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Alpine 68-14470Z66-A GPS Receiver User Manual

1. Radiator Cap 84 MAINTENANCE Brakes Hand Brake The front and rear brakes are hvdraulic disc brakes activated bv 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 operation 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 30 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 Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 32 85 MAINTENANCE Toe Alig
2. 13 SAFETV Safetv 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 57 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill 14 SAFETV Safetv Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn e Always follow proper procedures for travel ing down hills as des
3. Coolant Bottle Cap Electrical Fuse Relay Radiator ADC Fluid Cap Reservoir 48 OPERATION Failure to operate the ATV properlv 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 ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures 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 33 Always exercise extreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 73 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
4. A B 3888 a boom THE 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area Use the SELECT button SEL to toggle through the information area options SELECT button operation is locked out at speeds above approximatelv 15 MPH 25 km h Tip The reverse override button also acts as the SELECT button when pressed and released quickly The transmission cannot be in reverse when using the override button as a SELECT button This feature does not contain a vehi cle speed lockout function and can be used at any operating speed Standard Metric Display 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 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 t
5. 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 116 MAINTENANCE Transporting the ATV 1 i A Stop the engine Place the transmission in PARK Lock the parking brake Secure the fuel cap oil cap and seat Alwavs tie the frame of the ATV to the transporting unit securelv with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars Remove the key to prevent loss during transporting 117 ADJUSTMENTS 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 1 Remove the three cover screws from the right han dlebar control and remove the cover 2 With 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
6. PN 5632219 PN 7043500 PN 3235621 PN 3234620 EBS models require no helix spring adjustment 127 SPECIFICATIONS Sportsman 850 XP XP EPS Maximum Weight Capacitv 575 Ibs 261 kg Dry Weight 784 Ibs 356 kg XP 796 lbs 361 kg XP EPS Fuel Capacity 5 25 gal 20 1 XP 4 5 gal 17 1 XP EPS 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 32 oz 950 ml Front Rack Storage Box Capacity 120 Ibs 54 kg Rear Rack Capacity 240 lbs 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 575w Compression Ratio 11 1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1200 100 RPM Ignition Timing 6 5 BTDC 1200 RPM Engine warm
7. Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel 5 Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride gt Frame fasteners Pre Ride Engine oil level Pre Ride 5 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 gt Power steering unit Daily Inspect daily clean often if equipped Headlamp taillight Daily Check operation gt Air filter Weekly Inspect replace as needed E main element gt Engine oil change 20H 1 Month 500 800 Perform a break in oil and filter change see page 49 gt Brake pad wear 10H Monthly 100 160 Inspect periodically Battery 20H Monthly 200 320 Check terminals clean test gt Demand drive fluid 25 H Monthly 250 400 Inspect level gt Rear gearcase oil 25H Monthly 250 400 Inspect level gt Transmission oil 25H Monthly 250 400 Inspect level gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 70 Periodic Maintenance Chart MAINTENANCE Item Maintenance Inte
8. auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control which may result in 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 32 Auxiliary Foot Brake Brake Fluid Reservoir FEATURES AND CONTROLS Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition kev is turned to the ON position EPS remains engaged whether the vehicle is moving or idle See page 39 for EPS Warning Indicator information 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 To shift gears brake to a complete sto
9. 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 owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle For 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 We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clot
10. ADC fluid 200 H 24M 2000 3200 Change fluid Spark arrestor 300 H 36 M 3000 4800 Clean out E Valve clearance 1000 H 10000 Inspect adjust E 16000 Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 71 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 68 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factorv 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 washing or submerging Item Recommended Capacity Fill Plug Drain Plug Inspection Lubricant at Fluid Torque Torque Procedure Change 550 Engine Oil PS 4 PLUS 2 at 15 17 ft lbs Page 73 Performance 1 91 20 23 Nm Svnthetic 2W 50 850 Engine Oil JPS 4 PLUS 2 qt as 12 ft lbs Page 73 Performance 1 91 16 Nm Svnthetic 2W 50 Transmission Synthetic 320z 10 14 ft lbs 10 14 ft lbs Page 76 Oil Sportsman XP 950 ml 14 19 Nm 14 19 Nm Transmission Fluid Demand Drive Demand Drive 9 3 oz 8 10 ft Ibs 11 ft lbs Page 77 Fluid Front LT Premium 275 ml 11 14 Nm 15 Nm G
11. Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created bv 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 111 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 recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon 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 Oil and Filter Change the oil and filter See page 74 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 114 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 68 Demand drive unit front gearcase ADC fluid ADC models change everv two vears Rear gearcase Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean following the instruction
12. ECE mark consists of a circle surrounding the letter E followed bv the distinguishing number of the countrv which has 051039 granted approval The approval number and serial 0006 31 number will also be displaved on the label SAFETV Safe Riding Gear Eve Protection Do not depend on eveglasses or sunglasses for eve protection When ever riding a Polaris vehicle alwavs 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 eve 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 Riding 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 vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sp
13. Rider Information Center Sportsman 850 XP XP EPS Diagnostic Codes 46 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 Ignition 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 Idl
14. 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 easy 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 104 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 belt and or clut
15. bax Filter OWA 7 Reinstall the air box cover S and the seat 91 MAINTENANCE Fuse Replacement If the engine stops or will not start or if vou experience other electrical failures a fuse mav need replacement Locate and correct anv short cir cuits that mav have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 2 3 92 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 Fuse Box BUMPER 3 BUMPER ECU FAN LIGHTS amp FAN LIGHTS 4 RELAY RELAY petay RELAY E RELAY RELAY VI WIRES LIGHTS DRIVE LIGHTS B CHASSIS 20A 0A i 20A i REDAN EF NSWITCH i EFI UNSWITCH R 1175140 20A 10A 20A 10A BUMPER BUMPER ECU FAN EFI LIGHTS A FAN EFI LIGHTS A RELAY RELAY RELAY RELAY JB SOLENOID peray RELAY RELAY amp WRES gt WRES LIGHTS DRIVE JACCESSORV s LIGHTS DRIVE JAccessonv s CHASSIS 20A 20A 20A Bl cuassis 20A 20A 20A RELAY EFI UNSWITCH epas R RELAY EFI UNSWITCH EPas B ea 20A 10A 30A pali 20A 10A 30A MAINTENANCE Lights Poor lighting can result in reduced visibilitv when driving Headlight and taillight lenses become
16. counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 98 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is grav tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper tvpe and heat range for the engine and the service The tip should not be flakv and white A white insulator tip indicates overheating caused bv 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 99 MAINTENANCE Vehicle Immersion If vour 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 present dry the air box and replace the filter with a new filter Remove the spark plugs 3 4 Turn the engine over several times using the electric start 5 Dry the spark plugs
17. fits properlv and eve protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adverselv affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrving a Passenger Carrving a passenger greativ reduces the operator s abilitv to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 12 Safetv Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and drivewavs mav adverselv 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 appropriate for the terrain the visibility and operating conditions and your experience SAFETY
18. from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery 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 Be careful not to allow cleaning solution or tap water into a conventional battery 105 MAINTENANCE Batterv Batterv Removal Remove the seat Disconnect the black negative battery cable first Disconnect the red positive battery cable last Disconnect the battery hold down strap On conventional batteries remove the battery vent tube Qe ie ee tA E Li
19. level a Coolant hoses Inspect for leaks Throttle Ensure proper operation ln Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 27 Air filter pre filter Inspect clean 91 Headlamp Check operation A Brake light tail lamp Check operation 97 Riding gear Wear approved helmet goggles and 8 protective clothing ADC Fluid Ensure proper level 80 50 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 vehicle 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 stu
20. level BED 5 Add the recommended fluid P as needed Maintain the oil El i OE level in the safe range ea between the FULL and ADD marks Do not overfill 6 Reinstall and tighten the Full Add dipstick W 550 73 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 72 for fluid recommendations capacities and plug torques Alwavs change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Alwavs change the oil filter whenever changing oil 550 Drain OD ziju 4 to front 4 O O Plug Filter Access 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 around 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 74 MAINTENANCE Engine Oil Oil and Filter Change 9 10 11 12 13 14 15 16 17 18 19 20 21 Place shop
21. right side of the Level unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level Fill Plug 2 Add the recom mended 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 1 Position the vehicle on a level surface Remove the fill plug va Drain Plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completelv Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended fluid Reinstall the fill plug Torque to specification Dm pp Check for leaks Dispose of used fluid properly 77 MAINTENANCE Rear Gearcase Oil See the table on page 72 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 68 See page 125 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 bottom of the fill hole threads Do not overfill Oil Check 1 Position the vehicle on a 7 s level surface 2 Remove the fill plug Fill Plug Check the oil level Drain Plug 3 Add the recommended oil as needed to brin
22. 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 61 e Travel slowly e Balance your weight carefully e Avoid sudden movements e Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes e 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 19 SAFETV Safetv Warnings Improper Cargo Loading Overloading the ATV or carrving towing cargo improperlv mav cause changes in handling which could cause loss of control or an accident e Never exceed the stated load capacity for this ATV e Cargo should be properly distributed and securely attached e Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking e Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or
23. terrain mav 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 Alwavs be alert to changing terrain conditions 17 SAFETV Safetv Warnings 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 63 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 18 SAFETV Safetv 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 62 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel
24. the operator fall through the ice Never operate the ATV on a frozen body 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 20 SAFETV Safetv Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident After anv overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering svstems Phvsical Skills Safe operation of this rider active vehicle requires good judgement and phvsical skills Persons with cognitive or phvsical disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Svstems Exhaust svstem components are verv hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust svstem components Alwavs keep combustible materials awav from the exhaust svstem Use caution when traveling through tall grass especiallv drv grass Unauthorized Use of the ATV Leaving the kevs in the ignition can lead to unauthorized use of the vehicle which
25. the rear edge Pull upward abruptly to disengage the under seat fasteners Remove the seat MAINTENANCE Side Panel Footwell Removal Remove the seat before removing a side panel Remove the screws and rivets securing the side panel or footwell see illustration Plastic Rivet Torx Head Screw Ap Be e Plastic VV Hex Head Screw 87 MAINTENANCE Tires A WARNING Operating vour ATV with worn tires improperlv inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injurv or death Alwavs follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Alwavs use original equipment size and tvpe when replacing tires Refer to the specifications section beginning on page 126 for recom mended tire type size and pressure Tire Tread Depth l Alwavs replace tires 1 8 8 mm Z when tread depth is worn to 1 8 3 mm or less 7 AS A 88 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 1 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
26. tighten Water present in fuel Replace with fresh recommended fuel 122 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 Incorrect fuel Inspect and replace 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 Possible Lean Fuel Cause Low or contaminated fuel See vour dealer Solution Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter See vour dealer
27. 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 118 2 3 mm Gap Arm Stop Pin Cable Adjuster Boot Lock Nut Adjuster ADJUSTMENTS Throttle Cable Freeplav 4 5 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 ser vice 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 recommended 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 119 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted by rotati
28. will be clear 4 If the 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 30 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 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 31 FEATURES AND CONTROLS Auxiliary Foot Brake AWARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill Use caution when applying the auxiliary brake Do not aggressively apply the
29. 129 WARRANTV LIMITED WARRANTV Polaris Sales Inc 2100 Highwav 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days 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 the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV 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 130 WARRANTV WARRANTV COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND
30. 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 125 SPECIFICATIONS Sportsman 550 XP XP EPS Maximum Weight Capacitv 575 Ibs 261 kg Drv Weight 732 Ibs 332 kg XP 744 Ibs 337 5 kg XPS Fuel Capacity 5 25 gal 20 1 XP 4 5 gal 17 1 XP EPS 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 32 oz 950 ml Front Rack Storage Box Capacity 120 Ibs 54 kg Rear Rack Capacity 240 lbs 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 ESS550PLE 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
31. Center 3 Tip 10 11 12 Speed Display This area displays vehicle ground speed or engine rotational speed when the corresponding display is selected See page 40 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 appears when the lights are set to high beam Clock 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 dis play for 5 10 seconds See page 42 for resetting instructions Engine Overheat Warning This indicator flashes to indicate an overheated engine If the indicator stops flashing but remains illu minated the overheating condition remains and the system will automatically reduce engine power Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 42 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 ligh
32. 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 50 6 Pull only light loads 7 Change both the oil and the filter at 20 hours one month or 500 miles 800 km whichever comes first 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 49 OPERATION Pre Ride Checklist Failure to inspect and verifv that the ATV is in safe operating condition before operating increases the risk of an accident Alwavs inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake svstem lever travel Ensure proper operation 2 Brake fluid Ensure proper level 30 Auxiliary brake Ensure proper operation 32 Front suspension Inspect lubricate if necessary 72 Rear suspension Inspect lubricate if necessary 72 Steering Ensure free operation Tires Inspect condition and pressure 88 Wheels fasteners Inspect ensure fastener tightness a Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level Ensure proper
33. ENANCE 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 2 104 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 10 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 Batterv 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 AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result
34. Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 89 MAINTENANCE Tires Wheel Installation 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 tt 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 Ibs 102 Nm Steel Lug Nut 45 ft Ibs 61 Nm 90 MAINTENANCE Air Filter 1 Remove the seat 2 Remove the air box cover screws and remove the air box cover 3 Remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new E main filter if needed a a 6 Reinstall the filter into the air Main C4
35. Ignition System Electronic Fuel Injection Idle RPM 1650 100 RPM 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 126 SPECIFICATIONS Sportsman 550 XP XP 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 7 1 Tires Pressure Front 26x8 14 AT 7 psi 48 3 kPa 26x10 14 AT 5 psi 34 5 kPa Single Control Hydraulic Disc All Wheel Foot Activated Hydraulic Disc Rear Wheel Hydraulic lock all wheel Tires Pressure Rear Brakes Front Rear Brakes Auxiliary Brake Parking 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 Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 23 58 Red Black Red White 52 BA 500 Feet 0 6000 PN 5632218 PN 7043500 PN 3235621 PN 3234620 1800 3700 23 54 Red Black Red White 52 BA 500 6000 12000
36. Incorrect fuel Possible Rich Fuel Cause Fuel is verv high octane Replace with recommended fuel 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 123 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace 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 dealer Engine Overheating Possible Cause Solution Debris lodged in screen Clean the screen Plugged Radiat
37. Pantone 426c POLARIS The Way Out 200 Sportsman 550 XP Sportsman 550 XP EPS Sportsman 850 XP Sportsman 850 XP EPS Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information his is an adult vehicle only Operation is prohibited for those under 16 years of age Pantone 426c AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS vl For your nearest Polaris dealer or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921973 Rev 03 Printed in USA 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
38. REMEDIES The Polaris limited warrantv excludes anv failures that are not caused bv a defect in material or workmanship This warrantv does not cover accidental damage normal wear and tear abuse or improper handling This warrantv also does not cover anv ATV that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL 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 Some states do not permit t
39. Recoverv Bottle Coolant The recoverv 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 Ifthelevelis 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 Recovery Bottle Cap 83 MAINTENANCE Cooling Svstem Radiator Coolant To ensure that the coolant maintains its abilitv to protect the engine Polaris recommends that vou drain the svstem completelv everv 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 coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to func tion properly Contact your dealer for the correct replacement part 5 Reinstall the front rack
40. Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure 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 104 for drying out the PVT 100 MAINTENANCE Spark Arrestor A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injurv or death Never run the engine in an enclosed area Remove anv combustible materials from the area Wear eve 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 svstem can get extremelv hot Do not perform service on the spark arrestor 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 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine Quickly squeeze and release the throttle lever B several times to purge car L 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 re
41. Spark Plug Type Gap Champion 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 128 SPECIFICATIONS Sportsman 850 XP XP 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 3 7 1 Tires Pressure Front 26x8 14 AT 7 psi 48 3 kPa Tires Pressure Rear 26x 10 14 AT 5 psi 34 5 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 Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 24 63 Red White Red White 52 BA 500 Feet 0 6000 PN5632215 PN 7043349 PN 3235621 PN 3234620 1800 3700 24 60 Red White Red White 52 BA 500 6000 12000 PN 5632216 PN 7043349 PN 3235621 PN 3234620 EBS models require no helix spring adjustment
42. al 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 CAN 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 45 FEATURES AND CONTROLS Instrument Cluster
43. ally altered or any engine that 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 If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 888 704 5290 135 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 136 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 138
44. als that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this 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 call the Con sumer 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 SAFETV Safe Riding Gear Alwavs wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injurv Eve Protection Gloves Long Pants Helmet Wearing a helmet can prevent a severe head injurv Whenever riding a Polaris vehicle alwavs wear a helmet that meets or exceeds established safetv standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The
45. aw all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 132 WARRANTV Exported Vehicles EXCEPT WHERE SPECIFICALLV REQUIRED BV LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris deale
46. cap 5 Reinstall the front rack 80 MAINTENANCE Active Descent Control ADC Fluid Fluid Change 1 Position the vehicle on a level Bleeder surface Before performing the Screw ta fluid change allow the vehicle Cap to sit for at least 30 minutes Bleeder Thoroughiv 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 reservoir may result in inadequate bleeding and reduced performance of the system Fill the reservoir to the maximum line with fresh ADC fluid Remove the protective caps from the bleeder valves Slowly loosen one of the screws turn counter clockwise 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 valves 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 8 Torque the valves to 80 in Ibs 9 Nm Reinstall the 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 Re
47. carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 64 OPERATION Hauling Cargo Never exceed the weight capacities specified for vour ATV on warning labels and in the specifications section of this manual Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possi ble When operating over rough or hillv terrain reduce speed and cargo weight to maintain stable driving condi tions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavv cargo to extend belt life Towing Loads Alwavs 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 bv the amount of tongue weight e The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity e 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 instal
48. ch See page 49 121 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 Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and
49. could result in an accident or overturn Alwavs remove the ignition kev when the vehicle is not in use 21 SAFETV Safetv Labels and Locations Warning labels have been placed on the vehicle for vour 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 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 e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e 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 e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 22 SAFETV 7 Discretionary Warnin
50. cribed in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 59 e 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 36 e Always check the terrain carefully before descending a hill e Shift your weight rearward e Never travel down a hill at high speed e 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 58 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 60 15 SAFETV Safetv Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn e Always maintain a steady speed when climbing a hill e Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 36 If all forward speed is lost e Keep body w
51. d away at the front and rear of the battery 9 Install the seat 107 MAINTENANCE Batterv Batterv 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 Bat tery Tender charger or by charging about once a month to make 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 125 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery ist ri fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 108 MAINTENANCE Batterv Batterv Charging Conventional Batterv 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 106 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the bat
52. d the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e 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 111 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 e Wheel bearings e Electrical components e Radiator e Switches and controls e Transmission seals e Fuel system components e Cab and body panels e 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 Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container P
53. dirtv during normal operation 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 Lift the 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 counterclockwise to remove it 5 Install the new lamp Make sure the tab on the lamp locates properly in the housing 6 Reassemble the pod 93 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 mately 25 ft 7 6 m from a wall Place the transmission in PARK 25 ft 7 6 m Lamp Center Height 2 Sem 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch t
54. e 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 SECURE 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
55. e traction When the rear wheels regain traction the demand drive unit will automatically disengage 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 ADC 4X4 34 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 35 FEATURES AND CONTROLS Active Descent Control ADC Svstem The ADC svstem allows engine braking to all four wheels when the vehicle descends a hill or incline Alwavs move the 4X4 switch to ADC AXA before ascending or descending a hill Engaging Active Desc
56. e 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman 850 XP XP EPS Diagnostic Codes Component Condition SPN FMI Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 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 Circuit Grounded 520203 4 Idle Speed Speed Too High 520211 3 Speed Too Low 520211 4 EPS Models Only Steering Over Current Shut Down Current Above Normal Grounded 520221 6 Steering Excessive Current Error Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Partial T1 Shorted to Ground 520223 4 Failure T1 Shorted to Bus 520223 3 S
57. e 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 After the 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 Set the time as outlined in steps 3 5 of Method 1 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area Diagnostic Displav 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 Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key
58. e it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 134 WARRANTV U S A EPA Emissions Limited Warrantv This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date after 5000 km 3100 miles or after 500 hours of operation whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacin
59. earcase Fluid Rear ATV Angle Drive 7 1 0z 10 14 ft Ibs 10 14 ft lbs Page 78 Gearcase Oil Fluid or GL5 80 210 ml 14 19 Nm 14 19 Nm 90 weight gear lube Brake Fluid DOT 4 Only Page 30 ADC Fluid Polaris ADC Page 80 Fluid Front Prop Polaris Premium Grease fittings 3 pumps maximum every 500 miles Shaft Yoke U Joint Lube before long periods of storage or after pressure Front Prop Shaft Yoke 12 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Svn thetic 2W 50 4 cycle oil or a similar oil for this engine See the table on page 72 for fluid recommendations capacities and plug torques Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 125 for the part numbers 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 Oil Level Check the oil level when the engine is cold Access the oil dip stick and fill tube from the left side of the ATV 1 Position the vehicle on a level surface Dipstick 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall and tighten the dip Full Add stick 4 Remove the dipstick and FULL gt 000 lt ADD check the oil
60. eight uphill e Apply the brakes e Lock the parking brake when fully stopped e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 60 If the ATV begins rolling downhill e Keep body weight uphill e Never apply engine power e Never apply the rear brake while rolling backwards Apply the single lever brake gradually e When fully stopped apply the rear brake as well and then lock the parking brake e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 60 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 16 SAFETV Safetv Warnings Operating on Slipperv Terrain Failure to use extra caution when operating on excessivelv rough slipperv or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessivelv rough slipperv or loose terrain Alwavs use extra caution on rough slipperv or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar
61. ent Control The ADC svstem will automaticallv engage when all four of the follow ing conditions occur e The 4X4 switch must be in the ADC 4X4 position e Vehicle speed must be 15 mph 25 km h or less e The throttle must be closed throttle lever released e 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 e The 4X4 switch is moved out of the ADC 4X4 position e 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 36 FEATURES AND CONTROLS Instrument Cluster Xour ATV is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission The instrument cluster measures distance in miles kilometers as well as hours of operation In addition to showing vehicle speed the instrument cluster also dis plavs the following items engine speed odometer resettable trip meters 2 total engine hours of operation service interval timer and indicator gear position fuel level AWD status EPS status if equipped high beam status batterv voltage warning temperature warning and diagnos tic displav mode These features are outlined on the following pages cus Hikaia Indicator Rider Information Center EPS Warning Indicator if equipped SHGEGEGE GE i Neutral Indicator Ov
62. er Temperature Indicator 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 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for one second at start up If the instrument cluster fails to illuminate a batterv over voltage mav have occurred and the instrument cluster mav have shut off to protect the electronic speedome ter If this occurs take the ATV to vour Polaris dealer for proper diagno sis The information center is set to displav standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 41 12 11 7 10 9 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 2 Information Display Area This area displays odometer tripme ters engine hour meter and programmable service hour interval 38 FEATURES AND CONTROLS Instrument Cluster Rider Information
63. ft the batterv out of the ATV Be careful not to tip a conventional batterv sidewavs which could spill electrolvte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 106 MAINTENANCE Batterv Batterv Installation Using a new batterv that has not been fullv charged can damage the bat terv and result in a shorter life It can also hinder vehicle performance Follow the batterv charging instructions on page 109 before installing the batterv 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries 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 CO ON Verify that cables are properly routed Cables should be safely tucke
64. g Safety Labels and Locations i General Warning Age 16 Warning Reverse Override Warning 4X4 Caution Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees 25 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill e 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 Warning 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 23 SAFETV Safetv Labels and Locations No Passenger Warning Tire Pressure Load Warning No Passenger Warning WARNING NEVER ride as a passenger Ib 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 p
65. g or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance 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 prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES 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 incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship 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 structur
66. g signal words and svmbols appear throughout this manual and on vour vehicle Xour safetv is involved when these words and svm bols are used Become familiar with their meanings before reading the manual A The safetv alert svmbol indicates a potential personal injurv hazard WARNING A WARNING indicates a hazardous situation which if not avoided mav result in death or serious injurv CAUTION A CAUTION indicates a hazardous situation which if not avoided mav result in minor or moderate injurv NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety 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 e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV e Never operate an ATV without proper instruction Take a training course Purchasers of a new Po
67. g the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to specification 78 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 79 MAINTENANCE Active Descent Control ADC Fluid If vour vehicle is equipped with Active Descent Control there are two fluid levels that must be maintained demand drive fluid and ADC fluid See page 77 for demand drive fluid maintenance Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Maintain the fluid level between the minimum and maximum marks on the reservoir We recommend the use of Polaris ADC Fluid See page 125 for the part numbers of Polaris products NOTICE Donotuse brake fluid Brake fluid will damage rubber components in the hvdraulic svstem 1 Remove the front rack ADC Fluid 2 View the fluid level in the Reservoir reservoir 3 Ifthe level is below the minimum mark remove the cap and add the recommended fluid 4 Reinstall the
68. he 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 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area 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 factorv 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 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 mod
69. he exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 131 WARRANTV ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITV AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form 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 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 If any of the above terms are void because of state or federal l
70. he footwell The drain plug is located on the bottom left side of the gearcase Oil Check 1 Remove the footwell see page 87 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 1 Remove the footwell Fill Level Fill Plug Drain Plug 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely a Clean and reinstall the drain plug Torque to specification F 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 a SIONA 76 MAINTENANCE Front Gearcase Demand Drive Fluid See the table on page 72 for fluid recommendations capacities and plug torques Alwavs check and change the demand drive fluid at the inter vals outlined in the Periodic Maintenance Chart beginning on page 68 See page 125 for the part numbers of Polaris products Use the recommended fluid Use of other fluids mav result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads See below for capacitv The fill plug is located on the right side of the 3 demand drive unit The drain plug is located on the Q Fill bottom
71. hing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2008 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 Printed in U S A 2009 Sportsman 550 850 XP XP EPS Owner s Manual P N 9921973 TABLE OF CONTENTS Introduction si onan tee Sere bb d a bba 4 Safety 6 4 4 c in A d B Ot AN 7 Features and Controls 26 Operation i i 2 2 Li ia a eee we ie ion 49 Emission Control Systems 67 Maintenance ssseneennnnnnnnn nn 68 Adjustments 220002e cece eee 118 Troubleshooting 00200e eee eee 121 Polaris Products siket ib eek et 125 Specifications l i sia xa eee sees lees 126 Warranty i ote Siete n Gd ATOR eRe ee es 130 Maintenance Log 000eeees 136 INDOX viet ee ee eee tee eae ae 139 INTRODUCTION The followin
72. hly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e If 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 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 11 SAFETV Safetv Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective evewear increases the risk of a serious injuries in the event of an accident Alwavs wear an approved helmet that
73. hrottle before pressing the override button The reverse override button also acts as a MODE button when held down for approximately one half second 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 36 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position 26 FEATURES AND CONTROLS Switches Engine Stop Switch f Move the stop switch either ny left or right to the OFF position a Th to stop the engine quickly OCN Move the stop switch to the RUN position before attempt PEE eae CRET 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 53 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change 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 27 FEATURES AND CONTROLS Throttle Lever A WARNING 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 con
74. icate 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 52 OPERATION Starting the Engine 1 Position the vehicle on a level surface outdoors or in a well venti lated area 2 Place the transmission in PARK 3 Lock the parking brake Tip The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged 4 Sit on the vehicle and move the engine stop switch to RUN 5 Do not press the throttle while starting the engine 6 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 7 Ifthe engine does not start return the key to the OFF position and wait five seconds 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 m
75. ing improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 55 OPERATION Driving on Slipperv Surfaces Miet ka Sidewavs Turn in Skid direction of COC _ COSC _ SA D Skid ICIS lt gt La O O x x ECSAC 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 the direction of the skid and shifting your body weight forward 56 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 GO VN GS 10 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 36 Drive straight uphill Avoid climbi
76. install the cap securelv Clean up anv drips or spills 81 MAINTENANCE Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thoroughly Cooling System The engine coolant level is controlled by the recovery system Recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap 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 Clean Often 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 Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 125 for the part numbers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 82 MAINTENANCE Cooling Svstem
77. into the headlight assembly 4 Turn the headlight harness clockwise to secure the head lamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light assembly 2 Turn the lamp counterclockwise to remove it 3 meal the new lamp Taillight 4 Reinstall the harness connector 5 Test the light for proper opera tion 97 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 126 for the recom mended spark plug tvpe and gap for vour vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Alwavs use Polaris recommended spark plugs Torque Specification Plug Condition 550 XP XP EPS 850 XP XP EPS New Spark Plug 9 11 ft Ibs 18 20 ft Ibs 12 15 Nm 24 27 Nm Previously Installed 17 20 ft Ibs 18 20 ft lbs 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 99 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
78. ion e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pav 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 immediatelv if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 68 MAINTENANCE Periodic Maintenance Chart A WARNING Improperly performing the procedures marked with a could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Enmission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions E Have an authorized Polaris dealer perform these services 69 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Pre Ride See Pre Ride Checklist on Front suspension Pre Ride page 50
79. 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 A set of two numbers will also appear in the display e The 2 6 digit suspect parameter number SPN in the information area indicates which component is generating the fault code e 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 44 47 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 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Displav 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 from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage Sportsman 550 XP XP EPS Diagnostic Codes Component Condition SPN FMI Throttle Posi
80. ke 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 29 FEATURES AND CONTROLS Master Cvlinder 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 master cylinder before each ride Cylinder Hees 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 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
81. l a hitch longer than 4 10 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use 65 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 66 Stop the engine Place the transmission in PARK Lock the parking brake Always block the rear wheels on the downhill side EMISSION CONTROL SVSTEMS Noise Emission Control Svstem Do not modifv 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 arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor 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 8343 1 c Violations are subject to monetary penalties Fed eral regulations can be viewed online at www gpoaccess gov ecft 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 All exhaust gases exit through the exhaust system Exhaust Emission Con
82. laris ATV and their eligible family members are entitled to take the ATV RiderCourses Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourses e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e 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 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 Engine Serial Number Kye Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETV Safetv Training ATV safetv training is a top prioritv for Polaris When vou purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCoursest You were also provided with printed materi
83. n cause loss of control 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 59 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 60 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 36 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 handlebars 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 slowly controlling speed with the service brake until the vehicle is on more level ground OPERATION Driving Through Water Xour 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 enteri
84. nd learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately 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 L A Alwavs 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 required 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 63 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrving or towing cargo improperlv can alter vehicle handling and mav cause loss of control or brake instabilitv which can result in serious injurv or death Alwavs 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 vehicl
85. ng 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 68 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil 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 possible follow the vehicle immersion inspection and drying procedures outlined on page 100 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 e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 61 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 62 Always check for obstacles before operating in a new area Look ahead a
86. ng 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 57 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 58 Slow down Shift body weight uphill Keep your feet on the footrests 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 A i ID Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 36 Avoid steep hills 25 maximum Shift body weight uphill Drive straight downhill Slow down Excessive speed when traveling downhill ca
87. ng the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory springs are available through your Polaris dealer Handlebars The handlebars can 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 120 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 60 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 104 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes
88. nment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out WARNING Severe injury or death can result from improper toe alignment and 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 ona level surface La 2 Place the 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 that the string is flush l l l l l l with the side of the rear I tire If available you may use a long straight l e l edge instead of string 2 4 Measure the distance 1 from the string to the KOL ee rim at the front 1 and O rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your Polaris dealer for ser vice 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 86 Seat Removal 1 2 Grasp one side of the seat near
89. nts 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 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 51 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 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 Commun
90. o high beam 4 Observe 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 5 The adjustment screw is located on the right side of the headlight pod To adjust the beam loosen the screw Adjust the headlamp to the desired position then tighten the screw Adjustment Screw 94 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 95 MAINTENANCE Lights Headlight Housing Replacement 1 2 96 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 counterclockwise and pull the harness assemblv awav from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly
91. olishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e 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 112 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 113 MAINTENANCE
92. or 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 124 POLARIS PRODUCTS iew Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 95 l 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 I Gearcase Transmission Lubricants 2877606 Synthetic Sportsman XP Transmission Fluid qt 95 l 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 1 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 l 2876144 Active Descent Control ADC Fluid 2871653 Premium ATV Angle Drive Fluid 8 02 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug 2876251 Demand Drive LT Premium Fluid 8 0z 237 ml Coolant 2871323 60 40 Coolant gal 3 8 1 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml
93. p 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 YEZ 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 in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time Fuel Tank Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface 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 E 85 fuel The fuel tank is designed to allow for the normal expansion of fuel Do not over fill Do not fill the tank neck 33 FEATURES AND CONTROLS All Wheel Drive System The All 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 36 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 automatically engage any time the rear wheels los
94. peating 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 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor clean out plug and remove the exhaust outlet cover or plug 101 MAINTENANCE PVT Svstem A WARNING Failure to complv with the instructions in this warning can result in severe injurv 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 e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 102 MAINTENANCE PVT Svstem The ba
95. r If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle 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 per form the warranty repair If You Move If vou move to another countrv be sure to contact Polaris Customer Assistance and the customs department of the destination countrv before vou move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 133 WARRANTV Exported Vehicles How to Get Service If Purchased From A Private Partv If vou purchase a Polaris product from a private citizen outside of the countrv in which the vehicle was originallv purchased all warrantv coverage will be denied Notice If your vehicle is registered outside of the country wher
96. rayers 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 SAFETV Safetv Warnings A WARNING Failure to operate the ATV properlv 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 ATV safely and could be susceptible to accident or injury 10 SAFETV Safetv Warnings Handling Gasoline Gasoline is hig
97. ressure Front 7 0 psi 48 3 kPa Rear 5 0 psi 34 5 kPa e Maximum weight capacity 575 lbs 261 kg 7175440 24 SAFETV Safetv Labels and Locations Rack Warning Rack Warning Clutch Cover Warning under seat Clutch Cover Warning WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e 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 Front and Rear WARNING e 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 e Max Rack Loads Front 120 Ibs 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 25 FEATURES AND CONTROLS Switches Headlight Switch Mode Reverse Override Button Engine Main Kev Stop Switch Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter svstem 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 t
98. rval Remarks whichever comes first Hours Calendar Miles Km E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E JETC Switch replace if necessarv E Throttle Body 50H 6M 500 800 Inspect duct for proper seal Intake Duct ing air leaks Drive belt 50 H 6M 500 800 Inspect replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Radiator 50 H 6M 1000 1600 Inspect clean external surfaces gt Cooling hoses 50H 6M 1000 1600 Inspect for leaks 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 gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid Fuel svstem 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed gt Wiring 100 H 12M 1000 1600 Inspect for wear routing securitv applv dielectric grease to connectors subjected to water mud etc E Clutches drive 100H 12M 1000 1600 jInspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years E
99. s on the container Run the engine for several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plugs and add 2 3 tablespoons 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 measured amount of oil Reinstall the spark plugs Torque to specification Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs 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 If Polaris fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 115 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 68 Batterv Maintenance Remove the battery and recharge it as outlined on page 109 Store the battery in a cool dry place Storage Area Covers Set the tire pressure and safely support the ATV with the tires 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 mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation
100. sic operation of the Polaris PVT svstem is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of cen trifugal 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 operation 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 slip 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 103 MAINT
101. t charger use the guidelines on the next page for recharging 109 MAINTENANCE Batterv Batterv Charging Sealed Batterv Always verify battery condition before and l 2 hours after the end of charging State of Charge Time 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 110 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a 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 clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first an
102. tact 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 electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control 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 Polaris Electronic Throttle Con trol ETC 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 28 FEATURES AND CONTROLS Brake Lever A WARNING Operating the ATV with a spongy brake lever can result in loss of braking 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 bra
103. teering Torque Sensor T2 Partial T2 Shorted to Ground 520224 4 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 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 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 Error No RX Message for 2 Seconds 520230 9 EPAS CAN Comm Transmit Error No TX Message for 2 Seconds 520231 9 47 FEATURES AND CONTROLS Front Rack Compartment Release the front rack latches and remove the rack to gain access to the front compart ment To reinstall the rack hold the rack as shown in the illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following compo nents in the front compart ment e Radiator cap e Brake fluid reservoir e ADC fluid reservoir e Coolant recovery bottle cap e Electrical fuse relay components Brake Fluid Reservoir
104. tery See page 107 Make sure the positive terminal polarity is properly connected Battery Charging Sealed Battery 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 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 curren
105. tion 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 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman 550 XP XP EPS Diagnostic Codes Component Condition SPN FMI Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load 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 Sign
106. towels beneath the oil filter Using an oil filter wrench available from vour Polaris dealer turn the filter counter clockwise to remove it Using a clean drv 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 Oil Filter Install the new filter and rotate it clockwise bv 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 used filter and oil properlv 75 MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Svnthetic Sportsman XP Trans mission Fluid for this transmission See the table on page 72 for fluid recommendations capacities and plug torques Alwavs check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 See page 125 for the part numbers of Polaris products Maintain the oil level at the bot tom of the fill plug hole The fill plug is located on the right side of the ATV behind t
107. trol System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The vehicle compliance labels can be found on the frame tubing of the vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 67 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep vour vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessarv When inspection reveals the need for replacement parts use genuine Polaris parts available from vour Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 136 Service and adjustments are important for proper vehicle operation If vou 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 riding conditions and an average vehicle speed of approximatelv 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequentiv Severe Use Definit
108. ts cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Check Engine Warning Indicator This indicator appears if an EFI related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result See your dealer 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 EPS Warning Indicator 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 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Displav Area Use the MODE button to toggle through the speed display options MODE button operation is locked out at speeds above approximately 15 MPH 25 km h Tip The reverse override button also acts as a MODE button when held down for approximately one half second The transmission cannot be in reverse when using the over ride button as a MODE button MODE SELECT This feature does not contain a Button Button vehicle speed lockout function and can be used at any operating speed Ground Speed Mode Ground speed is displayed in either miles per hour MPH or kilometers per hour km h Engine Speed Mode Engine speed is displayed in revolutions per minute RPM 4998889
109. ust be drained Water accu mulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 53 OPERATION Driving Procedures pa po pa ON pa ee 54 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 oh 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 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 Turn

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