Polaris Offroad Vehicle 550 Touring EPS User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

A card containing important ATV safety 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• 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, making it the finest machine we’ve ever produced.

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 clothing delivered right to your door!

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris

Industries Inc.

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.

2010 SPORTSMAN 550/850 Touring EPS Owner’s Manual

P/N 9922090

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Emission Control Systems . . . . . . . . . . . . . . . 75

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 131

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 135

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 136

Declaration of Conformity. . . . . . . . . . . . . . . 140

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 149

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and sym-

bols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in

minor or moderate injury.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual

can result in severe injury or death. A Polaris ATV is not a toy and can be

hazardous to operate. This vehicle handles differently than other vehicles, such

as motorcycles and cars. A collision or rollover can occur quickly, even during

routine maneuvers like turning, or driving on hills or over obstacles, if you fail to

take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and

operating procedures before operating a Polaris ATV. Keep this manual with

the ATV.

• Never operate an ATV without proper instruction. Take a training course.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age.

• Never permit a guest to operate the ATV unless the guest has read this

manual and all product labels and has completed a certified safety training

course.

Download from Www.Somanuals.com. All Manuals Search And Download.

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

VIN

####

Key

Number

550

850

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Training

ATV safety training is a top priority for Polaris. Polaris strongly

encourages you and any family members who will be riding the ATV to

take a training course.

If you purchased a new Polaris ATV in the United States, your dealer

provided instruction to you about the authorized ATV RiderCourse^sm

that is available to you and your eligible family members. This training

is included in the purchase price of your ATV. You were also provided

with printed materials that explain safe operating procedures. You

should review this information on a regular basis.

If you purchased a used Polaris ATV in the United States, you can enroll

in the ATV RiderCourse^smfor a fee. Call ATV Enrollment Express at

(800) 887-2887 or visit www.atvsafety.org.

If you purchased a Polaris ATV outside the United States, please contact

your dealer or local law enforcement agencies for information about

safety training.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws

and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance

program outlined in your owner's manual. This preventive maintenance

program is designed to ensure that all critical components on your vehi-

cle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY in the United

States, call the Consumer Product Safety Commission at 1-800-

638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call

Polaris at 1-800-342-3764.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective

clothing for comfort and to reduce the chance of injury.

Helmet

Eye Protection

Long

Sleeves

Gloves

Long Pants

Boots

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds established

safety 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 ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever riding a Polaris vehicle, always wear shatterproof goggles or use a

shatterproof helmet face shield. Polaris recommends wearing approved

Personal Protective Equipment (PPE) bearing markings such as VESC

8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and

protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs.

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, sprayers, or large racks, may change the handling char-

acteristics of the vehicle. Use only Polaris-approved accessories, and

familiarize yourself with their function and effect on the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

WARNING

Failure to operate the ATV properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Heed all safety

warnings outlined in this section of the owner’s manual. See the OPERATION

section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this ATV without proper instruction

increases the risk of an accident. The operator

must understand how to operate the ATV properly

in different situations and on different types of

terrain.

Beginning and inexperienced operators should

complete the recommended safety training before

operating this vehicle. See page 7.

Never permit a guest to operate the ATV unless the

guest has read this manual and all product labels

and has completed a certified safety training

course.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age. Never allow anyone under 12 years of age to ride as a

passenger on this 2-up ATV.

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 or ride on this ATV safely and could be susceptible to accident or injury.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated

area.

• Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Protective Apparel

Riding in this vehicle without wearing an

approved helmet and protective eyewear

increases the risk of a serious injuries in the

event of an accident.

Operator and passenger must always wear an

approved helmet that fits properly and eye

protection (goggles or face shield).

Carrying a Passenger

Do not carry a passenger until you have at

least two hours of driving experience with this vehicle.

Carrying More Than One

Passenger

Carrying more than one passenger greatly

reduces the operator's ability to balance and

control the ATV, which may result in an

accident or overturn.

Never carry more than one passenger on this

2-up ATV.

Using Alcohol or Drugs

Operating the ATV after consuming alcohol or

drugs could adversely affect operator

judgment, reaction time, balance and

perception.

Never consume alcohol or drugs before or

while operating an ATV.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces

(including sidewalks, paths, parking lots and

driveways) may adversely affect the

handling of the ATV and could result in loss

of control and accident or overturn.

Avoid operating the ATV on pavement. ATV

tires are designed for off-road use. If it's

unavoidable, travel slowly and avoid sudden

turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads

or highways could result in a collision with

another vehicle.

Never operate the ATV on any public street,

road or highway, including dirt and gravel

roads. In many states it's unlawful to

operate ATVs on public streets, roads and

highways.

Operating at Excessive

Speeds

Operating the ATV at excessive

speeds increases the operator's risk

of losing control.

Never operate at excessive speeds.

Travel at speeds appropriate for

your skills, your passenger's skills,

and operating conditions.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Physical Control of the ATV

Removing even one hand or foot can reduce

ability to control the vehicle or could cause loss

of balance and ejection from the ATV.

If a person's feet are not firmly planted on the

footrests, they could come into contact with the

wheels or other moving parts and lead to

accident or injury.

Always keep both hands on the handlebars

and both feet on the footrests of the ATV during

operation. A passenger should always be

seated in the passenger seat with both feet on the footrests and both hands on

the passenger grab handles at all times. The passenger should never hold on to

the operator.

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.

Practice turning at slow speeds before

attempting to turn at faster speeds.

Never turn at excessive speed.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

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 63. Always move the 4X4 switch to

ADC 4X4 before ascending or descending a hill.

Descending Hills Improperly

Improperly descending a hill could cause loss of

control or overturn.

• Always follow proper procedures for traveling

down hills as described in the owner's manual.

See page 65.

• 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 39.

• Always check the terrain carefully before

descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which

would cause the vehicle to lean sharply to one

side. Travel straight down the hill when

possible.

Crossing Hillsides

Driving on a sidehill is not recommended.

Improper procedure could cause loss of control

or overturn. Avoid crossing the side of any hill

unless absolutely necessary.

If crossing a hillside is unavoidable, always

follow proper procedures as described in the

owner's manual. See page 64.

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 66.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly

dismounting while climbing a hill could cause

an overturn.

• Always maintain a steady speed when

climbing a hill.

• Always move the 4X4 switch to ADC 4X4

before ascending or descending a hill. See

page 39.

If all forward speed is lost:

• Lean forward to keep body weight uphill. A

passenger should also lean uphill.

• Apply the single lever brakes.

• Lock the parking brake when fully stopped.

• Dismount on the uphill side of the vehicle, or on the left if the vehicle is

pointing straight uphill. Have a passenger dismount first, then the operator

may dismount.

• Turn the ATV around and remount, following the procedure described in the

owner's manual. See page 66.

If the ATV begins rolling backwards:

• Keep operator and passenger body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards.

• Apply the single-lever brake gradually.

• When fully stopped, apply the foot brake as well, and then lock the parking

brake.

• Dismount on the uphill side of the vehicle, or on the left if the vehicle is

pointing straight uphill. Have a passenger dismount first, then the operator

may dismount.

• Turn the ATV around and remount, following the procedure described in the

owner's manual. See page 66.

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 15 degrees.

>15°

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating

on excessively rough, slippery or loose terrain

could cause loss of traction, loss of control,

accident or overturn.

Do not operate on excessively rough, slippery

or loose terrain until you've learned and

practiced the skills necessary to control the

ATV on such terrain.

Always use extra caution on rough, slippery

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 terrain may contain hidden rocks,

bumps, or holes that could cause loss of

control or overturn.

Travel slowly and use extra caution when

operating on unfamiliar terrain. Always be

alert to changing terrain conditions.

Operating 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 70.

Before shifting into reverse gear, always

check for obstacles or people behind the ATV.

When it's safe to proceed, back slowly.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

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.

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 69.

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 slowly and use extra caution

to reduce the chance of skidding or sliding.

Do not operate on excessively slippery

surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

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

68):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or

stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. After leaving water, test the

brakes. Apply them lightly several times while driving. The friction will help dry

out the pads.

Improper Cargo Loading

Overloading the ATV or carrying/towing

cargo improperly may cause changes in

handling, which could cause loss of control

or an accident.

• Never exceed the stated load capacity for

this ATV.

• Cargo should be properly distributed and

securely attached.

• Reduce speed when carrying cargo or

pulling a trailer. Allow a greater distance

for braking.

• Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer.

• Always follow the instructions in the owner's manual for operating with a

passenger. See page 60.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Operating on Frozen Bodies of

Water

Operating on frozen bodies of water may

result in serious injury or death if the ATV

and/or riders 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Warnings

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. After any overturn or

accident, have a qualified service dealer inspect the entire machine for possible

damage, including (but not limited to) brakes, throttle and steering systems.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical

skills. Persons with cognitive or physical disabilities who operate this vehicle

have an increased risk of overturn and loss of control. Never secure a

passenger to the vehicle or to the operator with a belt, rope or similar device.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause burns and fire. Do not touch hot exhaust system

components. Always keep combustible materials away from the exhaust

system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,

which could result in an accident or overturn. Always remove the ignition key

when the vehicle is not in use.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection.

Read and follow the instructions on each label carefully. If any of the

labels shown in this manual differ from the labels on your vehicle,

always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, con-

tact your Polaris dealer to purchase a replacement. Replacement safety

labels are provided by Polaris at no charge. The part number is printed

on the label.

Reverse Override Warning/AWD Caution

WARNING

Reverse Override Warning

Improper use of override

AWD Caution

button can lead to loss of

Age 16

Warning

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

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases the chances of

severe injury or death to both operator and passenger.

NEVER operate this ATV if you are under age 16.

7175375

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Labels and Locations

General Warning

WARNING

Improper ATV use can result in SEVERE

INJURY or DEATH

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR FOR DRIVER AND

PASSENGER

NEVER USE ON PUBLIC ROADS

NEVER CARRY MORE THAN 1 PASSENGER

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate:

• without proper ATV training or instruction

• at speeds too fast for your skills or the

conditions

General Warning

• on public roads - a collision can occur with

another vehicle

• with a passenger unless passenger seat is securely in place

THE OPERATOR MUST ALWAYS:

• use proper riding techniques to avoid overturns on hills and rough terrain and

in turns

• avoid paved surfaces - pavement may seriously affect handling and control

• reduce speed and use extra caution at all times when carrying a passenger -

dismount passenger when conditions require

• make sure passenger reads and understands this label and passenger safety

label

LOCATE AND READ OPERATOR’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175844

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Labels and Locations

Passenger Warning/Discretionary Warning

WARNING

PASSENGER SAFETY

To reduce the risk of SEVERE INJURY or

DEATH

NEVER CARRY MORE THAN ONE

PASSENGER

NEVER RIDE AFTER USING DRUGS OR

ALCOHOL

NEVER carry a passenger too small to firmly

plant feet on footrests and securely grasp

hand holds.

Passenger Warning

Discretionary Warning

THE PASSENGER MUST ALWAYS:

• use an approved helmet and protective gear

• securely grasp hand holds and plant feet firmly on footrests while seated in

the passenger seat

• tell operator to slow down or stop if uncomfortable - get off and walk if

conditions require

WARNING

• Never operate this ATV on HILLS steeper than 15 degrees

15°. To

prevent overturn on hilly terrain, use throttle and brakes gradually, and shift

weight uphill.

• REVERSE operation can be dangerous even at low speeds. Steering

becomes difficult. To prevent loss of control, avoid sudden braking or sharp

turns.

7175845

Tire Pressure/Load Warning

WARNING

Tire Pressure/Load

Warning

Improper tire pressure or overloading can cause

loss of control.

Loss of control can result in severe injury or

death.

• Cold tire pressure:

Front: 7.0 psi (48.3 kPa)

Rear: 5.0 psi (34.5 kPa)

• Maximum weight capacity: 735 lbs. (333 kg)

• Lug nut torque values:

Steel rims 45 ft-lbs. (61 Nm)

Aluminum rims 75 ft-lbs. (102 Nm)

7175846

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Labels and Locations

Rack/Box

Warning

Rack/Box

Warning

Clutch Cover

Warning

Rack/Box Warning

WARNING

• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch.

•

Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg)

7175448

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or

death.

7175488

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Switches

Headlight

Switch

4X4

Switch

Mode/Reverse

Override

Switch

Main Key

Switch

Engine

Stop Switch

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain

additional wheel speed while backing, depress the override switch.

WARNING! Pressing the override button while the throttle is open can cause

loss of control, which may result in serious injury or death. Always release the

throttle before pressing the override button.

The reverse override button also acts as a MODE button when held

down for approximately one half second. 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 39. The

vehicle automatically engages 4X4 when operating in reverse if the

switch is set to either 4X4 position.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Switches

Engine Stop Switch

Move the stop switch either

left or right to the OFF position

to stop the engine quickly.

Move the stop switch to the

RUN position before attempt-

ing to start the engine. The

engine will not start or run

when the switch is off.

OFF

RUN

OFF

Both the main switch and the engine stop switch will shut off all electri-

cal power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 57.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Throttle Lever

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 contact your dealer for service before

operating the vehicle.

Failure to check or maintain proper operation of the throttle system can result in

an accident if the throttle lever sticks during operation. Always check the lever

for free movement and return before starting the engine. Also check

occasionally during operation.

Modifications to the 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 lim-

ited, and power to the rear

wheels will be reduced.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Brake Lever

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 brake lever toward the

handlebar to apply the front and

rear brakes. These brakes are

hydraulically activated disc type

brakes that are activated by only

one lever.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever

should feel firm. Any sponginess

would indicate a possible fluid leak or low master cylinder fluid level,

which must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Master Cylinder/Brake Fluid

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

cylinder before each ride.

Master Cylinder

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 window

on the top of the master cylin-

der. The eye will appear dark

when the fluid level is full.

When fluid is low, the eye will

be clear.

Indicator

Window

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).

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Auxiliary Foot Brake

WARNING

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

auxiliary brake when going forward. The rear wheels may skid and slide

sideways, causing loss of control and serious injury or death.

The auxiliary brake system is

intended to be used as a backup for

the main brake system. Should the

main system fail, use the auxiliary

foot brake.

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

Brake Fluid

Reservoir

Check the brake fluid level fre-

quently for the auxiliary brake sys-

tem. Access the reservoir under the

front box. See page 36.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear

selector is located on the

right side of the vehicle.

Gear

Selector

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

P: Park

To shift gears, brake to a

complete stop. When the

engine is idling, move

the lever to the desired

gear.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is

moving could cause transmission damage.

Whenever the ATV is left unattended, always place the transmission in

PARK and lock the parking brake.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and

when operating at less than seven miles per hour for extended periods of

time.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Electronic Power Steering (EPS)

Electronic power steering (if equipped) engages when the ignition key is

turned to the ON position. EPS remains engaged whether the vehicle is

moving or idle. See page 42 for EPS Warning Indicator information.

Passenger Seat

Always make sure the passenger seat is installed and securely latched

before operating with a passenger. Test the seat latch by attempting to

pull the seat upward. If the lock-out is not working properly, do not

allow a passenger to ride the vehicle. See your Polaris dealer for ser-

vice.

See pages 95-96 for passenger seat adjustment procedures.

See page 95 for passenger seat removal and installation procedures.

Beverage Holders

This vehicle is equipped with

beverage holders on each side

of the passenger seat. To

secure a beverage or other

container, remove the rubber

retainer strap from one side of

the holder. Place the container

into the recess and reinstall the

strap over the top of the con-

tainer. Place one of the rubber

cylinders through one of the

Tight Position

holes to secure a strap.

When trailering the vehicle,

and whenever a holder is not

in use, always secure the rub-

ber straps in one of the tighter

positions to prevent loss of the

retainer.

Less Tight Position

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Fuel Tank

Always refuel with the engine

stopped, and outdoors or in a well

ventilated area. Refuel on a level

surface.

Fuel Tank

Cap

Remove the fuel tank cap and add

fuel. Use either leaded or unleaded

gasoline with a minimum pump

octane number of 87=(R+ M/2)

octane. Do not use fuel with ethanol

content greater than 10%, such as

E-85 fuel.

The fuel tank is designed to allow

for the normal expansion of fuel. Do

not overfill. Do not fill the tank

neck.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Front Storage Box

Open the front storage box to access the under-compartment area.

1. Release the front

box cover latches

and lift the cover.

2. Release the plunger

latches that secure

the box to the

frame.

3. Close the cover and

Cover Latches

Plunger Latches

lift the unlatched

edge of the box to

disengage the plungers. Pivot the box forward.

4. To remove the box completely, disengage the plungers and slide the

box rearward and upward.

5. Always secure the plunger latches and the cover latches before

operating the vehicle.

Access the following components under the front box:

• Radiator cap

• Coolant recovery bottle cap

• Brake fluid reservoir

• ADC fluid reservoir

• Electrical/fuse/relay components

Electrical/Fuse/Relay

ADC Fluid

Brake Fluid

Reservoir

Coolant

Bottle Cap

Radiator

Cap

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

All Wheel Drive System

The All Wheel Drive system is

controlled by the 4X4 switch.

ADC 4X4

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 39.

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.

4X4

Switch

When in 4X4, the demand drive

unit will automatically engage

any time the rear wheels lose

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system allows engine braking to all four wheels when the

vehicle descends a hill or incline. Always move the 4X4 switch to ADC

4X4 before ascending or descending a hill.

Engaging Active Descent Control

The ADC system will automatically engage when all four of the follow-

ing conditions occur:

• The 4X4 switch must be in the ADC 4X4 position

• Vehicle speed must be 15 mph (24 km/h) or less

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the fol-

lowing conditions occur:

• The 4X4 switch is moved out of the ADC 4X4 position

• Vehicle speed exceeds 15 mph (24 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Your 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-

plays 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, battery voltage warning, temperature warning and diagnos-

tic display mode. These features are outlined on the following pages.

High Beam

Directional

Indicator

Rider Information Center

EPS Warning

Indicator

Neutral

Indicator

Over-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.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 battery over-voltage may have occurred and the

instrument cluster may have shut off to protect the electronic speedome-

ter. If this occurs, take the ATV to your Polaris dealer for proper diagno-

sis.

The information center is set to display standard units of measurement

and a 12-hour clock at the factory. To change to metric and/or a 24-hour

clock, see page 44.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

3. Speed Display - This area displays vehicle ground speed or engine

rotational speed when the corresponding display is selected. See

page 43.

4. 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.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

5. High Beam Indicator - This indicator appears when the lights are

set to high beam.

6. 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 46 for resetting instructions.

7. 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.

8. 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 46

for resetting instructions.

9. Under / Over Voltage - This warning usually indicates that the

ATV is operating at an RPM too low to keep the battery charged. It

may also occur when the engine is at idle and high electrical load

(lights, cooling fan, accessories) is applied. Drive at a higher RPM

or recharge the battery to clear the warning.

10. 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.

11. 4X4 Indicator - This indicator illuminates when the 4X4 system is

engaged (switch is on either ADC 4X4 or 4X4).

12. 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Speed Display Area

Use the MODE button to toggle

through the speed display options.

MODE button operation is locked

out at speeds above approximately

15 MPH (25 km/h).

Tip: The reverse override button also

acts as a MODE button when held

down for approximately one half

second. The transmission cannot

be in reverse when using the over-

ride button as a MODE button.

This feature does not contain a

vehicle speed lockout function and

can be used at any operating

speed.

SELECT

Button

MODE

Button

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).

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Use the SELECT button (SEL) to toggle through the information area

options. SELECT button operation is locked out at speeds above

approximately 15 MPH (25 km/h).

Tip: The reverse override button also acts as the SELECT button when pressed

and released 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Odometer Mode

The odometer records and displays the distance traveled by the ATV.

Trip Meter Mode

The trip meters record the distance traveled by the ATV on each trip if

reset before each trip. To reset a trip meter, select the trip meter 1 or trip

meter 2 mode. Press and hold the MODE button on the instrument clus-

ter until the total changes to 0. In the Rider Information Center, the trip

meter display contains a decimal point, but the odometer displays with-

out a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display 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 factory. Use the following procedure to

change the service interval.

1. Press the SELECT button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the SELECT button

to advance the hours to the desired setting (including OFF). When

the digits stop flashing, the interval has been set.

Clock Mode

Use one of the following two methods to reset the clock.

Method 1

1. Select the Hour Meter Mode.

2. Press and hold the mode button on the instrument cluster until the

hour display flashes. Release the button.

3. Press and release the SELECT button to advance the hours.

4. 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only.

Please see your Polaris dealer for all major repairs.

The diagnostic mode is accessible 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 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.

• The 2-6 digit suspect parameter number (SPN) in the information area

indicates which component is generating the fault code.

• The 1-2 digit failure mode indicator (FMI) number in the clock area indi-

cates the fault mode, such as open or short circuit.

4. See pages 48-51 for code definitions and failure descriptions.

Tip: More than one fault may be active. Press and hold the MODE button to tog-

gle through all currently active diagnostic codes.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load: There is a break in the wires that lead to the item listed in

the chart (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 Touring EPS Diagnostic Codes

Component

Throttle Position Sensor

Condition

Voltage Too High

SPN

FMI

Voltage Too Low

Engine Temperature Sensor

Intake Air Temperature Sensor

Voltage Too High

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Voltage Too High

110

105

102

636

523

651

1268

1347

1071

Voltage Too Low

Manifold Absolute Pressure Sensor Voltage Too High

Voltage Too Low

Crankshaft Position Sensor

Gear Sensor Signal

Circuit Fault

Voltage Too Low (to Calibrate)

Voltage Too High

Signal Fault

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Injector 1 (MAG)

Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded

Driver Circuit Short to B+

Fuel Pump Driver Circuit

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Fan Relay Driver Circuit

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN 550 Touring EPS Diagnostic Codes

Component

Idle Air Control

Condition

Driver Circuit Grounded

Shorted Load*

SPN

520193

520193 11

FMI

Starter Enable Circuit

All Wheel Drive Control

System Power

Driver Circuit Short to B+

Voltage Too High

Voltage Too low

Voltage Too High

Voltage Too Low

Signal Out of Range

Throttle Stuck

1321

520207

168

Throttle Safety Signal

520194

520203

Active Descent Control System

Driver Circuit Short to B+

EPS Models Only

Steering Over Current Shut Down

Steering Excessive Current Error

Current Above Normal or

Grounded

Current Above Normal or

Grounded

520221

520222

Steering Torque Sensor T1 Partial

Failure

T1 Shorted to Ground

T1 Shorted to Bus

T2 Shorted to Ground

T2 Shorted to Bus

520223

520224

520225

Steering Torque Sensor T2 Partial

Failure

Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground

T1 and T2 Shorted to Bus

T1 Shorted to Ground & T2

Shorted to Bus

520225 16

T2 Shorted to Ground & T1

Shorted to Bus

520225 17

T1 and T2 are Shorted

520225

520226

520227

520228

Steering Position Sensor P1 Partial

Failure

P1 Shorted to Ground

P1 Shorted to Bus

P2 Shorted to Ground

P2 Shorted to Bus

Steering Position Sensor P2 Partial

Failure

Steering Position Sensor Full Failure P1 and P2 Shorted to Ground

P1 and P2 Shorted to bus

EPAS Inverter Temperature

Greater than 110 Degrees C

Greater than 120 Degrees C

No RX Message for 2 Seconds 520230

520229 16

520229

EPAS CAN Communications

Receive Error

EPAS CAN Communications

Transmit Error

No TX Message for 2 Seconds 520231

*Assumes unipolar configuration of stepper motor

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN 850 Touring EPS Diagnostic Codes

Component

Throttle Position Sensor

Condition

Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Voltage Too High

SPN

110

FMI

Engine Temperature Sensor

110

Intake Air Temperature Sensor

105

102

636

Voltage Too Low

Manifold Absolute Pressure Sensor Voltage Too High

Voltage Too Low

Signal Out of Range

Circuit Fault

Plausibility Fault

Speed Too High

Plausibility Fault

Voltage Too Low

Voltage too high

Signal fault

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Crankshaft Position Sensor

Vehicle Speed Signal

Gear Sensor Signal

523

651

652

1268

1269

1347

1071

634

1321

Injector 1 (MAG) (SDI Part Load)

Injector 2 (PTO) (SDI Part Load)

Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+

Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+

Fuel Pump Driver Circuit

Fan Relay Driver Circuit

Idle Air Control

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Position Out of Range

Starter Enable Circuit

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN 850 Touring EPS Diagnostic Codes

Component

Chassis Relay

Condition

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Voltage Too High

SPN

FMI

520208

520207

168

All Wheel Drive Control

System Power

Voltage Too low

168

Throttle Safety Signal

Voltage Too High

Voltage Too Low

Signal Out of Range

Throttle Stuck

520194

520203

520211

Active Descent Control System Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Speed Too High

Speed Too Low

Idle Speed

EPS Models Only

Steering Over Current Shutdown Current Above Normal/Grounded

Steering Excessive Current Error Current Above Normal/Grounded

Steering Torque Sensor T1 Par- T1 Shorted to Ground

520221

520222

520223

520224

520225

tial Failure

T1 Shorted to Bus

Steering Torque Sensor T2 Par- T2 Shorted to Ground

tial Failure

T2 Shorted to Bus

Steering Torque Sensor Full

Failure

T1 and T2 Shorted to Ground

T1 and T2 Shorted to Bus

T1 Short to Ground & T2 Short to Bus 520225 16

T2 Short to Ground & T1 Short to Bus 520225 17

T1 and T2 are Shorted

P1 Shorted to Ground

P1 Shorted to Bus

P2 Shorted to Ground

P2 Shorted to Bus

P1 and P2 Shorted to Ground

P1 and P2 Shorted to bus

Greater than 110 Degrees C

Greater than 120 Degrees C

520225

520226

520227

520228

Steering Position Sensor P1

Partial Failure

Steering Position Sensor P2

Partial Failure

Steering Position Sensor Full

Failure

EPAS Inverter Temperature

520229 16

520229

520230

520231

EPAS CAN Comm. Receive Err No RX Message for 2 Seconds

EPAS CAN Comm. Transmit Err No TX Message for 2 Seconds

IC CAN Comm. w/EPAS

EPAS Offline

520230 31

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

WARNING

Failure to operate the ATV properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 35. Always exercise

extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 81. Add oil if

necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to famil-

iarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 54.

6. Pull only light loads.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the ATV is in safe operating condition

before operating increases the risk of an accident. Always inspect the

ATV before each use to make sure it's in safe operating condition.

Item

Remarks

Page

Passenger seat latch

Ensure latch is secure

Ensure proper operation

Brake system/lever travel

Brake fluid

Ensure proper level

Auxiliary brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels/fasteners

100

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level

Ensure proper level

Coolant hoses

Throttle

Inspect for leaks

Ensure proper operation

122

Indicator lights/switches

Engine stop switch

Air filter, pre-filter

Headlamp

Ensure operation

Ensure proper operation

Inspect, clean

101

Check operation

103

Brake light/taillight

Riding gear

Check operation

107

Wear approved helmet, goggles, and

protective clothing

ADC Fluid

Ensure proper level

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to oper-

ate this vehicle.

3. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

4. Before operating, learn how to use the auxiliary brake for emer-

gency situations (if service brakes become inoperable).

5. 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.

6. 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.

7. Drive in a manner appropriate for your skills, your passenger’s

skills and operating conditions. Never operate at excessive speeds.

Never attempt wheelies, jumps, or other stunts. Never remove your

hands from the handlebars while operating, and always keep both

feet on the footrests.

8. Never consume alcohol or drugs before or while operating an ATV.

9. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

10. Never operate a damaged ATV. After any overturn or accident, have

a qualified service dealer inspect the entire machine for possible

damage.

11. Never operate the ATV on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Communicate to oncoming operators by signaling the number of vehi-

cles in your group. When stopping, move your vehicle to the edge of the

trail as far as possible to allow others to pass safely.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Tip: Do not press the throttle while starting the engine.

5. 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.

6. If the 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 must be drained. Water accu-

mulation increases as outside temperature decreases.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 54.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

6. Sit upright with both feet on the footrests and both hands on the

handlebars.

7. Start the engine and allow it to warm up.

8. Shift the transmission into gear.

9. Check your surroundings and determine your path of travel.

10. Release the parking brake.

11. Slowly depress the throttle with your right thumb and begin driving.

12. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Turning the Vehicle

Both rear wheels drive

equally at all times. This

means that the outside wheel

must travel a greater distance

than the inside wheel when

turning, and the inside tire

must slip traction slightly.

1. Slow down.

2. Never turn quickly when

carrying a passenger or

cargo.

3. Steer in the direction of

the turn.

4. Keep both feet on the

footrests.

5. Lean your upper body to the inside of the turn while supporting your

weight on the outer footrest. This technique alters the balance of

traction between the rear wheels, allowing the turn to be made

smoothly. The same leaning technique should be used for turning in

reverse.

6. Practice making turns at slow speeds before attempting to turn at

faster speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn

abruptly or at sharp angles. Never turn at high speeds.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving with a Passenger

1. Never allow anyone under 12 years of age to ride as a passenger on

this 2-up ATV. Make sure any passenger is tall enough to comfort-

ably and safely reach the grab handles and footrests.

2. Do not carry a passenger until you have at least two hours of driving

experience with this vehicle.

3. Make sure the passenger is wearing appropriate riding gear, includ-

ing an approved helmet with a rigid chin guard. See page 8.

4. Perform the pre-ride

inspection. See page 54.

5. Always make sure the

passenger seat is installed

and securely latched

before operating with a

passenger.

6. Lock the parking brake.

7. Mount the vehicle from

the left side. After the

operator is seated, the

passenger should mount

the vehicle from the left

side. Always make sure

the brake is engaged to

ensure the vehicle remains motionless whenever a passenger

mounts or dismounts.

8. Allow a passenger to ride only in the approved passenger seat.

9. Do not carry more than one passenger.

10. Slow down. Control may be more difficult with a passenger on

board. Allow more time and distance for braking.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving with a Passenger

11. Ride to the ability of your passenger, instead of to your own ability.

Avoid unexpected or aggressive maneuvers that could cause a pas-

senger to fall from the vehicle.

12. Do not cross a hillside with a passenger on board. See page 64.

13. A passenger should always be seated in the passenger seat with both

feet on the footrests and both hands on the passenger grab handles

at all times. The passenger should never hold on to the operator.

Never secure a passenger to the vehicle or to the operator with a

belt, rope or similar device.

14. Make sure the passenger understands the importance of "active

riding." When hill-climbing or performing maneuvers, a passenger

should shift body weight in the same manner in which the driver

shifts body weight. For example, the passenger should lean to the

inside of a turn along with the operator and should always lean

uphill when climbing and descending hills.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel,

or during freezing weather, follow these precautions:

1. Do not operate on excessively 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.

Turn in

direction of

skid

Sideways

skid

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Uphill

15° 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. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 39.

2. Drive straight uphill.

3. Avoid steep hills (15° maximum).

4. Always check the terrain carefully before ascending any hill.

5. Never climb hills with excessively slippery or loose surfaces.

6. Keep both feet on the footrests.

7. Shift body weight uphill. A passenger should also shift body weight

uphill.

8. Proceed at a steady rate of speed and throttle opening. Opening the

throttle suddenly could cause the ATV to flip over backwards.

9. 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.

10. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

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. Slow down.

2. Avoid crossing the side of a steep hill.

3. Do not cross a hillside with a passenger on board. Ask the passenger

to dismount and walk across the hillside before remounting the

vehicle.

4. Lean into the hill, transferring your upper body weight toward the

hill while keeping your feet on the footrests.

5. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Downhill

15° Maximum

When driving downhill, follow these precautions:

1. Always check the terrain carefully before descending a hill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 39.

3. Always descend a hill with the transmission in forward gear. Do not

descend a hill with the transmission in neutral.

4. Slow down. Never travel down a hill at high speed.

5. Drive straight downhill. Avoid traveling down a hill at an angle,

which would cause the vehicle to lean sharply to one side.

6. Shift body weight uphill. A passenger should also shift body weight

uphill.

7. Apply the brakes slightly to aid in slowing. Applying the brakes too

firmly may cause the rear wheels to lock, which could result in loss

of control.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

8 ft. (2.4 m)

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Turning Around on a Hill (K-Turn)

1. Stop and lock the parking brake while keeping body weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 39.

3. Leave the transmission in forward and shut off the engine.

4. If a passenger is on board, ask the passenger to dismount first, then

the operator may dismount. Dismount on the uphill side of the vehi-

cle, or on the left if the vehicle is pointing straight uphill. A passen-

ger should not remount until the vehicle returns to firm, level

ground.

5. Staying uphill of the vehicle, turn the handlebars full left.

6. While holding the brake lever, 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.

7. Lock the parking brake. Remount the vehicle from the uphill side,

keeping body weight uphill. A passenger should not remount until

the vehicle returns to firm, level ground.

8. Start the engine with the transmission still in forward.

9. Release the parking brake and proceed slowly, controlling speed

with the brake lever, until the vehicle is on more level ground.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Through Water

Your ATV can operate

through water with a

maximum recommended

depth equal to the bottom of

the footrests. Follow these

procedures when operating

through water:

1. Determine water depths

and current before

entering water.

2. Choose a crossing

where both banks have

gradual inclines.

Maximum Depth

3. Avoid operating

through deep or fast-

flowing water.

NOTICE: Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined in

the maintenance chart. See page 76. The following areas need

special attention: engine oil, transmission oil, demand drive fluid and

all grease fittings.

If the vehicle tips or overturns in water, or if the engine stops during or

after operating in water, restarting can result in serious engine

damage. Transport the vehicle to your dealer for service before

restarting the engine. If this is not possible, follow the vehicle

immersion inspection and drying procedures outlined on page 110,

then see your dealer for service at the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several

times while driving slowly. The friction will help dry out the pads.

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for haz-

ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

5. Always have a passenger dismount before operating over an obsta-

cle that could cause a fall from the vehicle or vehicle tipover.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Be aware

that a passenger can obstruct your view.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

7. Do not use the override switch 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these

precautions:

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle

handling and may cause loss of control or brake instability, which can result in

serious injury or death. Always follow these precautions when hauling cargo:

Never carry cargo on the rear rack when operating the ATV in the 2-up mode

with a passenger.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of the

operator, passenger, 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 carrying loads on the

front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

1/3

Hauling Cargo

Never exceed the weight capacities

specified for your ATV on warning

labels and in the specifications sec-

tion of this manual.

2/3

1. Cargo weight should be evenly

distributed (1/3 on the front

rack and 2/3 on the rear rack)

and mounted as low as possible.

2. When operating over rough or

hilly terrain, reduce speed and

cargo weight to maintain stable

driving conditions.

3. Do not obstruct the headlight beam with cargo.

4. Slow down.

5. Use low forward gear when hauling or towing heavy cargo to

extend belt life.

6. Always operate the vehicle with extreme caution whenever hauling

or towing loads. Balance, handling, and control may be affected.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Hauling Cargo

Towing Loads

Always attach a towed load to the hitch point. Remove the hitch from

the ATV when not towing a trailer. If towing a load, reduce rear rack

cargo weight by the amount of tongue weight.

• The combination of rear rack cargo weight and tongue weight must

not exceed the rear rack capacity.

• The total load (operator, passenger, accessories, cargo and weight on

hitch) must not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or exceeding

the maximum tongue weight capacity

can result in serious damage to the

vehicle and will void your ATV

Maximum

4" (10 cm)

warranty. Never install 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.

Maximum Towing Capacities

Do not exceed maximum towing capacities. Avoid towing on inclines.

550 EFI

850 EFI

Maximum Towed Load (Level Ground)

Maximum Vertical Hitch Weight

1500 lbs. (680 kg)

150 lbs. (68 kg)

1500 lbs. (680 kg)

150 lbs. (68 kg)

Download from Www.Somanuals.com. All Manuals Search And Download.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so

may affect compliance with U.S.A. EPA noise control requirements (40

CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to

be in accordance with the USFS standard 5100-1c. Federal 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 420. Violations are subject to monetary penalties. Federal

regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases

are forced back to the combustion chamber by the intake system. All

exhaust gases exit through the exhaust system.

Exhaust Emission Control 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on

page 149.

Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have a

qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

miles per hour. Vehicles subjected to severe use must be inspected and

serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or crank-

case. Change oil immediately if the oil level begins to rise. Monitor the

oil level, and if it continues to rise, discontinue use and determine the

cause or see your dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

WARNING

Improperly performing the procedures marked with a Q 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

X Perform these operations more often for vehicles subjected to severe

use.

Emission-related service

(Failure to conduct this maintenance will not void the emissions

warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Make adjustments as

needed. See Pre-Ride

Checklist on page 54.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Passenger seat

latch

Wheels/fasteners

Frame fasteners

Engine oil level

Pre-Ride

Daily

X Air filter, pre-filter

Inspect; clean often; replace

as needed

Coolant

Daily

Check level daily, change

coolant every 2 years

X ADC fluid

Check level daily, add as

needed

X Power steering unit

Daily

Inspect daily; clean often

Check operation

Headlight/taillight

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X Air filter,

Weekly

1 Month

Monthly

Inspect; replace as needed

E main element

X Engine oil change

20 H

10 H

500 (800) Perform break-in oil and filter

change (see page 52)

X Brake pad wear

100 (160) Inspect periodically

Battery

20 H

25 H

Monthly

200 (320) Check terminals; clean; test

ADC fluid

Change fluid if extreme use

conditions (see page 88)

X Rear gearcase oil

25 H

Monthly

250 (400) Inspect level

(if equipped)

X Transmission oil

25 H

Monthly

3 M

250 (400) Inspect level

X Demand drive fluid 25 H

X General

50 H

500 (800) Lubricate all fittings, pivots,

cables, etc.

lubrication

Throttle Cable/

ETC Switch

50 H

6 M

500 (800) Inspect; adjust; lubricate;

replace if necessary

E Throttle Body

50 H

6 M

500 (800) Inspect duct for proper seal-

ing/air leaks

Intake Duct

Drive belt

500 (800) Inspect; adjust; replace as

needed

Cooling system

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

X Radiator

50 H

6 M

1000 (1600) Inspect; clean external

surfaces

(if applicable)

X Cooling hoses

1000 (1600) Inspect for leaks

(if applicable)

X Engine oil change 100 H

6 M

1000 (1600) Change the oil and filter

1000 (1600) Change fluid

X Rear gearcase oil

100 H

12 M

(if equipped)

X Transmission oil

100 H

12 M

1000 (1600) Change fluid

X Demand drive fluid 100 H

Fuel system

100 H

1000 (1600) Check for leaks at tank cap,

lines, filter, pump; replace

lines every two years

X Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Spark plug

100 H

12 M

1000 (1600) Inspect; replace as needed

X Wiring

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

and driven)

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

200 H

24 M

2000 (3200) Change every two years

X ADC fluid

2000 (3200) Change every two years;

every 25 hours if extreme use

conditions (see page 88)

Spark arrestor

300 H

36 M

3000 (4800) Clean out

Valve clearance

Toe adjustment

Headlight aim

1000 H

10000

(16000)

Inspect; adjust

Inspect periodically; adjust

when parts are replaced

Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 76. Items not listed in the

chart should be lubricated at the General Lubrication interval.

The a-arms and upper control arms are lubricated at the factory, and no

additional lubrication will be needed. However, if these components are

subjected to severe use, grease zerks have been provided for additional

lubrication at the user's discretion.

Item

Recommended Capacity

Fill Plug

Torque

Drain Plug Inspection

Torque Procedure

Lubricant

at Fluid

Change

550 Engine Oil PS-4 PLUS

Performance

2 qt.

---

15-17 ft. lbs. Page 81.

(20-23 Nm)

(1.9 l)

Synthetic 2W-50

850 Engine Oil PS-4 PLUS

Performance

2 qt.

(1.9 l)

12 ft. lbs. Page 81.

(16 Nm)

Synthetic 2W-50

Transmission Synthetic

32 oz.

10-14 ft. lbs. 10-14 ft. lbs. Page 84.

Oil

SPORTSMAN

XP Transmission

Fluid

(946 ml) (14-19 Nm) (14-19 Nm)

Demand Drive Demand Drive

9.3 oz.

8-10 ft. lbs.

11 ft. lbs. Page 86.

(15 Nm)

Fluid (Front

Gearcase)

PLUS Fluid

(275 ml) (11-14 Nm)

Rear

ATV Angle Drive

7.1 oz.

10-14 ft. lbs. 10-14 ft. lbs. Page 87.

Gearcase Oil Fluid (or GL5 80- (210 ml) (14-19 Nm) (14-19 Nm)

90 weight gear

lube)

Brake Fluid

ADC Fluid

DOT 4 Only

---

Page 30.

Page 88.

Demand Drive

PLUS Fluid

Front Prop

Shaft Yoke

Polaris Premium Grease fittings (3 pumps maximum) every 500 miles,

U-Joint Lube

before long periods of storage, or after pressure

washing or submerging.

Front

Front Prop Shaft Yoke

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on

page 80 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 135 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. Never check the

oil with the engine running.

1. Position the vehicle on a

level surface.

2. Access the oil dipstick and

fill tube from the left side of

Dipstick

the ATV. Remove the dip-

stick. Wipe it dry with a

clean cloth.

Full

Add

3. Reinstall and tighten the dip-

stick.

4. Remove the dipstick and

check the oil level.

850

5. Add the recommended fluid

as needed. Maintain the oil

level in the safe range

between the FULL and ADD

marks. Do not overfill.

Full

Add

6. Reinstall and tighten the dip-

stick.

550

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Engine Oil

Oil and Filter Change

See the table on page 80 for fluid recommendations, capacities and plug

torques. Always change the oil and filter at the intervals outlined in the

Periodic Maintenance Chart beginning on page 76. Always change the

oil filter whenever changing oil.

550 Drain

Plug

to front

850 Drain

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Engine Oil

Oil and Filter Change

9. Place shop towels beneath

the oil filter. Using an oil fil-

ter wrench (available from

your Polaris dealer), turn the

filter counter-clockwise to

remove it.

550

850

10. Using a clean dry cloth, clean

the filter sealing surface on

the crankcase.

11. 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

12. Install the new filter and rotate it clockwise by hand until the filter

gasket contacts the sealing surface, then turn it an additional 1/2

turn.

13. Remove the dipstick. Add the proper amount of the recommended

oil. Do not overfill.

14. Reinstall the dipstick.

15. Place the transmission in PARK.

16. Lock the parking brake.

17. Start the engine. Allow it to idle for one to two minutes.

18. Stop the engine.

19. Check for leaks.

20. Check the oil level. Add oil as needed to bring the level to the upper

mark on the dipstick.

21. Dispose of used filter and oil properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transmission Oil

Polaris recommends the use of Polaris Synthetic SPORTSMAN XP

Transmission Fluid for this transmission. See the table on page 80 for

fluid recommendations, capacities and plug torques. Always check and

change the transmission oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 76. See page 135 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

Fill

Level

the ATV behind the footwell. The

drain plug is located on the bottom

left side of the gearcase.

Oil Check

1. Remove the footwell (see

page 97).

2. Remove the fill plug. Check

Fill Plug

the oil level.

Drain Plug

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transmission Oil

Oil Change

1. Remove the footwell.

2. Place a drain pan under the gearcase. Remove the drain plug. Allow

the oil to drain completely.

3. Clean and reinstall the drain plug. Torque to specification.

4. Remove the fill plug. Add the proper amount of the recommended

oil.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Reinstall the footwell.

8. Dispose of used oil properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

See the table on page 80 for fluid recommendations, capacities and plug

torques. Always check and change the demand drive fluid at the inter-

vals outlined in the Periodic Maintenance Chart beginning on page 76.

See page 135 for the part numbers of Polaris products.

Use the recommended fluid. Use of other fluids may result in improper

operation of components.

Maintain the fluid level at the bottom of the fill hole threads. See below

for capacity.

The fill plug is located on

the right side of the

demand drive unit. The

Fill

Level

drain plug is located on the

bottom right side of the

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

Drain Plug

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.

2. Place a drain pan under the demand drive unit. Remove the drain

plug. Allow the fluid to drain completely.

3. Clean and reinstall the drain plug. Torque to specification.

4. Add the proper amount of the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks. Dispose of used fluid properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Rear Gearcase Oil

See the table on page 80 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 76. See

page 135 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

Level

Maintain the fluid level at the

bottom of the fill hole threads.

Do not overfill.

Oil Check

1. Position the vehicle on a

level surface.

Fill Plug

2. Remove the fill plug.

Check the oil level.

Drain Plug

3. Add the recommended oil

as needed to bring the

level to the bottom of the

fill hole threads. Do not overfill.

4. Reinstall the fill plug. Torque to specification.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Active Descent Control (ADC) Fluid

If your vehicle is equipped with Active Descent Control, there are two

fluid levels that must be maintained (demand drive fluid and ADC

fluid). See page 86 for demand drive fluid maintenance.

Check and change the ADC fluid at the intervals outlined in the Periodic

Maintenance Chart beginning on page 76.

NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to

extreme use. Extreme use includes operation in ADC mode for

prolonged periods or in environments that necessitate primary

operation in ADC mode.

We recommend the use of Polaris Demand Drive Plus Fluid for the

ADC unit. Maintain the fluid level between the minimum and maximum

marks on the reservoir. See page 135 for the part numbers of Polaris

products.

NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in

the hydraulic system.

Fluid Check

1. Access the reservoir under

the front box. See page 36.

ADC Fluid

Reservoir

2. View the fluid level in the

reservoir.

3. If the level is below the

minimum mark, remove

the cap and add the

recommended fluid.

4. Reinstall the cap.

5. Close and secure the front

box and cover.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level

surface. Before performing the

fluid change, allow the vehicle

to sit for at least 30 minutes.

Bleeder

Screw

Cap

Bleeder

2. Thoroughly clean the areas

around and on the ADC

reservoir and bleeder valves

(one on each side of the

differential).

Valve

Screw

3. 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.

4. Fill the reservoir to the maximum line with fresh ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. 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. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

8. 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.

9. Reinstall the cap securely. Clean up any drips or spills.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Power Steering Unit

Clean

Often

If your model is equipped with

power steering, frequently clean

the areas around and on the

power steering unit to allow

proper cooling. Clean these areas

thoroughly.

Steering Assembly

The steering assembly of the ATV should be checked periodically for

loose nuts and bolts. If loose nuts and bolts are found, see your Polaris

dealer for service before operating the vehicle.

Cooling System

The engine coolant level is controlled, or maintained, by the recovery

system. The 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.

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 135 for the part

numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Recovery Bottle Coolant

The recovery bottle fluid level can be viewed from inside the front right

wheel well. Access the recovery bottle cap under the front box. See page

36.

1. View the fluid level in the bottle.

2. If the level is low, 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).

3. Reinstall the cap.

4. Close and secure the front box and cover.

Maximum

Mark

Minimum

Mark

Recovery

Bottle Cap

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine,

Polaris recommends that you drain the system completely every two

years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for

maintenance or repair. If the recovery bottle has run dry, check the level

in the radiator. Add coolant as needed.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap

while the engine is warm or hot. Always allow the engine to cool before

removing the pressure cap.

1. Access the pressure cap under the

front box. See page 36.

2. Remove the pressure cap.

3. Using a funnel, slowly add cool-

ant through the radiator filler

neck.

4. Reinstall the pressure cap. Use of

a non-standard pressure cap will

not allow the recovery system to

function properly. Contact your

dealer for the correct replacement

part.

5. Close and secure the front box and

Radiator

Cap

cover.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brakes

Hand Brake

The front and rear brakes are hydraulic disc brakes, activated by moving

the single brake lever toward the handlebar. These brakes are self-

adjusting.

Under normal operation, the diaphragm extends into the reservoir as

fluid level drops. If the fluid level is low and the diaphragm is not

extended, a leak is likely and the diaphragm should be replaced. To

ensure proper diaphragm 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).

3/64" (1 mm)

5. Check the security and surface condition

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 0" to 1/8" (0-3 mm).

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 on a

level surface.

2. Place the handlebars in a

straight-ahead position.

Stand

String

3. Tie a length of string

between two stands as

shown in the illustration.

Position the stands so

that the string is flush

with the side of the rear

tire. If available, you

may use a long straight-

edge instead of string.

4. Measure the distance

from the string to the

rim at the front (1) and

rear (2) of the front rim.

The rear measurement

should be 1.5 mm more than the front measurement on each side of

the vehicle to obtain the recommended 0" to 1/8" (0-3 mm) toe out

alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

6. If you discover improper alignment, see your Polaris dealer for ser-

vice.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Seats

Passenger Seat Removal

1. Pull the latch at the rear of the seat.

2. Pivot the rear of the seat upward and

remove the front legs of the seat base

from the frame.

3. To reinstall the seat, position the

front legs of the seat base under the

frame. Pivot the rear of the seat

downward onto the latch. Press

down firmly on the seat pad until the

latch clicks. Test the seat latch by attempting to pull the seat

upward.

Passenger Seat Backrest Adjustments

The passenger backrest can be adjusted horizontally and vertically.

1. Unzip the two zippers at the bot-

tom of the backrest pad. Lift the

pad upward to remove it from the

backrest frame.

2. To adjust the backrest forward or

rearward, loosen the top adjuster

bolt. Pivot the adjuster forward or

rearward to one of the three

adjustment positions and tighten

the bolt.

3. To adjust the backrest upward or

downward, loosen the four verti-

cal adjustment screws on the front

side of the backrest frame. Slide

the backrest upward or downward

to the desired position and tighten

the screws.

4. Reinstall the backrest pad.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Seats

Passenger Seat Suspension

1. Remove the passenger seat.

2. Remove the fastener retaining the

passenger seat shock to the passenger

seat support.

3. Pivot the seat support upward to

access the lower shock fastener.

Remove the lower shock fastener.

4. Remove the shock from the vehicle.

If adjustment is necessary, use a suit-

able pliers or spanner wrench. Adjust

the shock to the desired spring pre-

load. Rotate the adjustment cam to

the left to increase preload.

5. Reinstall the shock.

6. Torque the upper and lower shock

fasteners to 38 ft. lbs. (51 Nm).

7. Reinstall the passenger seat.

Operator Seat Removal

1. Remove the passenger

seat. See page 95.

2. Grasp one side of the oper-

ator’s seat near the rear

edge.

3. Pull upward abruptly to

disengage the under-seat

fasteners.

4. Remove the seat.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Side Panel/Footwell Removal

1. Remove the seat before removing a side panel.

2. Remove the fasteners securing the side panel or footwell to remove

it.

Plastic Rivet

Hex Head Screw

Plastic Rivet

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Tires

WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires

or improperly installed tires will affect vehicle handling and could cause an

accident resulting in serious injury or death. Always follow all tire maintenance

procedures as outlined in this manual and on the labels on the vehicle. Always

use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 136 for recom-

mended tire type, size and pressure.

Tire Tread Depth

Always replace tires

when tread depth is

worn to 1/8" (3 mm)

or less.

1/8" (3 mm)

Download from Www.Somanuals.com. All Manuals Search And Download.

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. Elevate the side of the vehicle by placing a suitable stand under the

footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

4. Install the wheel nuts and finger-tighten them.

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

WARNING! Loose nuts could cause a tire to come off during operation, which

could result in an accident or overturn. Always ensure that all nuts are torqued to

specification.

75 ft. lbs.

(102 Nm)

45 ft. lbs.

(61 Nm)

Cast Aluminum

Steel

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos-

ened for service.

Wheel Type

Nut Type

Nut Torque

Aluminum

Steel

Lug Nut

75 ft. lbs. (102 Nm)

45 ft. lbs. (61 Nm)

100

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Air Filter

1. Remove the seat.

Screws

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

main filter if needed.

Pre-Filter

Main

Filter

6. Reinstall the filter into the air

box.

7. Reinstall the air box cover

and the seat.

101

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Fuse Replacement

If the engine stops or will not start, or if you experience other electrical

failures, a fuse may need replacement. Locate and correct any short cir-

cuits that may have caused the blown fuse, then replace the fuse. Spare

fuses are provided in the fuse box.

1. Access the fuses under the front box. See page 36.

2. Remove the fuse box cover.

3. Remove the suspect fuse from the fuse panel. If the fuse is blown,

install a new fuse with the same amperage rating.

4. Reinstall the fuse box cover.

5. Close and secure the front box and cover.

Fuse Box

550

850

102

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight

and taillight lenses become dirty during normal operation. Clean head-

lights frequently and replace burned out headlamps 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 counter-clockwise to remove it.

5. Install the new lamp. Make sure the tab on the lamp locates properly

in the housing.

6. Reassemble the pod.

103

Download from Www.Somanuals.com. All Manuals Search And Download.

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" (5 cm)

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 to 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 knob is

Adjustment

located on the right side of

the headlight pod. Adjust

the beam to the desired

position by turning the

knob either clockwise or

counter-clockwise.

Screw

104

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

Low Beam Adjustment

Phillips Screw

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.

105

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

Headlight Housing Replacement

1. Remove the five (5)

headlight pod screws.

2. Lift the pod cover and

disconnect the

speedometer harnesses

from the speedometer.

3. Unplug the headlamp

from the wiring harness.

4. Use a small screwdriver

to remove the o-rings

from the headlight

mounting tabs.

5. Pull the headlight housing up to release it from the locking tabs.

6. Carefully pull the assembly up and out of the pod.

7. Reverse the steps to install the new housing and reassemble the pod.

106

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight

harness counter-clockwise and

pull the harness assembly away

from the headlight assembly.

2. Remove the headlamp and install

the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

Harness

4. Turn the headlight harness clock-

wise to secure the headlamp.

Taillight/Brakelight Lamp Replacement

1. Remove the harness connector

Connector

from the back of the light assem-

bly.

Lamp

2. Turn the lamp counter-clockwise

to remove it.

3. Install the new lamp.

4. Reinstall the harness connector.

5. Test the light for proper operation.

107

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 136 for the recom-

mended spark plug type and gap for your vehicle. Torque spark plugs to

specification.

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

Torque Specification

Plug Condition

550

850

New Spark Plug

9-11 ft. lbs.

(12-15 Nm)

18-20 ft. lbs.

(24-27 Nm)

Previously Installed

Spark Plug

17-20 ft. lbs.

(23-27 Nm)

18-20 ft. lbs.

(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

plug for correct color. See page 109.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Rotate the spark plug counter-clockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to specifi-

cation.

108

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This indi-

cates the proper type and heat range for the engine and the service.

The tip should not be flaky and white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect fuel.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil, use

of non-recommended oil or incorrect throttle body adjustments.

109

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Vehicle Immersion

If your vehicle becomes immersed, major engine damage can result if

the machine is not thoroughly inspected. Take the vehicle to your dealer

before starting the engine. If it's impossible to take your ATV to a dealer

before starting it, follow the steps outlined below.

1. Move the ATV to dry land or at the very least, to water below the

footrests.

2. Check the air box. If water is present, dry the air box and replace the

filter with a new filter.

3. Remove the spark plug.

4. Turn the engine over several times using the electric start.

5. Dry the spark plugs. Reinstall the plugs or install new plugs.

6. Attempt to start the engine. If necessary, repeat the drying proce-

dure.

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 114 for drying out the PVT.

110

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could

result in serious injury or death. Never run the engine in an enclosed area.

Remove any combustible materials from the area. Wear eye protection and

leather work gloves. Do not stand behind or in front of the vehicle while purging.

Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark

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.

4. Quickly squeeze and

release the throttle lever

several times to purge car-

bon from the system.

5. If carbon comes out of the

exhaust, cover or plug the

exhaust outlet(s). Wear

protective gloves.

Clean-Out Plug

6. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 4.

7. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

8. Repeat steps 4 to 6 until no more particles are expelled.

9. Stop the engine. Allow the arrestor to cool.

10. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

111

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury

or death.

Do not modify any component of the PVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The PVT system has been

precision balanced. Any modification will cause the system to be out of balance,

creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as

outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install it

in any other product.

• Always make sure the PVT housing is securely in place during operation.

112

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

PVT System

The basic operation of the Polaris PVT system is dependent on engine

speed and vehicle torque requirements. As engine speed increases, the

force exerted on the movable drive sheave by the 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.).

113

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

PVT System

When To Use Low Range and High Range

Condition

Range to Use

Operating at speeds less than 7 MPH (11 km/h)

Towing heavy loads

Low

High

Operating in rough terrain (swamps, mountains, etc.)

Operating at speeds greater than 7 MPH (11 km/h)

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. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain completely. Rein-

stall the drain plug.

3. Start the engine. Place the transmission in PARK.

4. 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.

5. Allow the engine RPM to settle to idle speed, then shift the trans-

mission to the lowest available range.

6. Test for belt slippage. If the belt slips, repeat the process.

7. Take the vehicle to your dealer for service as soon as possible.

114

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

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.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result 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.

115

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Removal

1. Remove the passenger seat and the seat pivot bolt.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Disconnect the battery hold-down strap.

5. On conventional batteries, remove the battery vent tube.

6. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte.

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.

116

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 119 before installing

the battery.

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. Coat the terminals with dielectric grease or petroleum jelly.

5. Secure the battery hold-down strap.

6. Connect and tighten the red (positive) cable first.

7. Connect and tighten the black (negative) cable last.

8. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

9. Install the seat.

117

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it's fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

Polaris recommends maintaining battery charge by using a Polaris 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 135 for the part numbers

of Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will

Upper

Mark

Lower

Mark

deteriorate rapidly. Check the battery

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.

118

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 116.

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 battery. See page 117. Make sure the positive terminal

is toward the front of the vehicle.

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. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the 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 current

charger, use the guidelines on the next page for recharging.

119

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

120

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Camber and Caster

The camber and caster are non-adjust-

able.

Rear Spring

The rear shock absorber spring is

adjusted by rotating the adjuster either

clockwise or counter-clockwise to

increase or decrease spring tension.

Accessory springs are available through

your Polaris dealer.

Adjuster

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

10-12 ft. lbs. (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.

Bolts

121

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not

satisfactory, please see your Polaris dealer for adjustment.

Throttle Cable Freeplay

1. Remove the four cover

screws from the right han-

dlebar control and remove

the cover.

2. With the handlebars

straight ahead, place very

Throttle

Arm

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.

2-3 mm Gap

If adjustment is needed:

Arm Stop Pin

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.

Cable

Adjuster

2. Loosen the adjuster lock nut.

3. Rotate the boot to turn the

adjuster until 2-3 mm of

freeplay is achieved between

the stop pin and the throttle

arm. While adjusting free-

play, flip the throttle lever

back and forth repeatedly.

Boot

(continued on next page)

Lock Nut

Adjuster

122

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Throttle Cable Freeplay

4. Place the transmission in PARK. Lock the parking brake.

5. Start the engine and allow the idle to stabilize. If necessary, tap the

throttle lever to ensure the idle speed settles.

6. If idle speed remains above or below the recommended setting (see

specification pages), verify the correct gap. If gap is correct and idle

speed is still not satisfactory, please see your Polaris dealer for ser-

vice.

7. 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.

8. When adjustments are complete, tighten the locknut.

9. Squeeze the end of the rubber boot and slide it over the cable

adjuster to its original position.

10. Ensure the control cover seal is in place, then reinstall the cover and

screws.

123

Download from Www.Somanuals.com. All Manuals Search And Download.

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

and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

124

Download from Www.Somanuals.com. All Manuals Search And Download.

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 decals. Avoid directing the water stream at the follow-

ing items:

• Wheel bearings

• Radiator

• Transmission seals

• Cab and body panels

• Electrical components

• Switches and controls

• Fuel system components

• 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.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the

finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

125

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

126

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the

protective film created by fogging and damage could occur. Never

start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See

page 124.

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 82.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter. See page

101.

2. Clean the air box.

127

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the

Periodic Maintenance Chart beginning on page 76.

• Demand drive unit (front gearcase)

• ADC fluid (ADC models) (change every two years)

• Rear gearcase

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc-

tions on the container. Start the engine. Allow it to idle for several

minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plug and add 2-3 tablespoons of engine oil. To

access the plug hole, use a section of clear 1/4" hose and a small

plastic squeeze bottle filled with the pre-measured amount of oil.

3. Reinstall the spark plug. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap and rein-

stall the caps onto the plugs.

5. 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.

6. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and injectors should be completely drained of gasoline.

128

Download from Www.Somanuals.com. All Manuals Search And Download.

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 76.

Battery Storage

See pages 118-119 for storage and charging procedures. Store the bat-

tery 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.

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.

129

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Secure the fuel cap and oil cap.

5. Always tie the frame of the ATV to the transporting unit securely

with suitable straps or rope. Do not attach tie straps to the front A-

arm bolt pockets, racks or handlebars.

6. Remove the key to prevent loss during transporting.

130

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or Use low range during loading.

tall trailer in high range

Starting out going up a

steep incline

Use low range or turn around using the K-turn (see page

66).

Driving at low RPM or

Drive at a higher speed or use low range more frequently.

ground speed (3-7 MPH) See page 114.

Insufficient warm-up at

low ambient tempera-

tures

Warm the engine at least 5 minutes. With the transmission

in neutral, advance the throttle to about 1/8 throttle in

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

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 Dry out the PVT. See page 114. Inspect clutch seals for

or snow ingestion into the damage if repeated leaking occurs.

PVT system

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

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 53.

131

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

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

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Immediately see your Polaris dealer

Recharge the battery to 12.8 VDC

See your dealer

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Inspect, clean and/or replace spark

plug(s)

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

Loose ignition connections

Water present in fuel

Check all connections and tighten

Replace with fresh recommended fuel

132

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Kinked or plugged fuel tank vent line

Low octane fuel

Add or change fuel, clean the fuel system

Inspect and replace

Replace with recommended fuel

Incorrect fuel

Possible Rich Fuel Cause

Solution

Fuel is very high octane

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

Inspect and clean or replace

Clogged air filter

133

Download from Www.Somanuals.com. All Manuals Search And Download.

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

Water is present in fuel

Inspect and replace

Replace with new fuel

Fouled or defective spark plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

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

Plugged Radiator

Clean the screen.

Use a garden hose to flush any debris

from the radiator fins. NOTICE: High

pressure washers can deform the radiator

fins and reduce cooling efficiency.

134

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS PRODUCTS

Part

Number

Description

Engine Lubricant

2870791

2876244

2876245

Fogging Oil (12 oz. Aerosol)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Gearcase / Transmission Lubricants

Synthetic SPORTSMAN XP Transmission Fluid (qt./.95 l)

Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)

Premium AGL Synthetic Gearcase Lube (gal./3.8 l)

Demand Drive Plus Fluid (qt./.95 l)

2877606

2873602

2873603

2877922

2877923

2871653

2872276

2870465

Demand Drive Plus Fluid (gal./3.8 l)

Premium ATV Angle Drive Fluid (8 oz./237 ml)

Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

Pump for Gallon (3.8 l) Jug

Coolant

2871323

2871534

60/40 Coolant (gal./3.8 l)

60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

2871312

2871322

2871423

2871460

2871515

2871551

2871329

Grease Gun Kit, Premium All Season

Premium All Season Grease (3 oz./89 ml cartridge)

Premium All Season Grease (14 oz./414 ml cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz./89 ml cartridge)

Premium U-Joint Lube (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel^TM

Additives / Miscellaneous

Carbon Clean Plus

)

2871326

2870652

2872189

2871956

2859044

Fuel Stabilizer

DOT 4 Brake Fluid

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

135

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

SPORTSMAN 550 Touring EPS

Maximum Weight Capacity

735 lbs. (333 kg) (includes operator, passenger,

cargo, accessories)

Dry Weight

772 lbs. (350 kg)

Front Rack/Storage Box Capacity 120 lbs. (54 kg)

Rear Rack Capacity

Hitch Tongue Weight

240 lbs. (109 kg)

150 lbs. (68 kg) (Rear rack capacity and tongue

weight not to exceed 240 lbs./109 kg)

Hitch Towing Rating

1500 lbs. (680 kg) on level ground

1995 lbs. (905 kg)

Unbraked Trailer Towing

Capacity*

Overall Length

86.5 in. (219.7 cm)

47.6 in. (121 cm)

58.25 in. (148 cm)

57 in. (145 cm)

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Fuel Capacity

11.25 in. (28.6 cm)

96 in. (244 cm) unloaded

4.5 gal. (17 l)

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Fluid Capacity

Rear Gearcase Fluid Capacity

Fuel System

2 qts. (1.9 l)

9.3 oz. (275 ml)

32 oz. (946 ml)

7.1 oz. (210 ml)

Visteon Electronic Fuel Injection

Electronic Fuel Pump (in tank)

ES550PLE011

Fuel Delivery

Engine

Displacement

549 cc

Bore x Stroke

96.6 x 75 mm

Alternator Output

Compression Ratio

Starting System

Ignition System

Ignition Timing

Idle RPM**

490w @ 1350 RPM/Peak 630w

9.6:1

Electric

Visteon EFI (ECU Controlled)

13° +/- 3° BTDC @ 1650 RPM

1750 +/- 50

Throttle Body/Size

Spark Plug / Gap

Mikuni/42 mm

NGK BKR6E / .035 in. (0.9 mm)

* Based on EU Directive 76/432/EC

**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.

136

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

SPORTSMAN 550 Touring EPS

Lubrication System

Pressurized Wet Sump

Transmission Type

Automatic PVT (Polaris Variable Transmission)

In-Line H-L-N-R-P

Front Suspension

Dual a-arm, 9" (22.9 cm) travel

Rear Suspension

Dual a-arm with Rolled IRS, 10" (25.4 cm) travel

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

5.034:1

4.508:1

2.693:1

3.818:1

3.7:1

Drive Ratio, Rear

Tire Type/Pressure, Front

Maxxis AT 26 x 8 - 14

7 psi (48.3 kPa)

Tire Type/Pressure, Rear

Maxxis AT 26 x 10 - 14

5 psi (34.5 kPa)

Brakes, Front/Rear

Brake, Auxiliary

Brake, Parking

Headlight

Single-Control Hydraulic Disc, All-Wheel

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

Taillight

12v/7 watts

Brake Light

Instrumentation

12v/27 watts

Multifunction Instrument Cluster

Clutching

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Meters

(Feet)

0-1800

(0-6000)

23-58

PN 1322911

Red/Black

PN 7043500

Red/White

PN 3234621

1800-3700

(6000-12000)

23-54

PN 1322914

Red/Black

PN 7043500

Red/White

PN 3234621

137

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

SPORTSMAN 850 Touring EPS

Maximum Weight Capacity

735 lbs. (333 kg) (includes operator, passenger,

cargo, accessories)

Dry Weight

798 lbs. (362 kg)

Front Rack/Storage Box Capacity 120 lbs. (54 kg)

Rear Rack Capacity

Hitch Tongue Weight

240 lbs. (109 kg)

150 lbs. (55 kg) (Rear rack capacity and tongue

weight not to exceed 240 lbs./55 kg)

Hitch Towing Rating

1500 lbs. (680 kg) on level ground

1995 lbs. (905 kg)

Unbraked Trailer Towing

Capacity*

Overall Length

86.5 in. (219.7 cm)

47.6 in. (121 cm)

58.25 in. (148 cm)

57 in. (145 cm)

11.25 in. (28.6 cm)

96 in. (244 cm) unloaded

4.5 gal. (17 l)

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Fuel Capacity

Engine Oil Capacity

Coolant Capacity

2 qts. (1.9 l)

Demand Drive Fluid Capacity

Transmission Fluid Capacity

Rear Gearcase Fluid Capacity

Fuel System

9.3 oz. (275 ml)

32 oz. (946 ml)

7.1 oz. (210 ml)

Bosch Multi-Port Sequential Electronic Fuel

Injection

Fuel Delivery

Engine

Electronic Fuel Pump (in tank)

EH085OLE013

Displacement

Bore x Stroke

Alternator Output

Compression Ratio

Starting System

Ignition System

Ignition Timing

Idle RPM

850 cc

87 x 71.5 mm

475w @ 1200 RPM/Peak 575w

11.0:1

Electric

Bosch EFI (ECU Controlled)

6° +/- 5° BTDC @ 1200 RPM

1200 +/- 50

Throttle Body/Size

Spark Plug / Gap

Mikuni Dual Bore/40 mm

REA8MCX / .035 in. (0.9 mm)

* Based on EU Directive 76/432/EC

138

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

SPORTSMAN 850 Touring EPS

Lubrication System

Pressurized Wet Sump

Transmission Type

Automatic PVT (Polaris Variable Transmission)

In-Line H-L-N-R-P

Front Suspension

Dual a-arm, 9" (22.9 cm) travel

Rear Suspension

Dual a-arm with Rolled IRS, 10" (25.4 cm) travel

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

5.034:1

4.508:1

2.367:1

3.818:1

3.7:1

Drive Ratio, Rear

Tire Type/Pressure, Front

Maxxis AT 26 x 8 - 14

7 psi (48 kPa)

Tire Type/Pressure, Rear

Maxxis AT 26 x 10 - 14

5 psi (34.5 kPa)

Brakes, Front/Rear

Brake, Auxiliary

Brake, Parking

Headlight

Single-Control Hydraulic Disc, All-Wheel

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

Taillight

12v/7 watts

Brake Light

Instrumentation

12v/27 watts

Multifunction Instrument Cluster

Clutching

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Meters

(Feet)

0-1800

(0-6000)

24-68

PN5632418

Red/Green

PN 7043382

Red/White

PN 3234621

1800-3700

(6000-12000)

24-63

PN 5632215

Red/White

PN 7043349

Red/White

PN 3234621

139

Download from Www.Somanuals.com. All Manuals Search And Download.

DECLARATION OF CONFORMITY

Polaris Industries Inc.,

2100 Hwy 55, Medina, MN 55340 U.S.A.

Telephone 763-542-0500

We, Polaris Industries Inc., declare that the vehicles listed below conform to the

essential health and safety requirements applicable to off-road all-terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES

TEST / EVALUATION METHODS

98/37/EC as amended (Machinery Directive)

EN 1050 hazard analysis

CD 77/311/EEC driver-perceived noise level

2004/108/EC as amended (EMC Directive)

CISPR 12:2001

CAN/CSA-C108.4-M92

EN 55012:2002

EN 61000-6-2:2001

PRODUCT IDENTIFICATION

VEHICLE SERIES

TRADE NAME

MODEL

YEARS

SOUND

PRESSURE

dB (A)

___KA05__

___KA09__

___FA09__

___VA17__

___PB20__

___BA32__

___CA32__

___BA50__

___GJ45__

___GJ52__, ___GP52__

___LH27__

___LH46__

___MN50__

OUTLAW 50

OUTLAW 90

SPORTSMAN 90

RZR 170

PHOENIX 200

TRAIL BLAZER 330

TRAIL BOSS 330

SCRAMBLER 500

OUTLAW 450

2008, 2009, 2010

2009, 2010

76.8

81.3

76.8

79.6

80.7

81.1

80.2

80.4

80.8

77.2

83.6

77.2

80.1

80.4

76.5

85.8

2008, 2009, 2010

2009, 2010

OUTLAW 525

SPORTSMAN 300

SPORTSMAN 400

SPORTSMAN 500 EFI

SPORTSMAN 550 EFI

___ZN55__ ___ZX55__

___TN55__, ___DN55__ SPORTSMAN X2/TOURING 550 2010

___MN76__ SPORTSMAN 800 2008, 2009, 2010

___TN85__, ___DN85__ SPORTSMAN X2/TOURING 850 2010

___CL76__

___ZN85__, ___ZX85__

SPORTSMAN 800 6X6

SPORTSMAN 850 EFI

2009, 2010

2010

___RH50__, ___HH50__ RANGER 500 EFI 4X4

___HH76__

___WH76__

___HR__

___HY__

___VH76__

RANGER 800 EFI 4X4

RANGER 800 EFI CREW

RANGER 800 6X6

RANGER HD 800 4X4

RANGER RZR

2010

2008, 2009, 2010

Authorized Signatory:

__________________________________

Alexander A. Kennedy, Product Compliance

Polaris Industries Inc., Engineering Operations

301 5th Avenue SW, Roseau, MN 56751

140

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 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 (if equipped) 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 transfer-

able 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.

141

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in

material or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any 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.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental

conditions and/or contamination for which they were not designed or not intended,

including but not limited to the following items:

•

Wheels and tires

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered “consumable,” meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

•

Spark Plugs

Filters

Fuel

Sealants

Hotel fees

Towing charges

Mileage

Rentals/Loss of product use

•

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Meals

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

142

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

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 the 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.

143

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY 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 law, 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 USFS standard 5100-1c for at least 1000 hours when subjected to normal use

and when maintenance and installation are in accordance with Polaris recommendations.

144

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY 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 dealer. 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 you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you 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.

145

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

How to Get Service

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen, to be kept and used outside of

the country in which the vehicle was originally purchased, all warranty coverage will be

denied.

Notice

If your vehicle is registered outside of the country where 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

146

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the Polaris standard limited warranty

for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this

emissions-certified vehicle is designed, built and equipped so it conforms with applica-

ble U.S. Environmental Protection Agency emission regulations. Polaris warrants that

the vehicle is free from defects in materials and workmanship that would cause it to fail

to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is

first purchased and continues for a period of 500 hours of engine operation, 5000 kilo-

meters (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase,

whichever comes first.

This emissions limited warranty covers components whose failure increases the vehi-

cle’s regulated emissions, and it covers components of systems whose only purpose is to

control emissions. Repairing or replacing other components not covered by this war-

ranty is the responsibility of the vehicle owner. This emissions limited warranty does not

cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emis-

sions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative emis-

sions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

147

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

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 structurally altered, or when the vehicle has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of Polaris.

Owners are responsible for performing the scheduled maintenance identified in the

owner's manual. Polaris may deny warranty claims for failures that have been caused by

the owner’s or operator’s improper maintenance or use, by accidents for which Polaris

has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission con-

trol devices or systems on your vehicle. Polaris recommends that you contact an autho-

rized Polaris dealer to perform any service that may be necessary for your vehicle.

Polaris also recommends that you use only Pure Polaris parts. It is a potential violation

of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the

effectiveness of the vehicle's emission controls. Tampering with emission controls is

prohibited by federal law.

If you have any questions regarding your warranty rights and responsibilities, please

contact the Polaris Warranty Department at 1-888-704-5290.

148

Download from Www.Somanuals.com. All Manuals Search And Download.

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

149

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

0-9

4X4 Switch . . . . . . . . . . . . . . . . . 26, 37

Clutching (550). . . . . . . . . . . . . . . . 137

Clutching (850). . . . . . . . . . . . . . . . 139

Cold Weather Operation. . . . . . . . . . 57

Consumer Product Safety . . . . . . . . . . 7

Coolant Bottle. . . . . . . . . . . . . . . . . . 91

Coolant, Radiator . . . . . . . . . . . . . . . 92

Cooling System. . . . . . . . . . . . . . 90-92

Corrosion Removal, Chrome . . . . . 126

Crankcase Emission Control System 75

Accessories . . . . . . . . . . . . . . . . . . . 129

Active Descent Control Fluid . . . 88-89

Active Descent Control System . . . . 39

ADC System . . . . . . . . . . . . . . . . . . . 39

Air Filter . . . . . . . . . . . . . . . . . . . . . 101

All Wheel Drive System. . . . . . . 37-38

Auxiliary Foot Brake . . . . . . . . . . . . 93

Demand Drive Fluid . . . . . . . . . . . . . 86

Diagnostic Codes (550) . . . . . . . 48-49

Diagnostic Codes (850) . . . . . . . 50-51

Disengaging Active Descent Control 39

Display, Standard/Metric . . . . . . . . . 44

Drink Holders . . . . . . . . . . . . . . . . . . 34

Drive Belt Wear/Burn. . . . . . . . . . . 131

Drivetrain Break-In. . . . . . . . . . . . . . 53

Driving Downhill . . . . . . . . . . . . . . . 65

Driving in Reverse . . . . . . . . . . . . . . 70

Driving on a Sidehill. . . . . . . . . . . . . 64

Driving on Slippery Surfaces . . . . . . 62

Driving Over Obstacles . . . . . . . . . . 69

Driving Procedures . . . . . . . . . . . . . . 58

Driving Through Water . . . . . . . . . . 68

Driving Uphill. . . . . . . . . . . . . . . . . . 63

Driving with a Passenger . . . . . . 60-61

Battery . . . . . . . . . . . . . . . . . . 115-120

Charging (Conventional) . . . . 119

Charging (Sealed) . . . . . . 119-120

Fluid (Conventional). . . . . . . . 118

Installation . . . . . . . . . . . . . . . 117

Removal . . . . . . . . . . . . . . . . . 116

Storage . . . . . . . . . . . . . . . . . . 118

Belt Life . . . . . . . . . . . . . . . . . . . . . . 33

Beverage Holders . . . . . . . . . . . . . . . 34

Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Box, Front . . . . . . . . . . . . . . . . . . . . . 36

Brake Fluid, Auxiliary Foot Brake . . 32

Brake Fluid, Main Brake System . . . 30

Brake Lever. . . . . . . . . . . . . . . . . . . . 29

Brake, Foot . . . . . . . . . . . . . . . . . 32, 93

Brake, Hand Lever . . . . . . . . . . . . . . 93

Brake, Parking . . . . . . . . . . . . . . . . . 31

Brakelight Lamp Replacement . . . . 107

Brakes . . . . . . . . . . . . . . . . . . . . . . . . 93

Break-In Period. . . . . . . . . . . . . . 52-53

Electromagnetic Interference . . . . . . 75

Electronic Power Steering . . . . . . . . 34

Emissions Limited Warranty . 147-148

Engaging 4X4 . . . . . . . . . . . . . . . . . . 38

Engaging Active Descent Control . . 39

Engine Break-In . . . . . . . . . . . . . . . . 53

Engine Fogging. . . . . . . . . . . . . . . . 128

Engine Oil. . . . . . . . . . . . . . . . . . 81-83

Engine Stop Switch. . . . . . . . . . . . . . 27

EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 34

EPS Warning Indicator. . . . . . . . . . . 42

Equipment Modifications . . . . . . . . . . 9

Etiquette, Trail Riding . . . . . . . . . . . 56

Exhaust Emission Control System . . 75

Eye Protection. . . . . . . . . . . . . . . . . . . 9

Camber Adjustment . . . . . . . . . . . . 121

Cargo. . . . . . . . . . . . . . . . . . . . . . 73-74

Cargo Loading . . . . . . . . . . . . . . . . . 72

Caster Adjustment. . . . . . . . . . . . . . 121

Chrome Wheel Care . . . . . . . . . . . . 126

Cleaning and Storage . . . . . . . 124-129

Clothing . . . . . . . . . . . . . . . . . . . . . . . 9

151

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Fluid

Hand Brake . . . . . . . . . . . . . . . . . . . . 93

Handlebar Adjustment. . . . . . . . . . . 121

Hauling Cargo . . . . . . . . . . . . . . . 72-74

Headlight Housing Replacement. . . 106

Headlight Lamp Replacement . . . . . 103

Headlight Switch . . . . . . . . . . . . . . . . 27

Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8

High Beam Adjustment . . . . . . . . . . 104

High Range Use. . . . . . . . . . . . . . . . 114

Hub Tightening . . . . . . . . . . . . . . . . . 99

Active Descent Control . . . . . . 88

ADC. . . . . . . . . . . . . . . . . . . 88-89

Brake . . . . . . . . . . . . . . . . . . . . 30

Demand Drive . . . . . . . . . . . . . 86

Engine Oil . . . . . . . . . . . . . . 81-83

Front Gearcase. . . . . . . . . . . . . 86

Rear Gearcase Oil . . . . . . . . . . 87

Transmission . . . . . . . . . . . . 84-85

Fluid Change

ADC. . . . . . . . . . . . . . . . . . . . . 89

Demand Drive . . . . . . . . . . . . . 86

Engine Oil . . . . . . . . . . . . . . 82-83

Rear Gearcase . . . . . . . . . . . . . 87

Transmission . . . . . . . . . . . . . . 85

Idle RPM Adjustment . . . . . . . . . . . 122

Immersion Maintenance . . . . . . . . . 110

Instrument Cluster . . . . . . . . . . . . 40-51

Fluid Level

ADC. . . . . . . . . . . . . . . . . . . . . 88

Brake . . . . . . . . . . . . . . . . . . . . 30

Brake (Auxiliary). . . . . . . . . . . 32

Brake Fluid . . . . . . . . . . . . . . . 30

Coolant (Bottle) . . . . . . . . . . . . 91

Coolant (Radiator) . . . . . . . . . . 92

Demand Drive . . . . . . . . . . . . . 86

Engine Oil . . . . . . . . . . . . . . . . 81

Rear Gearcase . . . . . . . . . . . . . 87

Transmission . . . . . . . . . . . . . . 84

Foot Brake, Auxiliary . . . . . . . . . . . 32

Footwell Removal . . . . . . . . . . . . . . 97

Front Box. . . . . . . . . . . . . . . . . . . . . 36

Front Gearcase Fluid . . . . . . . . . . . . 86

Fuel Recommendations . . . . . . . . . . 35

Fuel Safety. . . . . . . . . . . . . . . . . . . . 11

Fuel Tank Cap . . . . . . . . . . . . . . . . . 35

Fuse Replacement . . . . . . . . . . . . . 102

Key Switch . . . . . . . . . . . . . . . . . . . . 27

K-Turn . . . . . . . . . . . . . . . . . . . . . 66-67

Lights . . . . . . . . . . . . . . . . . . . 103-107

Headlight Housing. . . . . . . . . . 106

Headlight Lamp. . . . . . . . . . . . 103

High Beam Adjustment . . . . . . 104

Low Beam Adjustment . . . . . . 105

Lower Headlamp Replacement 107

Taillight/Brakelight/Worklight 107

Low Beam Adjustment . . . . . . . . . . 105

Low Range Use . . . . . . . . . . . . . . . . 114

Lower Headlamp Replacement . . . . 107

Lubrication Guide . . . . . . . . . . . . . . . 80

Maintenance Chart. . . . . . . . . . . . 76-79

Master Cylinder. . . . . . . . . . . . . . . . . 30

Metric/Standard Display . . . . . . . . . . 44

Mode Switch . . . . . . . . . . . . . . . . . . . 26

Modifications. . . . . . . . . . . . . . . . . . . . 9

Gasoline Handling . . . . . . . . . . . . . . 11

Gear Selector . . . . . . . . . . . . . . . . . . 33

Gearcase Oil, Front . . . . . . . . . . . . . 86

Gearcase Oil, Rear. . . . . . . . . . . . . . 87

Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9

Noise Emission Control System . . . . 75

152

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Oil

Safe Operation Practices. . . . . . . . . . 55

Safety Labels . . . . . . . . . . . . . . . 22-25

Age 16 Warning . . . . . . . . . . . . 22

AWD Caution . . . . . . . . . . . . . . 22

Clutch Cover Warning . . . . . . . 25

Discretionary Warning . . . . . . . 24

General Warning. . . . . . . . . . . . 23

Passenger Safety Warning . . . . 24

Rack Warning . . . . . . . . . . . . . . 25

Reverse Override Warning . . . . 22

Tire Pressure/Load Warning. . . 24

Safety Training . . . . . . . . . . . . . . . . . . 7

Safety Warnings . . . . . . . . . . . . 10-21

Age Restrictions . . . . . . . . . . . . 10

Carrying a Passenger . . . . . . . . 12

Carrying Multiple Passengers. . 12

Crossing Hillsides. . . . . . . . . . . 15

Deep Water . . . . . . . . . . . . . . . . 19

Descending Hills Improperly . . 15

Excessive Speeds . . . . . . . . . . . 13

Exhaust Exposure . . . . . . . . . . . 11

Failure to Inspect . . . . . . . . . . . 11

Frozen Bodies of Water . . . . . . 20

Handling Gasoline . . . . . . . . . . 11

Hot Exhaust Systems . . . . . . . . 21

Improper Cargo Loading . . . . . 19

Improper Hill Climbing . . . . . . 15

Improper Tire Maintenance . . . 18

Jumps and Stunts . . . . . . . . . . . 14

Operating a Damaged ATV . . . 21

Operating on Pavement. . . . . . . 13

Operating on Public Roads . . . . 13

Operating on Steep Hills. . . . . . 16

Operating Over Obstacles. . . . . 18

Operating Without Instruction . 10

Physical Control of the ATV . . 14

Physical Skills. . . . . . . . . . . . . . 21

Poor Visibility. . . . . . . . . . . . . . 20

Engine . . . . . . . . . . . . . . . . . 81-83

Rear Gearcase . . . . . . . . . . . . . . 87

Transmission. . . . . . . . . . . . 84-85

Oil Change

Engine Oil and Filter. . . . . . 82-83

Rear Gearcase . . . . . . . . . . . . . . 87

Transmission. . . . . . . . . . . . . . . 85

Oil Level

Engine . . . . . . . . . . . . . . . . . . . . 81

Rear Gearcase . . . . . . . . . . . . . . 87

Transmission. . . . . . . . . . . . . . . 84

Oil Recommendations. . . . . . . . . . . . 81

Operation on Public Lands . . . . . . . . 75

Override Switch . . . . . . . . . . . . . . . . 26

Parking Brake . . . . . . . . . . . . . . . . . . 31

Parking on an Incline . . . . . . . . . . . . 71

Passenger Seat. . . . . . . . . . . . . . . . . . 34

Periodic Maintenance Chart . . . . 76-79

Polaris Product List. . . . . . . . . . . . . 135

Polishing the Vehicle . . . . . . . . . . . 125

Power Steering . . . . . . . . . . . . . . . . . 34

Power Steering Unit (Cleaning) . . . . 90

Pre-Ride Checklist . . . . . . . . . . . . . . 54

PVT Break-In . . . . . . . . . . . . . . . . . . 53

PVT Drying. . . . . . . . . . . . . . . . . . . 114

PVT System . . . . . . . . . . . . . . 112-114

Rear Gearcase Oil . . . . . . . . . . . . . . . 87

Reverse Operation. . . . . . . . . . . . . . . 70

Reverse Override Switch . . . . . . . . . 26

Rider Information Center . . . . . . 41-51

Riding Area. . . . . . . . . . . . . . . . . . . . 56

Riding Gear. . . . . . . . . . . . . . . . . . . 8-9

153

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Safety Warnings. . . . . . . . . . . . . 10-21

Protective Apparel . . . . . . . . . . 12

Reverse Operation . . . . . . . . . . 17

Skidding or Sliding . . . . . . . . . 18

Slippery Terrain. . . . . . . . . . . . 17

Stalling While Climbing a Hill 16

Turning Improperly . . . . . . . . . 14

Unauthorized Use . . . . . . . . . . 21

Unfamiliar Terrain. . . . . . . . . . 17

Using Alcohol or Drugs. . . . . . 12

Seat Adjustments, Passenger . . . . . . 95

Seat Removal, Operator. . . . . . . . . . 96

Seat Removal, Passenger. . . . . . . . . 95

Seat Suspension, Passenger . . . . . . . 96

Seats. . . . . . . . . . . . . . . . . . . . . . . 95-96

Severe Use . . . . . . . . . . . . . . . . . . . . 76

Side Panel Removal. . . . . . . . . . . . . 97

Sidehilling . . . . . . . . . . . . . . . . . . . . 64

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor . . . . . . . . . . . . . . . . 111

Spark Plug Inspection . . . . . . . 108-109

Spark Plug Recommendations. . . . 108

Spark Plug Torque Specification. . 108

Spark Plugs . . . . . . . . . . . . . . . 108-109

Specifications. . . . . . . . . . . . . . 136-139

Spring Adjustment, Rear Shock . . 121

Standard/Metric Display . . . . . . . . . 44

Starting the Engine . . . . . . . . . . . . . 57

Steering Assembly. . . . . . . . . . . . . . 90

Storage. . . . . . . . . . . . . . . . . . . 124-129

Storage Box, Front. . . . . . . . . . . . . . 36

Storage Tips. . . . . . . . . . . . . . . 127-129

Suspension, Passenger Seat . . . . . . . 96

Switches

Taillight Lamp Replacement . . . . . . 107

Throttle Body Adjustment. . . . . . . . 122

Throttle Cable Freeplay. . . . . . 122-123

Throttle Lever . . . . . . . . . . . . . . . . . . 28

Tire Tread Depth . . . . . . . . . . . . . . . . 98

Tires . . . . . . . . . . . . . . . . . . . . . 98-100

Wheel Installation . . . . . . . . . . 100

Wheel Nut Torque . . . . . . . . . . 100

Wheel Removal . . . . . . . . . . . . . 99

Toe Alignment. . . . . . . . . . . . . . . . . . 94

Towing Capacities. . . . . . . . . . . . . . . 74

Towing Loads . . . . . . . . . . . . . . . . . . 74

Trail Etiquette . . . . . . . . . . . . . . . . . . 56

Training . . . . . . . . . . . . . . . . . . . . . . . . 7

Transmission . . . . . . . . . . . . . . . . . . . 33

Transmission Oil . . . . . . . . . . . . . 84-85

Transporting the ATV . . . . . . . . . . . 130

Tread Lightly. . . . . . . . . . . . . . . . . . . 56

Turning Around on a Hill . . . . . . 66-67

Turning the Vehicle. . . . . . . . . . . . . . 59

Vehicle Identification Numbers. . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . 110

VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . 124-125

Wheel Installation . . . . . . . . . . . . . . 100

Wheel Nut Torque Specifications . . 100

Wheel Removal . . . . . . . . . . . . . . . . . 99

4X4 Switch . . . . . . . . . . . . 26, 37

Engine Stop Switch . . . . . . . . . 27

Headlight Switch . . . . . . . . . . . 27

Main Key Switch. . . . . . . . . . . 27

Mode/Reverse Override Switch 26

154

Download from Www.Somanuals.com. All Manuals Search And Download.

Perlick Beverage Dispenser Party Pumps Tapping Equipment User Manual
Phase Technology Portable Speaker FP6030 User Manual
Philips Computer Monitor 107C64 User Manual
Philips Portable CD Player CD15 00 User Manual
Philips TV Receiver DCR5000 User Manual
Poulan Trimmer 545192168 User Manual
Primera Technology Printer LX810e User Manual
Prince Castle Kitchen Utensil CC User Manual
Profoon Telecommunicatie Telephone TX 230 User Manual
PYLE Audio DJ Equipment PYD1000 User Manual