill side d Z 63 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 64 Stop and lock the parking brake while keeping body weight uphill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handleb
7. Maximum Mark Minimum Mark Recovery Bottle Cap 99 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add cool ant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 5 Reinstall the front rack Radiator Cap 100 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 diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm oper
8. PN 5632216 PN 7043349 PN 3235088 PN 3235092 EBS models require no helix spring adjustment 141 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and
9. If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 146 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmansh
10. Inspect lubricate D Steering 50 H 6M 500 800 JLubricate b Front suspension 50 H 6M 500 800 Lubricate gt Rear suspension 50 H 6M 500 800 JLubricate D Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate E Throttle Release replace if necessary Switch E Throttle Body 50 H 6M 500 800 Inspect duct for proper Intake Duct sealing air leaks Drive belt 50 H 6M 500 800 jInspect replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test System yearly b Radiator 50 H 6M 1000 1600 Inspect clean external surfaces gt Cooling hoses 50H 6M 1000 1600 Inspect for leaks gt Oil lines fasteners 50H 6M 1000 1600 Inspect for leaks and loose fittings gt Engine oil change 100 H 6M 1000 1600 Change the oil and filter gt Demand drive fluid 100 H 12M 1000 1600 Change fluid normal use gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid b Transmission oil 100 H 12M 1000 1600 Change fluid gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 86 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replac
11. 1 Place the transmission in PARK 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 pointing toward forward rotation if equipped 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 75 ft Ibs 102 Nm Cast Aluminum Steel 45 ft Ibs 61 Nm Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Wheel Type Nut Type Nut Torque Aluminum Lug Nut 75 ft lbs 102 Nm Steel Lug Nut 45 ft Ibs 61 Nm 106 MAINTENANCE Air Filter Remove the seat 2 Remove the air box cover strap and remove the air box cover 3 Remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new Pre Filter main filter if needed pm 6 Reinstall the filter into the air Ld 6 E box ilter o 7 Reinstall the air box cover and the seat 107 MAINTENANCE Fuse Replacement If the engine stops or will not start or if you experience other e
12. Respect the environment in which you ride Find out where the designated riding areas are by con tacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 56 OPERATION Starting the Engine Position the vehicle on a level surface outdoors or in a well venti lated area Place the transmission in PARK Lock the parking brake The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged Sit on the vehicle and move the engine stop switch to RUN Do not press the throttle while starting the engine Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts If the engine does not start return the key to the OFF position and wait five s
13. The time will display for 5 10 seconds See page 46 for resetting instruc tions Service Reminder Display A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehi cle should be brought to your dealer for scheduled maintenance See page 46 for resetting instructions Under Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Check Engine Warning This icon displays if an EFI related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result See your dealer 4X4 Display This icon displays when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 Neutral Indicator This indicator illuminates in addition to dis playing in the gear indicator display when the transmission is in neutral EPS Warning Indicator If this indicator light remains on after starting the engine the EPS system is inoperative See your autho rized Polaris dealer for service 43 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD aude EPS Models Use the MODE button to toggle through the speed display options Use the SELECT button SEL to toggle through the information area opt
14. appropriate for the terrain the visibility and operating conditions and your experience 12 Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 61 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill SAFETY 13 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss
15. ter If this occurs take the ATV to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 39 jp E m mu mo mu mu JI If NAI ir Trip 1 RPM NA NANA NAAN INI VAN AN TANZAN NTAN N 36 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center 1 Tip Gear Display This area displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears Fuel Gauge Display The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Information Display This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval Active Descent Control Display This icon displays when ADC is active See page 33 Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See page 39 for resetting instruc tions Service Reminder Display A flashing wrench symbol
16. the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is pro grammed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval 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 only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the deter mination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit 40 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored in the
17. which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 27 FEATURES AND CONTROLS Master Cylinder Brake Fluid A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake fluid at the recommended level Do not overfill Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the Master Indicator master cylinder before each ride Cylinder Window 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is le
18. ATV safely and could be susceptible to accident or injury Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 10 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the
19. Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility Headlight Lamp Replacement When servicing a halogen lamp avoid touching the lamp with bare fin gers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 Remove the five 5 headlight pod screws 2 Liftthe pod cover and disconnect the speedom eter harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 3 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wir ing 4 Turn the lamp counter clockwise to remove it 5 Install the new lamp Make sure the tab on the lamp locates properly in the housing 6 Reassemble the pod 109 MAINTENANCE Lights 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 surface with the headlight approxi matelv 25 ft 7 6 m from a wall Place the transmission in PARK 25 ft 7 6 m Lamp Center Height 2 5 om 110 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine Turn the headlight switch to high beam O
20. MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 150 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 151 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 152 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 153 INDEX 0 9 4X4 Switch sssuu 24 32 A Access Front Compartment 52 Accessories 26 LL 132 Active Descent Control Fluid 94 95 Active Descent Control System 33 ADE System cen emm 33 Air Filter sso re hmm 107 All Wheel Drive System 32 33 Auxiliary Foot Brake 101 B Battery 20 eee ena 124 127 Charging re eet 126 127 Extreme Use 30 AH 3l Installation sana 125 Removal 124 COTA BC iirc rna eb 125 Belt Life i Lia vit tee eee et 25 BOOS mE 9 Brake Fluid Auxiliary Foot Brake 30 Brake Fluid Main Brake System 28 Brake
21. Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Modifications to the throttle release switch could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle release switch or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle release switch Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever engine speed will be limited and power to the rear wheels will be reduced 26 FEATURES AND CONTROLS Brake Lever A WARNING Operating the ATV with a spongy brake lever can result in loss of braking
22. PN 1322915 PN 7043803 PN 3235088 PN 3235092 EBS models require no helix spring adjustment 139 SPECIFICATIONS SPORTSMAN XP 850 H O 850 H O EPS Maximum Weight Capacity 575 lbs 261 kg includes operator cargo and accessories Dry Weight 759 Ibs 344 3 kg XP 767 lbs 347 9 kg XP EPS Fuel Capacity 5 25 gal 20 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacitv 2 qts 1 9 1 Rear Gearcase Oil Capacitv 7 1 oz 210 ml Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 37 oz 1100 ml Front Rack Storage Box Capacity 120 Ibs 54 kg Rear Rack Capacity 240 Ibs 109 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear rack load and tongue weight not to exceed 240 Ibs 109 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO850LE Displacement 850 cc Bore x Stroke 87x 71 5 Alternator Output 475w 1200 RPM Peak 630w Compression Ratio 11 1 Starting System Electric Ignition System Electronic Fuel Injection Ignition Timing 6 5 BTDC 1200 RPM Engine warm
23. S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 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 or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehic
24. SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new clock format either 24 hour or 12 hour Release the button 4 New settings remain until changed using the same procedure Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meters record the distance traveled by the ATV on each trip if reset before each trip To reset a trip meter select the trip meter 1 or trip meter 2 mode Press and hold the MODE button on the instrument clus ter until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays with out a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 45 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is pro grammed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the SELECT button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press
25. adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized POLARIS dealer 1 Position the vehicle on a level surface E 2 Placethe handlebars in a Stand straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so l that the string is flush with the side of the rear l tire If available you may use a long straight l edge instead of string 2 4 Measure the distance from the string to the Es rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 8 1 4 inch 3 6 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 4 1 2 inch 6 12 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 If you discover improper alignment see your POLARIS dealer for service Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your POLARIS dealer for service before operating the vehicle 102 MAINTENANCE Seat Removal 1 Grasp one side of the seat near the rear edge 2 Pull upward abruptly to disengage the under seat fasteners 3 Remove the seat Side Panel Footwell Removal Remove the seat before removing a side panel To remove a side panel or footwell remove the fastener
26. are above 200 lbs 91 kg and or front cargo loads are above 100 Ibs 45 kg Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer See pages 68 69 Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Variances in snow depth and or water currents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entire route ATV operators assume all risk associated with ice conditions on frozen bodies of water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 18 SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified
27. bottom of the fill hole threads Do not overfill Oil Check 1 Position the vehicle on a aa T level surface 2 Remove the fill plug Fill Plug Check the oil level Drain Plug 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to specification 96 MAINTENANCE Rear Gearcase Oil Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain hole 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks 8 Dispose of used oil properly 97 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 Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your POLARIS dealer for service before operating the vehicle Cooling System The engine coolant level is controlled by the recovery system Recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap
28. gauge when the key is turned off The code and message is lost but will reappear if the fault reoccurs after restart ing the engine If the CHECK ENGINE light illuminates retrieve the error codes from the dis play Please see your Polaris dealer for all major repairs Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI 1 Ifthe error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the numbers displayed in the gear position if any clock and odometer displays 4 Press the MODE button to advance to the next error code p Press and hold the MODE button to exit the diagnostics code menu 6 See pages 48 51 for code definitions and failure descriptions Please see your Polaris dealer for all major repairs 41 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models The rider information center is located in the instrument cluster All segments will light up SBE A x for one second at start up If the instrument cluster fails to illuminate a battery over volt ge age may have occurred and the cluster may B za Um have shut down to protect the electronic speed LOO ometer If this occurs take the ATV to your Polaris dealer for proper diagnosis The information center
29. longer active This allows the deter mination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the transmission in PARK 2 Press and release the SELECT button until the flashing check engine warning indicator appears in the display 3 Asetoftwo numbers will also appear in the display The 2 6 digit suspect parameter number SPN in the information area indicates which component is generating the fault code The 1 2 digit failure mode indicator FMI number in the clock area indi cates the fault mode such as open or short circuit 4 See pages 48 51 for code definitions and failure descriptions Tip More than one fault may be active Press and hold the MODE button to tog gle through all currently active diagnostic codes 47 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading fro
30. occur if the air box drain plug is not reinstalled and tightened properly 3 Remove the spark plugs Drain Plug 850 4 Turn the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure NOTICE Serious damage can occur after immersion if fluids are not changed promptly See your dealer as recommended 7 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 120 for drying out the PVT 116 MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrester while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK
31. possible follow the vehicle immersion inspection and drying procedures outlined on page 116 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level Proceed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 65 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 66 Alwavs check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantiv alert for haz ards such as logs rocks and low hanging branches Travel slowlv and use extra caution when operating on unfamiliar terrain Not all obstacles are immediatelv visible Never attempt to operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse D gs d ey or Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is require
32. procedure for spark plug installation Torque to specifi cation 114 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray tan 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 white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 115 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box If water is pres ent dry the air box and replace the es filter with a new filter If equipped remove the air box drain plug to drain water Make sure the E ring is on the drain plug and reinstall the drain plug NOTICE Serious damage could
33. received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 142 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after th
34. reinstall the drain plug Torque to specification Add the proper amount of the recommended fluid Reinstall the fill plug Torque to specification pulo Check for leaks Dispose of used fluid properly 93 MAINTENANCE Active Descent Control ADC Fluid Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 We recommend the use of POLARIS Demand Drive Plus Fluid for the ADC unit Maintain the fluid level between the minimum and maximum marks on the reservoir See page 137 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system Fluid Check 1 Remove the front rack ADC Fluid 2 View the fluid level in the Reservoir reservoir 3 Ifthe level 1s below the minimum mark remove the cap and add the recommended fluid 4 Reinstall the cap 5 Reinstall the front rack 94 MAINTENANCE Active Descent Control ADC Fluid Fluid Change 1 Position the vehicle on a level Bleeder surface Before performing the Screw en fluid change allow the vehicle Cap to sit for at least 30 minutes Bleeder Thoroughly clean the areas around and on the ADC reservoir and bleeder valves one on each side of the differential Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reservoir Debris in the res
35. risk of a serious injuries in the event of an accident Always wear an approved helmet that fits properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV 11 SAFETY Safety Warnings Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s
36. slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This tech nique alters the balance of trac tion between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for NS turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 59 OPERATION Driving on Slippery Surfaces Sideways Turn in Skid direction of C oec C oec RA N Skid qd TX lt gt L O O S BS CC NA Whenever riding on slipperv surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in t
37. slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 65 Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 17 Safety Warnings Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking e NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 lbs 17 kg e NEVER exceed 10 MPH 16 km h when rear cargo loads
38. the handlebars straight ahead place very light pressure on the throt tle lever A gap of 2 3 mm should be visible between the throttle arm stop pin and the throttle arm If adjustment is needed 1 Locate the throttle cable adjuster Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 2 3 mm of freeplay is achieved between the stop pin and the throttle arm While adjusting freeplay flip the throttle lever back and forth repeatedly continued on next page 122 2 3 mm Gap Arm Stop Pin Cable Adjuster Boot Lock Nut Adjuster MAINTENANCE Throttle Cable Freeplay 4 2 10 Place the transmission in PARK Lock the parking brake Start the engine and allow the idle to stabilize If necessary tap the throttle lever to ensure the idle speed settles If idle speed remains above or below the recommended setting see specification pages verify the correct gap If gap is correct and idle speed is still not satisfactory please see your POLARIS dealer for service With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommended setting If idle speed increases it may be necessary to increase the gap between the stop pin and throttle arm but do not exceed the rec
39. the winch to a strong portion of the vehicle frame or hitch 77 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum F Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m pom 78 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or d
40. tighten Water present in fuel Replace with fresh recommended fuel Leaking exhaust components See vour dealer 134 Engine Pings or Knocks TROUBLESHOOTING Possible Cause Poor qualitv or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low batterv voltage Recharge batterv to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See vour dealer Electronic throttle control malfunction See vour dealer Other mechanical failure See vour dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommend
41. 01 Handlebar Adjustment 121 Hauling Cargo 68 70 Headlight Housing Replacement 112 Headlight Lamp Replacement 109 Headlight Switch 24 Helle t ue mom Senna each nEn 8 High Beam Adjustment 110 High Range Use 120 l Idle RPM Adjustment 122 Immersion 2e vere 116 Indicator Lamps 35 Instrument Cluster 34 51 K Key Switel 55st tos eae dated 25 K T fn pee damn ena ears 64 L Lights sia stanza 109 113 Headlight Housing 112 Headlight Lamp 109 High Beam Adjustment 110 Low Beam Adjustment 111 Lower Headlamp Replacement 113 Taillight Brakelight 113 Low Beam Adjustment 111 Low Range Use 120 Lower Headlamp Replacement 113 Lubrication Guide 88 M Maintenance Chart 84 87 Master Cylinder 28 Metric Display 38 45 Mode Switch 24 Modifications 04 9 N Noise Emission Control System 83 O Oil Engine iler ERR 89 91 Rear Gearcase 96 97 Transmission 92 Oil and Filter Change 90 91 155 INDEX 0 Oil Change Rear Gearcase 97 Transmission 92 Oil Level Engine ts apr fk eben 89 Rear Gearcase 96 Transmission 92 Oil Recommendations 89 Operation on Public Lands
42. 9 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 137 SPECIFICATIONS SPORTSMAN 550 EPS Maximum Weight Capacitv 575 bs 261 kg includes operator cargo and accessories Dry Weight 718 Ibs 325 7 kg 724 lbs 328 4 kg EPS Fuel Capacity 5 25 gal 20 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 qts 1 9 1 Rear Gearcase Oil Capacity 7 1 oz 210 ml Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 37 oz 1100 ml Front Rack Storage Box Capacity 120 Ibs 54 kg Rear Rack Capacity 240 Ibs 109 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear rack load and tongue weight not to exceed 240 Ibs 109 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1786 Ibs 810 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine ES550PLE Displacement 549 7 cc Bore x Stroke 96 6 x 75 Alternator Output 490w 1350 RPM Peak 630w Compression Ratio 9 6 1 Starting System Electric Ignition System Electronic Fue
43. AMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS 148 WARRANTY U S A EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have be
44. AN Communications No RX Message for 2 Seconds 520230 9 Receive Error EPAS CAN Communications No TX Message for 2 Seconds 520231 9 Transmit Error Assumes unipolar configuration of stepper motor 49 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN XP 850 850 EPS Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Signal Out of Range 102 2 Crankshaft Position Sensor Circuit Fault 636 8 Plausibility Fault 636 2 Vehicle Speed Signal Speed Too High 84 8 Plausibility Fault 84 2 Gear Sensor Signal Voltage Too Low 523 4 Voltage too high 523 3 Signal fault 523 2 Injector 1 MAG SDI Part Load Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Driver Circuit Grounded 651 4 Injector 2 PTO SDI Part Load Driver Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Igniti
45. ES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Clock Mode Tip The clock must be reset any time the battery has been disconnected or dis charged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 39 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting
46. Ensure proper level 28 Auxiliarv brake Ensure proper operation 30 Front suspension Inspect lubricate if necessarv 88 Rear suspension Inspect lubricate if necessarv 88 Steering Ensure free operation Tires Inspect condition and pressure 104 Wheels fasteners Inspect ensure fastener tightness bs Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 55 Coolant level Ensure proper level a Coolant hoses Inspect for leaks Throttle Ensure proper operation 15 Indicator lights switches Ensure operation 24 Engine stop switch Ensure proper operation 25 Air filter pre filter Inspect clean 107 Headlamp Check operation 24 109 Brake light tail lamp Check operation 113 Riding gear Wear approved helmet goggles and 8 protective clothing ADC Fluid Ensure proper level 94 54 OPERATION Safe Operation Practices 1 2 10 11 12 13 14 Complete the recommended safetv training before operating this vehicle See page 7 Do not allow anvone under 16 vears of age to operate this vehicle Do not allow anvone with cognitive or phvsical disabilities to oper ate this vehicle Never carrv a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliarv brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the veh
47. IS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 129 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended See page 128 Oil and Filter Change the oil and filter See page 90 Fluid Levels Inspect the following fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 85 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes car
48. Levet o ee aeess 27 Brake FOOL xs irase Gates 30 101 Brake Hand Lever 101 Brake Parking 00000 29 Brakelight ccrte een 113 Brakes 30 5 33 one e heme 101 Break In Period 53 C Camber Adjustment 121 Cate ssi cin kem e ede ys 68 70 Caster Adjustment 121 Check Engine Indicator 4l Cleaning and Storage 128 131 Clothing 4 32 nete DRRERESPRA 9 Clutching 550 XP 139 Clutching 850 XP 141 Cold Weather Operation 57 Consumer Product Safetv 7 Coolant Bottle 65 65 coss 99 Coolant Radiator 100 Cooling System 98 100 Crankcase Emission Control Svstem 83 154 D Demand Drive Fluid 93 Diagnostic Codes 550 48 49 Diagnostic Codes 850 50 51 Disengaging Active Descent Control 33 Display Units Standard Metric 38 45 Drive Belt Wear Burn 133 Drivetrain Break In 53 Driving Downhill 63 Driving in Reverse 67 Driving on a Sidehill 62 Driving on Slipperv Surfaces 60 Driving Over Obstacles 66 Driving Procedures 58 Driving Through Water 65 Driving Uphill suus 61 E Electromagnetic Interference 83 Electronic Power Steering 31 Emissions Limited Warranty 148 149 Engaging 4X4 2 0 0 33 Engaging Active Desce
49. PMS 419 Sportsman 550 EPS Sportsman XP 850 H 0 Sportsman XP 850 H 0 EPS Owner s Manual for Maintenance and Safety 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safetv information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs e RANGERQ utility vehicles e VICTORY motorcycles e GEM vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced F
50. RE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 Ibs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 Ibs 45 kg Vehicle should never exceed 10 MPH 16 km h while towing a load on a level surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill 68 Hauling Cargo 1 Never exceed the weight capacities specified for vour ATV on warning labels and in th
51. RIS approved or equivalent accessories designed for ATV use Maximum Towing Capacities Do not exceed the following maximum capacities when towing Avoid towing on inclines 550 850 Maximum Towed Load Level Ground 1500 Ibs 680 kg 1500 Ibs 680 kg Maximum Vertical Hitch Weight 150 Ibs 68 kg 150 Ibs 68 kg 70 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions T5099 toe 10 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 80 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distract
52. Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction atspeeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough ter rain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 20 SAFETY Safety Labels and Locations General Warning Discretionary Warning Age 16 Warning Reverse Override Warning 4X4 Caution Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 25 degrees 257 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7175511 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 Reverse Override Wa
53. alerts the operator that the preset service interval has been reached The vehi cle should be brought to your dealer for scheduled maintenance See page 39 for resetting instructions 4X4 Display This icon displays when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 37 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly The transmission cannot be in reverse when using the override button as a MODE button This feature does not contain a vehi cle speed lockout function and can be used at any operating speed Display Units Standard Metric The display can be changed to display either standard or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automati cally exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position 2 Place the transmission in neutral 3 Press and hold the MODE button while turning the key to the ON position 4 When the display flashes the distance setting tap the MODE button to advance to the desired setting 5 Press and hold the MODE button to save the setting and advance to the next display option 6 Repeatthe procedure to change remaining display settings 38 FEATUR
54. amaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A Akinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been VRALIBIL L HEISE straightened out is shown at B right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right 4 Q Promptly discontinue use of a C winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 79 WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or shock loading Shock loading
55. amber 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 for lighter and heavier riders are avail able through your POLARIS dealer Handlebars The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right Handlebar 4 Torque the front two bolts to Bolts 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 121 MAINTENANCE Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your POLARIS dealer for adjustment Throttle Cable Freeplay Remove the four cover screws from the right han dlebar control and remove the cover 2 With
56. and release the SELECT button to advance the hours to the desired setting including OFF When the digits stop flashing the interval has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1 Select the Hour Meter Mode 2 Press and hold the mode button on the instrument cluster until the hour display flashes Release the button 3 Press and release the SELECT button to advance the hours 4 Afterthe hours are set press and release the MODE button to move to the minutes Use the same procedure to reset the minutes 5 When the digits stop flashing the clock has been set Method 2 1 With the key turned off press and hold the MODE button 2 While still holding the MODE button turn the key to the ON posi tion 3 Continue to hold the MODE button until the hour display flashes Release the button 4 Setthe time as outlined in steps 3 5 of Method 1 46 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models 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 only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no
57. and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 137 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 98 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 View the fluid level in the bottle 2 Ifthe level is low remove the front rack 3 Remove the bottle cap and add coolant as needed Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 4 Reinstall the cap 5 Reinstall the front rack
58. apacity Fill Plug Drain Plug See Lubricant at Fluid Torque Torque Page Change 550 Engine PS 4 5W 50 4 Cvcle 2 qt 1 9 I 15 17 ft Ibs 89 Oil 20 23 Nm 850 Engine PS 4 5W 50 4 Cvcle 2 qt 1 9 I 12 ft Ibs 89 Oil 16 Nm Transmission AGL Gearcase 37 oz 10 14 ft Ibs 10 14 ft Ibs 92 Oil Lubricant amp 1100 ml 14 19 Nm 14 19 Nm Transmission Fluid Demand Drive Demand Drive Fluid 9 3 oz 8 10 ft lbs 11 ft Ibs 93 Fluid Front 275 ml 11 14 Nm 15 Nm Gearcase Rear ATV Angle Drive 7 10z 10 14 ft Ibs 10 14 ft Ibs 96 Gearcase Oil Fluid or GL5 80 90 210 ml 14 19 Nm 14 19 Nm weight gear lube Brake Fluid DOT 4 Brake Fluid 28 ADC Fluid Demand Drive Fluid m 94 Front Prop U Joint Grease Grease fittings 3 pumps maximum every 500 Shaft Yoke miles before long periods of storage or after A Arms Front and Rear All Season Grease or grease conforming to NLGI No 2 Grease fittings after extreme use or if suspension becomes squeaky Front Prop Shaft Yoke 88 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS 4 Full Synthetic 5W 50 4 cycle oil or a similar oil for this engine See the table on page 88 for fluid recommendations capacities and plug torques Oil may need to be changed more frequently if POLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recommenda tions for ambien
59. ars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed s owly controlling speed with the service brake until the vehicle is on more level ground OPERATION Driving Through Water Your ATV can operate through water with a maximum recom mended depth equal to the bot tom of the footrests Follow these precautions when operat ing through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines Maximum Depth 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 85 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil ADC fluid and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not
60. ascending or descending a hill See page 33 If all forward speed is lost Keep body weight uphill Apply the brakes Lock the parking brake when fully stopped Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 64 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 64 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 15 Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Sli
61. ast 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easv clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 120 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new be
62. ation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 126 before installing the battery If your factory installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso ries please see your POLARIS dealer to purchase a 30 AH battery Before installing the 30 AH battery remove the plastic spacer at the bot tom of the battery compartment Save the spacer for future use 1 Ensure that the battery is fully charged Place the battery in the battery holder Coat the terminals with dielectric grease or petroleum jelly Secure the battery hold down strap Connect and tighten the red positive cable first Connect and tighten the black negative cable last Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 8 Install the front rack DICA AD Battery Storage 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 charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to ma
63. ation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 28 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Clean any grease using a rec ommended brake cleaner or alcohol Do not use spray lubricants or other petroleum based products If you discover any damage cracks excessive corrosion warping see your dealer for service before operating Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 30 101 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 4 1 2 inch 6 12 mm toe out WARNING Severe injury or death can result from improper toe alignment and
64. bon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system 130 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1 After stabilizing the fuel remove the spark plugs and add 2 3 table spoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre mea sured amount of oil 2 Reinstall the spark plugs Torque to specification 3 Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs 4 Turn the engine over several times using electric start Oil will be forced in and around the piston rings and ring lands coating the cyl inder with a protective film of fresh oil 5 If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 107 2 Clean the air box Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 85 Battery Maintenance Remove the battery and recharge it as outlined on page 126 Store the battery in a cool dry place Storage Area Covers Set the tire pressure and safely support the ATV with the tir
65. bserve the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring The adjustment screw is located on the right side of 3 a da the headlight pod To adjust the beam loosen the screw Adjust the headlamp to the desired position then tighten the screw MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw 111 MAINTENANCE Lights Headlight Housing Replacement im 2 112 Remove the five 5 headlight pod screws Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counter clockwise and pull the harness assemblv awav from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Tur
66. cuit Grounded 520203 4 Idle Speed Speed Too High 520211 3 Speed Too Low 520211 4 EPS Models Only Steering Over Current Shutdown Current Above Normal Grounded 520221 6 Steering Excessive Current Error Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Par T1 Shorted to Ground 520223 4 tial Failure T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Par T2 Shorted to Ground 520224 4 tial Failure T2 Shorted to Bus 520224 3 Steering Torque Sensor Full T1 and T2 Shorted to Ground 520225 4 Failure T1 and T2 Shorted to Bus 520225 3 T1 Short to Ground amp T2 Short to Bus 520225 16 T2 Short to Ground amp T1 Short to Bus 520225 17 T1 and T2 are Shorted 520225 2 Steering Position Sensor P1 P1 Shorted to Ground 520226 4 Partial Failure P1 Shorted to Bus 520226 3 Steering Position Sensor P2 P2 Shorted to Ground 520227 4 Partial Failure P2 Shorted to Bus 520227 3 Steering Position Sensor Full P1 and P2 Shorted to Ground 520228 4 Failure P1 and P2 Shorted to bus 520228 3 EPAS Inverter Temperature Greater than 110 Degrees C 520229 16 Greater than 120 Degrees C 520229 0 EPAS CAN Comm Receive Err JNo RX Message for 2 Seconds 520230 9 EPAS CAN Comm Transmit Err No TX Message for 2 Seconds 520231 9 IC CAN Comm w EPAS EPAS Offline 520230 31 Nn FEATURES AND CONTROLS Front Rack Compartment Release the front rack latches and remove the rack to gain access to the front co
67. d for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 67 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on only one rack increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECU
68. e lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe D ISpark plug 100 H 12M 1000 1600 Inspect replace as needed E gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts D Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings D Brake fluid 200 H 24M 2000 3200 Change every two years gt ADC fluid 200 H 24M 2000 3200 Change every two years D Spark arrester 300 H 36M 3000 4800 Clean out D Valve clearance 1000 H 10000 Inspect adjust E 16000 Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 87 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 85 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 However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion pressure washing or submerging Item Recommended C
69. e event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading 81 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware Permit your winch motor to cool down prior to servicing your winch Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased
70. e specifica tions 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 possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions OPERATION NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 Ibs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 Ibs 91 kg and or front cargo loads are above 100 Ibs 45 kg Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life 69 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding Maximum the maximum tongue weight capacity 4 10 cm can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your POLARIS ATV Always install POLA
71. e warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses e o c o o o ee o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings 143 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement renta
72. e when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level fre quently for the auxiliary brake sys tem The reservoir is located under the front rack Maintain the fluid level between the maximum and minimum marks Use DOT 4 brake fluid only NOTICE Do not use ADC fluid in the brake fluid reservoir ADC fluid will damage the rubber components of the brake system 30 Auxiliary Foot Brake Brake Fluid Reservoir FEATURES AND CONTROLS Electronic Power Steering EPS Electronic power steering EPS engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle See page 35 for EPS Warning Indicator information Fuel Tank Always refuel with the engine stopped and outdoors
73. econds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases 57 OPERATION Driving Procedures b 99 I ON ee 58 Wear a helmet and eye protection Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle Your ATV is equipped with a m 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 inside tire must
74. ed filter and oil properly 91 MAINTENANCE Transmission Oil POLARIS recommends the use of POLARIS AGL Gearcase Lubricant amp Transmission Fluid for this transmission See the table on page 88 for fluid recommendations capacities and plug torques Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 See page 137 for the part numbers of POLARIS products Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is located on the bottom rear of the gearcase Cil Check 1 Remove the footwell see page 103 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification 5 Reinstall the footwell Oil Change Remove the footwell 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely ad Clean and reinstall the drain plug Torque to specification gt Remove the fill plug Add the proper amount of the recommended oil Reinstall the fill plug Torque to specification Check for leaks Reinstall the footwell Dispose of used oil properly go ON 92 MAINTENANCE Front Gearcase Demand Drive Fluid See the table on page 88 for fluid recommendations capacitie
75. ed fuel Clogged fuel filter See your dealer Incorrect fuel Replace with recommended fuel Possible Rich Fuel Cause Fuel is verv high octane Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 135 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dea
76. ed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used POLARIS ATV in the United States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A POLARIS ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY in the United States call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call POLARIS at 1 800 342 3764 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds estab lished safety standards Approved helmets in the USA and Canada bear a U
77. en caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 149
78. en requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be req
79. ents are set at the factory for optimal performance and are not adjustable The emissions label is located on the right rear frame tubing of the Emissions Label vehicle Electromagnetic Interference This spark ignition system complies with Canadian standard ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the lim itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 83 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in safe reli able condition Inspect clean lubricate adjust and replace parts as nec essary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 150 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to seve
80. ervoir may result in inadequate bleeding and reduced performance of the system Fill the reservoir to the maximum line with fresh fluid Remove the protective caps from the bleeder valves Slowly loosen one of the bleeder valve screws turn counter clock wise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valve screws before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped air If the level drops below the minimum line add fluid to the maximum line and repeat step 6 before proceeding 7 Torque the bleeder valve screws to 80 in Ibs 9 Nm Reinstall the bleeder valve caps Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks Make sure the reservoir is free of debris Reinstall the cap securely Clean up any drips or spills 95 MAINTENANCE Rear Gearcase Oil See the table on page 88 for fluid recommendations capacities and plug torques Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 See page 137 for the part numbers of POLARIS products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Fill Maintain the fluid level at the Level
81. es slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensa tion and may promote corrosion and oxidation 131 MAINTENANCE Transporting the ATV l Stop the engine Place the transmission in PARK Lock the parking brake Secure the fuel cap oil cap and seat S gp po Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your POLARIS dealer 132 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 incline Use low range or turn around using the K turn see page 64 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequentiv See page 120 Insufficient warm up at low ambient tempera tures Warm the engine at le
82. ge the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights 24 FEATURES AND CONTROLS Switches Engine Stop Switch di Move the stop switch either left or right to the OFF position Fl to stop the engine quickly CN Move the stop switch to the OFF RUN OFF RUN position before attempt ing to start the engine The engine will not start or run when the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 57 for starting pro cedures Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the vehicle Selector High Gear Low Gear Neutral Reverse Park u To o shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed PPZOW 23 FEATURES AND CONTROLS Throttle Lever A WARNING
83. gine oil level on the dipstick See page 89 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 54 6 Pull only light loads Change both the oil and the filter at 25 hours Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period If a belt fails always clean away all debris when replacing the belt 53 OPERATION Pre Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake system lever travel Ensure proper operation idi Brake fluid
84. he direction of the skid and shifting your body weight forward 60 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions 1 9o cJ Qv D e Das P9 10 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 Drive straight uphill Avoid climbing steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 61 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 2 3 4 62 Slow down Shift body weight uphill Keep your feet on the footrests
85. icle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 55 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area
86. in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 82 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 EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system AII exhaust gases exit through the exhaust system Exhaust Emission Control yum Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI compon
87. ing Front suspension Rear suspension Tires Brake fluid level Pre Ride See Pre Ride Checklist on page 54 gt Air filter pre filter Daily Inspect clean often replace E as needed Coolant Daily Check level daily change coolant every 2 years gt ADC fluid Daily Check level daily add as needed b Power steering unit Daily Inspect daily clean often if equipped Headlamp taillight Daily Check operation 85 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter main Weekly Inspect replace as needed E element gt Brake pad wear 10H Monthiv 100 160 Inspect periodically Battery 20 H Monthly 200 320 Check terminals clean test b Engine oil change 25H 1M 250 400 JBreak in oil and filter change see page 53 gt Demand drive fluid 25 H 1M 250 400 Change fluid every 25 hours extreme use if ADC is subjected to extreme use See page 93 gt Demand drive fluid 25 H 1M 250 400 JBreak in oil level check gt Rear gearcase oil 25H 1M 250 400 Break in oil level check gt Transmission oil 25H 1M 250 400 JBreak in oil level check gt General lubrication 50H 3M 500 800 JLubricate all fittings pivots cables etc Shift linkage 50H 6M 500 800
88. ing Active Descent Control The ADC system will automatically engage when all four of the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 25 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 position Vehicle speed exceeds 15 mph 25 km h e The throttle is open throttle is applied e The transmission is shifted to neutral or park 33 FEATURES AND CONTROLS Instrument Cluster NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Digital Analog Gauge Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h Indicator Lamps Speedometer j Rider Information Center 34 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Indicator Lamps
89. ing winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch WA when the winch cable is under load Never use the winch for lifting or transporting people WINCH GUIDE Winch Safety Precautions 20 21 22 23 24 25 Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable T3 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Tip Consider practicing the operation and use of your winch before you actually need to use it in the field A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always foll
90. ions MODE and SELECT button opera tion 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 MODE SELECT second The reverse override but Button Button ton also acts as the SELECT but ton when pressed and released quickly The transmission cannot be in reverse when using the override but ton as a MODE or SELECT button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Speed Display Use the MODE button to toggle through the speed display options Ground speed is displayed in either miles per hour MPH or kilometers per hour km h Engine speed is displayed in revolutions per minute RPM 44 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models Display Units Standard Metric The display can be viewed in either standard or metric units of measure ment To change units 1 Press and hold the MODE button until vehicle speed is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the displayed units change Release the button 4 New settings remain until changed using the same procedure 12 Hour 24 Hour Clock Display 1 Press and hold the MODE button until RPM is displayed 2 Toggle through the information area using the
91. ions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed 71 WINCH GUIDE Winch Safety Precautions 11 12 13 14 15 16 17 18 19 72 Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 78 to feed and rewind the cable evenly before continuing the winch operation Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot dur
92. ip that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warra
93. is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 45 Is 42 Gear Display This area displays gear shifter posi tion H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears Information Display This area displays odometer tripmeters engine hour meter and programmable service hour interval Speed Display This area displays vehicle ground speed or engine speed See page 44 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models 4 Tip 10 11 12 13 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer High Beam Indicator This indicator illuminates when the lights are set to high beam Engine Overheat Warning This icon flashes to indicate an over heated engine If the icon stops flashing but remains illuminated the overheating condition remains and the system will automati cally reduce engine power Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button
94. ke up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 137 for the part numbers of POLARIS products 125 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less
95. l Injection Idle RPM 1425 50 Ignition Timing 13 3 BTDC 1350 RPM Engine warm Spark Plug Gap NGK BKR6E 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT POLARIS Variable Transmis sion Front Suspension Dual a arm with 9 2 23 cm travel Rear Suspension Progressive rate with 10 2 26 cm travel Based on EU Directive 76 432 EC 138 SPECIFICATIONS SPORTSMAN 550 EPS Transmission 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 Tires Pressure Front MAXXIS AT 26x8 14 7 psi 48 3 kPa Tires Pressure Rear MAXXIS AT 26x10 14 AT 7 psi 48 3 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 277 watts Instrument Cluster Digital LCD LED Digital Analog EPS Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 23 54G Dark Blue Red White 105 165 BA3 Feet 0 6000 PN 1322914 PN 7043803 PN 3235088 PN 3235092 1800 3700 23 51 Dark Blue Red White 105 165 BA3 6000 12000
96. le that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Safety Warnings A WARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an
97. lean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 128 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow ing items Wheel bearings Hlectrical components e Radiator Switches and controls Transmission seals Fuel system components Cab and body panels Labels and decals If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLAR
98. lectrical 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 l 2 3 108 Remove the front rack Remove the fuse box cover Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating Reinstall the fuse box cover Reinstall the front rack ES A UE RELAY RELAY RELAY RELAY B SOLENOID RELAY relay RELAY E WIRES gt WIRES gt LIGHTS DRIVE JACCESSORV s LIGHTS DRIVE ACCESSORY s CHASSIS 20A 20A 20A P cHassis 20A 20A 20A RELAY EFI UNSWITCH SPARE R RELAY EFI UNSWITCH SPARE JA Jasia 20A 10A 20A Eras 20A 10A 20A SPORTSMAN 550 SPORTSMAN XP 850 BUMPER B BUMPER B ECU FAN EFI LIGHTS A START FAN EFI LIGHTS A RELAY RELAY RELAY RELAY B SQLEMOD RELAY mgLAY RELAY JB WIRES gt WIRES 0 LIGHTS DRIVE ACCESSORY s LIGHTS DRIVE ACCESSORY s CHASSIS 20A 20A 20A 51 cassis 20A 20A 20A A RELAY EFI UNSWITCH EPAS R RELAY EFI UNSWITCH EPAS mu 20A 10A 30A KVA 20A 10A 30A SPORTSMAN 550 EPS SPORTSMAN XP 850 EPS MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation
99. ler Engine Overheating Possible Cause Solution Debris lodged in screen Clean the screen Plugged Radiator Use a garden hose to flush anv debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiencv 136 POLARIS PRODUCTS NM Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 1 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 I 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 I 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 I Gearcase Transmission Lubricants 2878068 ar 98 Synthetic Gearcase Lubricant amp Transmission Fluid 2878069 331 38 eer Gearcase Lubricant amp Transmission Fluid gal 3 2877922 Demand Drive Fluid qt 95 I 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 I Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 I 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 I Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 l 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 8
100. lip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc 119 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing 1 2 120 Position the vehicle on a level surface Remove the drain plug Allow the water to drain completely Rein stall the drain plug Start the engine Place the transmission in PARK Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 5 seconds Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible MAINTENANCE C
101. ls loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 144 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer Wh
102. lt and or clutch See page 53 133 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low batterv voltage Solution Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter See your dealer Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectiv installed spark plug wires See vour dealer Incorrect ignition timing See vour dealer Mechanical failure See vour dealer Loose ignition connections Check all connections and
103. m the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage SPORTSMAN 550 550EPS Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Crankshaft Position Sensor Circuit Fault 636 8 Gear Sensor Signal Voltage Too Low to Calibrate 523 4 Voltage Too High 523 3 Signal Fault 523 2 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Ignition Coil Primary Driver 1 MAG Driver Open Grounded 1268 5 Driver Circuit Short to B 1268 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347 3 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to B 1071 3 48 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 550 550 EPS Diagnostic Codes Component Condition SPN FMI ldle Air Control Driver Circuit Grounded 520193 5 Shorted L
104. matically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage ADC 4X4 There is no limit to the length of time the vehicle may remain in 4X4 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position 2X4 Mode When the switch is on 2X4 the ATV is in two wheel drive at all times 32 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable 4X4 until the engine RPM is below 3100 Once enabled 4X4 remains enabled until the 4X4 switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest Active Descent Control ADC System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Engag
105. may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and synthetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It gener ates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 80 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident WINCH GUIDE Shock Loading 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making th
106. mpart PUES ment To reinstall the rack i hold the rack as shown in the illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following components in the front compartment e Radiator cap Brake fluid reservoir e ADC fluid reservoir Battery Coolant recovery bottle cap Hlectrical fuse relay components Battery Brake Fluid ADC Fluid Reservoir Reservoir Coolant Bottle Cap Electrical Fuse Relay 52 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS ATV is the first 20 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 31 Always exercise extreme caution whenever handling gasoline 2 Check the en
107. n the headlight harness clockwise to secure the head lamp Taillight Brakelight Lamp Replacement Remove the harness connector from the back of the light assembly 2 Turn the lamp counter clock wise to remove it 3 Install the new lamp Taillight 4 Reinstall the harness connector 5 Testthe light for proper opera tion 113 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 138 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Torque Specification Plug Condition 550 850 New Spark Plug 9 11 ft Ibs 18 20 ft Ibs 12 15 Nm 24 27 Nm Previousiv Installed 17 20 ft Ibs 18 20 ft Ibs Spark Plug 23 27 Nm 24 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 115 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counter clockwise to remove it 3 Reverse the
108. nance Service Safety 82 Winch Operation 74 78 Winch Safety Precautions 71 73 Winch Shock Loading 80 81 INDEX 157 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer cu call 1 800 POLARIS PGLRHBIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924659 Rev 01 Printed in USA FENG QUE I UI IIT T T II
109. nch clutch and pull out the winch cable Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Read and follow the Shock Loading Winch Damping and Winch Rigging sections of this manual for details on safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you Lay the damper on top of the mid point of the winch cable length that is spooled out On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged
110. nd the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to specification 90 MAINTENANCE Engine Oil Oil and Filter Change 9 10 11 12 13 14 15 16 17 18 19 20 21 Place shop towels beneath the oil filter Using an oil filter wrench available from your POLARIS dealer turn the filter counter clockwise to remove it 850 Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and rotate it Oil Filter clockwise by hand until the filter gasket contacts the sealing sur face then turn it an additional 1 2 turn Remove the dipstick Add the proper amount of the recommended oil Do not overfill Reinstall the dipstick Place the transmission in PARK Lock the parking brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of us
111. nt Control 33 Engine Break In 53 Engine Fogging 131 Engine Oil esas eere 89 91 EPS Warning Indicator 43 Equipment Modifications 9 Error Codes Engine 41 Etiquette Trail Riding 56 Exhaust Emission Control System 83 Extreme Use 30 AH Battery 31 Eye Protection L xs is sisa te een 9 F Fluid ADC cinia rd as 94 95 Brake i crea eee es lee ee Seed 28 Coolant 122 eee 98 100 Demand Drive 93 Engine Qil 89 91 Rear Gearcase 96 97 Transmission Oil 92 F Fluid Change POD e caedes aes 95 Demand Drive 93 Engine Qil 90 91 Rear Gearcase 97 Transmission 92 Fluid Level AD Loi Ste N 94 Demand Drive 93 Engine Oil sse 89 Rear Gearcase 96 Transmission 92 Foot Brake Auxiliarv 30 Footwell Removal 103 Front Compartment 52 Front Gearcase Demand Drive 93 Front Rack Compartment 22 Fuel Safety LL 11 Fuel Tank Cap veo xr ames 31 Fuse Replacement 108 G Gasoline Handling 11 Gauge Code Definitions 48 51 Gauge Digital Analog 34 41 Gauge MFD EPS Models 42 47 Gear Selector ees e rev eds 25 Gearcase Oil Rear 96 97 GIOVES oues eee ca tare ee dean 9 H Hand Brake yerbeor RSS 1
112. nt is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost The manufacturer s label is located on the front right side of the vehicle behind the radiator Engine Serial Number Kor Number VU am Manufacturer s Label Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training ATV safety training is a top priority for POLARIS POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course If you purchased a new POLARIS ATV in the United States your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members This training is included in the purchase price of your ATV You were also provided with print
113. nty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system lgnition system Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions e Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units 147 WARRANTY U S A EPA Emissions Limited Warranty The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector gt o o o o o e o o o o As related to the evaporative emission control system The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL D
114. oad 520193 11 Starter Enable Circuit Driver Circuit Short to B 1321 3 All Wheel Drive Control Driver Circuit Short to B 520207 3 System Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Short to B 520203 3 EPS Models Only Steering Over Current Shut Down Current Above Normal or 520221 6 Grounded Steering Excessive Current Error Current Above Normal or 520222 6 Grounded Steering Torque Sensor T1 Partial T1 Shorted to Ground 520223 4 Failure T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Partial T2 Shorted to Ground 520224 4 Failure T2 Shorted to Bus 520224 3 Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Shorted to Ground amp T2 520225 16 Shorted to Bus T2 Shorted to Ground amp T1 520225 17 Shorted to Bus T1 and T2 are Shorted 520225 2 Steering Position Sensor P1 Partial P1 Shorted to Ground 520226 4 Failure P1 Shorted to Bus 520226 3 Steering Position Sensor P2 Partial P2 Shorted to Ground 520227 4 Failure P2 Shorted to Bus 520227 3 Steering Position Sensor Full Failure P1 and P2 Shorted to Ground 520228 4 P1 and P2 Shorted to bus 520228 3 EPAS Inverter Temperature Greater than 110 Degrees C 520229 16 Greater than 120 Degrees C 520229 0 EPAS C
115. ocedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install itin any other product Always make sure the PVT housing is securely in place during operation 118 MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the fly weights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On POLARIS ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the oper ation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1600 1800 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt s
116. of control or overturn Always follow proper procedures for travel ing down hills as described in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 63 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 62 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 64 14 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill Always move the 4X4 switch to ADC 4X4 before
117. ommended 2 3 mm gap When adjustments are complete tighten the locknut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Ensure the control cover seal is in place then reinstall the cover and screws 123 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion 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 Your ATV is equipped with a sealed battery which requires little main tenance POLARIS does not recommend using a conventional battery in this vehicle The orientation of the battery could result in electrolyte leakage which would shorten the life of the battery considerably Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Battery Removal 1 Remove the front rack Disconnect the black negative battery cable first Disconnect the red positive battery cable last Disconnect the battery hold down strap Lift the battery out of the ATV A de X P9 124 MAINTENANCE Battery Battery Install
118. on Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347 3 Driver Circuit Grounded 1347 4 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to B 1071 3 Driver Circuit Grounded 1071 4 Idle Air Control Driver Circuit Open Grounded 634 5 Driver Circuit Short to B 634 3 Driver Circuit Grounded 634 4 Position Out of Range 634 7 Starter Enable Circuit Driver Circuit Open Grounded 1321 5 Driver Circuit Short to B 1321 3 Driver Circuit Grounded 1321 4 50 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN XP 850 850 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 520207 3 Driver Circuit Grounded 520207 4 System Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Open Grounded 520203 5 Driver Circuit Short to B 520203 3 Driver Cir
119. ont and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 120 lbs 54 kg Rear 240 Ibs 109 kg 7175448 Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG 7170509 23 FEATURES AND CONTROLS Switches Headlight Switch Mode Reverse Override Button mh Engine Main Key Stop Switch Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override button WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button The reverse override button also acts as a MODE button when held down for approximately one half second See the instrument cluster information beginning on page 34 The transmission cannot be in reverse when using the override button as a MODE button 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 33 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Headlight Switch Use the headlight switch to turn the lights on and off and to chan
120. or worn WINCH GUIDE Winch Operation 11 The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 80 For your safety always follow these guidelines when winching a vehicle free 12 A ro J K mmo o m Release the winch clutch and spool out the necessary length of winch cable Align the winch cable as close as possible to the winching vehicle s centerline Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual Re engage the clutch on the winch Slowly winch in the slack in the winch cable Select the proper vehicle gear to propel the stuck vehicle in the direction of winching Shift to the lowest gear available on the stuck vehicle Slowly and carefully apply vehicle throttle and winch together to free the vehicle Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch Detach the winch cable hook Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach
121. or in a well ventilated area Refuel on a level sur face Remove the fuel tank cap and add fuel Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 such as E 65 fuel The fuel tank is designed to allow for the normal expansion of fuel Do not overfill Do not fill the tank neck Extreme Use 30 AH Battery If your factory installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso ries please see your POLARIS dealer to purchase a 30 AH battery 1 Fully charge the new battery before installing it See page 126 2 Toinstall the 30 AH battery remove the 18 AH battery See page 124 3 Remove the plastic spacer at the bottom of the battery compartment Save the spacer for future use 4 Install the new battery See page 125 31 FEATURES AND CONTROLS All Wheel Drive System The AII Wheel Drive system is controlled by the 4X4 switch ADC 4X4 Mode When the switch is on ADC 4X4 the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indi cator icon in the instrument clus ter display will be visible When in 4X4 the demand drive unit will auto
122. or safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period POLARIS POLARIS SPORTSMAN and SPORTSMAN XP are registered trademarks of POLARIS Industries Inc MAXXISQ is a registered trademark of Maxxis International Copyright 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original ins
123. ow all winch instructions and warnings in this manual Each winching situation is unique 74 Take your time to think through the winching you are about to do Proceed slowly and deliberately Never hurry or rush during winching Always pay attention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lift ing an accessory plow assembly Promptly replace any worn or damaged cable Never operate a winch or a vehicle in need of repair or service Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Hook Strap A AP Ca WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY NO YES A Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable Tip A tow strap is NOT in
124. ppery Terrain Failure to use extra caution when operating 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 extra caution on rough slippery or loose terrain Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 67 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels 16 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 66 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On
125. re use must be inspected and ser viced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oll level and if it continues to rise discontinue use and determine the cause or see your dealer 84 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related service failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services Perform all services at whichever maintenance interval is reached first Brake lever travel Brake system Wheels fasteners Frame fasteners Engine oil level Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steer
126. rning 4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 7175512 21 SAFETY Safety Labels and Locations No Passenger Warning Tire Pressure Load Warning No Passenger Warning WARNING NEVER ride as a passenger Paser ngers can cause a loss of control resulting in SEVERE INJURY or 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death e Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa Maximum weight capacity 575 Ibs 261 kg Lug nut torque values Steel rims 45 ft Ibs 61 Nm Aluminum rims 75 ft Ibs 102 Nm 22 SAFETY Safety Labels and Locations Rack Rack Warning Warning Clutch Cover Warning Hitch Capacit under seat Label Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7175488 Rack Warning Fr
127. s and plug torques Always check and change the demand drive fluid at the inter vals outlined in the Periodic Maintenance Chart beginning on page 85 See page 137 for the part numbers of POLARIS products Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use Extreme use includes any of the following operation in ADC mode for prolonged periods constant ADC operation on hilly or mountainous terrain ADC is the primary mode of all wheel drive operation Tip If the front gearcase is makes excessive noise during ADC operation change the demand drive fluid If the noise continues please see your POLARIS dealer for service Use the recommended fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check E Fill Position the vehicle on a level sur face Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Torque to specification Fluid Change Drain Plug 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and
128. s securing it to the frame Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Torx Head Screw Plastic Rivet V Hex Head Screw 103 MAINTENANCE Tires A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 138 for recom mended tire type size and pressure Tire Tread Depth i Always replace tires 1 8 3 mm z when tread depth is worn to 1 8 3 mm or less e AW 104 MAINTENANCE Tires Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized POLARIS dealer Wheel Removal l Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 105 MAINTENANCE Tires Wheel Installation
129. service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 19 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label General
130. t temperature operation See page 137 for the part num bers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Cil Level Check the oil level when the engine is cold Never check the oil with the engine running Position the vehicle on a level surface 2 Access the oil dipstick and fill tube from the left side of the ATV Remove the dip stick Wipe it dry with a clean cloth Full Add 3 Pau and tighten the dip C V V A FS Dipstick 4 Remove the dipstick and m 850 check the oil level 5 Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL and ADD Full Add marks Do not overfill 6 Reinstall and tighten the dipstick i WY 550 89 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 88 for fluid recommendations capacities and plug torques Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 Always change the oil filter whenever changing oil Filter Access 850 Drain Plug 550 Drain Plug 1 Position the vehicle on a level surface 2 Start the engine Allow it to warm up at idle for two to three min utes 3 Stop the engine 4 Clean the area arou
131. tended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 80 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a d hook or latch Always replace damaged parts before using the winch YES NO 75 WINCH GUIDE Winch Operation 5 6 7 10 76 Never remove the hook strap from the hook Release the wi
132. tructions Printed in U S A 2014 SPORTSMAN 550 EPS 2014 SPORTSMAN XP 850 H O SPORTSMAN XP 850 H O EPS Owner s Manual P N 9924659 TABLE OF CONTENTS IntrodUcllOn sscunse e REREERRRERERRRER EE 4 DANGLY axi gessute E ER ewe EE ene B bi RE 7 Features and Controls 24 Operation ucc Eh ER ER EEEE TREES 53 Winch Guide s c sux e IRE EERREEERARSEESS 71 Emission Control Systems 83 Maintenance LL 84 Troubleshooting Lssse 133 POLARIS Products 137 Specifications eeee 138 Warranty sce acRRERRE ERI SERECEEERAERA 142 Maintenance Log 150 in e L E E E E EE 154 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safetv alert svmbol indicates a potential personal injurv hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injurv WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injurv CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safe
133. ty Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death A POLARIS ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was con trolled as indicated by the test procedure s The uncertainty of vibration exposure measureme
134. uired to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product 145 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins NOTICE
135. until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 126 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1 2 hours after the end of charging Charge Time State of g Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 127 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to c
136. vel 3 View the brake fluid level through the indicator win dow on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 4 Ifthe fluid level is low remove the cover screws and add fluid to the fill line Do not overfill Use DOT 4 brake fluid only 5 Reinstall the cover Torque screws to 7 in lbs 8 Nm 28 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake Place the transmission in PARK 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 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 29 FEATURES AND CONTROLS Auxiliary Foot Brake A WARNING Never back down a hill Applying the auxiliary brak

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