Polaris 2010 Sportsman 550 XP, 2010 Sportsman 550 XP EPS, 2010 Sportsman 850 XP, 2010 Sportsman 850 XP EPS Owner's Manual

Pantone 426C

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

Owner's Manual

for Maintenance and Safety

Sportsman 550 XP

Sportsman 550 XP EPS

Sportsman 850 XP

Sportsman 850 XP EPS

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 1-800-342­3764 for assistance.

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Pantone 426C

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER operate:

S without proper training or instruction.
S at speeds too fast for your skills or the conditions.
S on public roads - a collision can occur with another

vehicle.
S with a passenger - passengers affect balance and

steering and increase risk of losing control.

ALWAYS:
S use proper riding techniques to avoid vehicle

overturns on hills and rough terrain and in turns.
S avoid paved surfaces - pavement may seriously affect

handling and control.

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

ALWAYS USE

AN APPROVED

HELMET AND
PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9922452 Rev 04
Printed in USA

1

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world­wide 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 recre­ational vehicles manufactured in the world today. Many years of experi­ence have gone into the engineering, design, and development of your
Polaris vehicle.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a factory certified Master Service Dealer

®

(MSD)

technician.
Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces­sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2

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

Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. 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 XP/XP EPS Owner’s Manual
P/N 9922452

3

TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Emission Control Systems . . . . . . . . . . . . . . . 67

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 125

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 126

Declaration of Conformity . . . . . . . . . . . . . . . 130

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 139

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4

INTRODUCTION

The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym­bols 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.

5

INTRODUCTION

Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A Polaris ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a Polaris ATV. Keep this manual with
the ATV.

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

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.

• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.

WARNING

6

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.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

####

VIN

Engine Serial Number

Key

Number

550 850

7

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

sm

for a fee. Call ATV Enrollment Express at

[phone] 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 vehi­cle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800­638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.

8

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

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.

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When­ever 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) mow­ers, blades, tires, sprayers, or large racks, may change the handling char­acteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.

10

SAFETY

Safety Warnings

Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.

Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.

Never permit a guest to operate the ATV unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.

Even though a child may be within the
recommended age group for operating some ATVs,
he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and
could be susceptible to accident or injury.

WARNING

11

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.

12

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.

Always wear an approved helmet that fits
properly and eye protection (goggles or face
shield).

Using Alcohol or Drugs

Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.

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

Carrying a Passenger

Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
overturn.

Never carry a passenger on this ATV.

13

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.

Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.

14

SAFETY

Safety Warnings

Physical Control of the ATV

Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
ATV. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.

Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of
traction, loss of control, accident or overturn.

Always follow proper procedures for turning
as described in the owner's manual.

Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.

Jumps and Stunts

Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.

Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 57. Always
move the 4X4 switch to ADC 4X4 before
ascending or descending a hill.

15

SAFETY

Safety Warnings

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. NOTE: A special technique is
required when braking while traveling down­hill. See page 59.

• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral. Always move the
4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 36.

• 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 58.

Never attempt to turn the ATV around on any hill
until you've mastered the turning technique (on
level ground) as described in the owner's
manual. See page 60.

16

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 36.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the brakes.

• Lock the parking brake when fully stopped.

• Dismount on uphill side, or to either side if ATV is pointed straight uphill.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 60.

If the ATV begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.

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

• Dismount on uphill side, or to either side if ATV is pointed straight uphill.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 60.

Operating on Steep Hills

Operating on excessively steep hills could cause
an overturn.

Never operate on hills too steep for the ATV or for
your abilities. Never operate the ATV on hills
steeper than 25 degrees.

17

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. 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.

18

SAFETY

Safety Warnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 63.

Before shifting into reverse gear, always check for obstacles or people behind
the ATV. When it's safe to proceed, back slowly.

Improper Tire Maintenance

Operating this ATV with improper tires
or with improper or uneven tire
pressure could cause loss of control or
accident.

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

Always maintain proper tire pressure as
described in the owner's manual and
on safety labels.

19

SAFETY

Safety Warnings

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 62.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.

Operating Through Deep Water

Operating the ATV through deep or fast­flowing water could cause the tires to float,
causing loss of control or overturn.

Avoid operating the ATV through deep or
fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page

61):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

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

stops, and do not make sudden throttle changes.

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

brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.

20

SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.

• Never exceed the stated load capacity for this ATV.

• Cargo should be properly distributed and securely attached.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater dis­tance for braking.

• Always follow the instructions in the owner's manual for carrying cargo or pull­ing a trailer.

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the
ATV and/or the operator fall through the ice.

Never operate the ATV on a frozen body of water.

Poor Visibility

Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.

21

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.

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.

22

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, con­tact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge. The part number is printed
on the label.

General Warning

WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk
of losing control

ALWAYS:

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

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

LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

23

SAFETY

Safety Labels and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 25 degrees 25°. To pre-

vent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.

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

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

7175511

Age 16 Warning

WARNING
Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death.
NEVER operate this ATV if you are under age 16.

7175374

Reverse Override Warning/4X4 Caution

WARNING
Improper use of the override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.

CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This

may cause severe drive shaft and clutch damage.

7175512

Discretionary WarningGeneral Warning

Reverse Override Warning

4X4 Caution

Age 16 Warning

24

SAFETY

Safety Labels and Locations

“No Passenger” Warning

WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7175378

Tire Pressure/Load Warning

WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 7.0 psi (48.3 kPa)
Rear: 5.0 psi (34.5 kPa)

• Maximum weight capacity: 575 lbs. (261 kg)

7175440

“No Passenger”

Warning

Tire

Pressure/Load

Warning

25

SAFETY

Safety Labels and Locations

Clutch Cover Warning

WARNING

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

operate vehicle with guard removed.

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

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

7175488

Rack Warning, Front and Rear

WARNING

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

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

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

7175448

Hitch Capacity Label

TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

7170509

+

Clutch Cover

Warning

+

+

Rack

Warning

Rack

Warning

26

FEATURES AND CONTROLS

Switches

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and depress
the override button.

WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.

The reverse override button also acts as a MODE button when held
down for approximately one half second. The transmission cannot be in
reverse when using the override button as a MODE button.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 36. The
vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.

2x4

Mode/Reverse

Override

Button

Main Key

Switch

Engine

Stop Switch

Headlight

Switch

4X4 Switch

27

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 attempt­ing to start the engine. The engine will not start or run when the switch
is off.

Both the main switch and the engine stop switch will shut off all electri­cal power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 53 for starting pro­cedures.

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
and the engine stop switch must be in the RUN position to operate the
headlights.

OFF OFFRUN

28

FEATURES AND CONTROLS

Throttle Lever

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 Con­trol (ETC), which is designed to
reduce the risk of a frozen or
stuck throttle. If the throttle
cable should stick in an open position when the operator releases the
throttle lever, engine speed will be limited, and power to the rear wheels
will be reduced.

WARNING

2x4

29

FEATURES AND CONTROLS

Brake Lever

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.

WARNING

30

FEATURES AND CONTROLS

Master Cylinder/Brake Fluid

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.

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
cylinder. The eye will
appear dark when the fluid
level is full. When fluid is
low, the eye will be clear.

4. If the fluid level is low, remove the cover screws and add fluid to the

fill line. Do not overfill. Use DOT 4 brake fluid only.

5. Reinstall the cover. Torque screws to 7 in. lbs. (.8 Nm).

WARNING

Master

Cylinder

Indicator

Window

31

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.

32

FEATURES AND CONTROLS

Auxiliary Foot Brake

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, which may result in serious injury or death.

The auxiliary brake system is
intended to be used as a backup for
the main brake system. Should the
main system fail, use the auxiliary
foot brake.

The auxiliary foot brake is located
on the inside of the right footrest.
Operate this brake with your right
foot.

If the rear wheels slide while using
the auxiliary brake, reduce brake
pedal pressure to brake the rear
wheels without skidding.

Brake Fluid Level

Check the brake fluid level fre­quently for the auxiliary brake sys­tem. The reservoir is located under
the front rack.

Maintain the fluid level between
the maximum and minimum marks.
Use DOT 4 brake fluid only.

NOTICE: Do not use ADC fluid in the

brake fluid reservoir. ADC
fluid will damage the rubber
components of the brake
system.

WARNING

Auxiliary

Foot Brake

Brake Fluid

Reservoir

33

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 39 for EPS Warning Indicator information.

Automatic Transmission Gear Selector

The transmission gear selector is
located on the right side of the vehicle.

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.

Fuel Tank

Always refuel with the engine stopped,
and outdoors or in a well ventilated area.
Refuel on a level surface.

Remove the fuel tank cap and add fuel.
Use either leaded or unleaded gasoline
with a minimum pump octane number of
87=(R+ M/2) octane. Do not use 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.

Gear

Selector

Fuel Tank

Cap

34

FEATURES AND CONTROLS

All Wheel Drive System

The All Wheel Drive system is
controlled by the 4X4 switch.

ADC 4X4 Mode

When the switch is on ADC 4X4,
the ADC system allows engine
braking to all four wheels when
the vehicle descends a hill or
incline. Always move the 4X4
switch to ADC 4X4 before
ascending or descending a hill.
See page 36.

4X4 Mode

When the switch is on 4X4, the
ATV is in 4X4, and the 4X4 indi­cator icon in the instrument clus­ter display will be visible.

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.

2x4

4X4

Switch

ADC 4X4

35

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.

36

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 follow­ing conditions occur:

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

• Vehicle speed must be 15 mph (25 km/h) or less

• The throttle must be closed (throttle lever released)

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

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the fol­lowing conditions occur:

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

• Vehicle speed exceeds 15 mph (25 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

37

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 dis­plays 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 diagnos­tic display mode. These features are outlined on the following pages.

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.

Rider Information Center

Directional

Indicator

High Beam

Indicator

Neutral

Indicator

Over-Temperature

Indicator

EPS Warning

Indicator

(if equipped)

38

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All seg­ments 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 speedome­ter. If this occurs, take the ATV to your Polaris dealer for proper diagno­sis.

The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 41.

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.

1

3

4

8

6

5

9

7

10

11

2

12

39

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 40.

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 dis­play for 5-10 seconds. See page 42 for resetting instructions.

7. Engine Overheat Warning - This indicator flashes to indicate an

overheated engine. If the indicator stops flashing but remains illu­minated, 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 42
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.

40

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 over­ride button as a MODE button.
This feature does not contain a
vehicle speed lockout function and
can be used at any operating
speed.

Ground Speed Mode

Ground speed is displayed in either miles per hour (MPH) or kilometers
per hour (km/h).

Engine Speed Mode

Engine speed is displayed in revolutions per minute (RPM).

MODE
Button

SELECT

Button

41

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 vehi­cle 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 measure­ment. To change units:

1. Press and hold the MODE button until vehicle speed is displayed.

2. Toggle through the information area using the SELECT button until

the odometer is displayed.

3. Press and hold the MODE button until the displayed units change.

Release the button.

4. New settings remain until changed using the same procedure.

12-Hour/24-Hour Clock Display

1. Press and hold the MODE button until RPM is displayed.

2. Toggle through the information area using the SELECT button until

the odometer is displayed.

3. Press and hold the MODE button until the clock displays the new

clock format (either 24-hour or 12-hour). Release the button.

4. New settings remain until changed using the same procedure.

Odometer Mode

The odometer records and displays 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 clus­ter until the total changes to 0. In the Rider Information Center, the trip
meter display contains a decimal point, but the odometer displays with­out a decimal point.

Hour Meter Mode

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

42

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 pro­grammed 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.

43

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 deter­mination 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 indi­cates the fault mode, such as open or short circuit.

4. See pages 44-47 for code definitions and failure descriptions.

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

gle through all currently active diagnostic codes.

44

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 XP / XP EPS Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor

Voltage Too High 51 3
Voltage Too Low 51 4

Engine Temperature Sensor

Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0

Intake Air Temperature Sensor

Voltage Too High 105 3
Voltage Too Low 105 4

Manifold Absolute Pressure Sensor Voltage Too High 102 3

Voltage Too Low 102 4
Crankshaft Position Sensor Circuit Fault 636 8
Gear Sensor Signal Voltage Too Low (to Calibrate) 523 4

Voltage Too High 523 3

Signal Fault 523 2
Injector 1 (MAG) Driver Circuit Open/Grounded 651 5

Driver Circuit Short to B+ 651 3
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5

Driver Circuit Short to B+ 1268 3
Fuel Pump Driver Circuit

Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

Driver Circuit Short to B+ 1071 3

45

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

*Assumes unipolar configuration of stepper motor

Sportsman 550 XP / XP EPS Diagnostic Codes

Component Condition SPN FMI

Idle Air Control Driver Circuit Grounded 520193 5

Shorted Load* 520193 11
Starter Enable Circuit Driver Circuit Short to B+ 1321 3
All Wheel Drive Control Driver Circuit Short to B+ 520207 3
System Power Voltage Too High 168 3

Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3

Voltage Too Low 520194 4

Signal Out of Range 520194 2

Throttle Stuck 520194 7
Active Descent Control System Driver Circuit Short to B+ 520203 3

EPS Models Only

Steering Over Current Shut Down Current Above Normal or

Grounded

520221 6

Steering Excessive Current Error Current Above Normal or

Grounded

520222 6

Steering Torque Sensor T1 Partial
Failure

T1 Shorted to Ground 520223 4

T1 Shorted to Bus 520223 3
Steering Torque Sensor T2 Partial

Failure

T2 Shorted to Ground 520224 4

T2 Shorted to Bus 520224 3
Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4

T1 and T2 Shorted to Bus 520225 3

T1 Shorted to Ground & T2

Shorted to Bus

520225 16

T2 Shorted to Ground & T1

Shorted to Bus

520225 17

T1 and T2 are Shorted 520225 2
Steering Position Sensor P1 Partial

Failure

P1 Shorted to Ground 520226 4

P1 Shorted to Bus 520226 3
Steering Position Sensor P2 Partial

Failure

P2 Shorted to Ground 520227 4

P2 Shorted to Bus 520227 3
Steering Position Sensor Full Failure P1 and P2 Shorted to Ground 520228 4

P1 and P2 Shorted to bus 520228 3
EPAS Inverter Temperature Greater than 110 Degrees C 520229 16

Greater than 120 Degrees C 520229 0
EPAS CAN Communications

Receive Error

No RX Message for 2 Seconds 520230 9

EPAS CAN Communications
Transmit Error

No TX Message for 2 Seconds 520231 9

46

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Sportsman 850 XP / XP EPS Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor Voltage Too High 51 3

Voltage Too Low 51 4

Engine Temperature Sensor Voltage Too High 110 3

Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0

Intake Air Temperature Sensor Voltage Too High 105 3

Voltage Too Low 105 4

Manifold Absolute Pressure Sensor Voltage Too High 102 3

Voltage Too Low 102 4
Signal Out of Range 102 2

Crankshaft Position Sensor Circuit Fault 636 8

Plausibility Fault 636 2

Vehicle Speed Signal Speed Too High 84 8

Plausibility Fault 84 2

Gear Sensor Signal Voltage Too Low 523 4

Voltage too high 523 3
Signal fault 523 2

Injector 1 (MAG) (SDI Part Load) Driver Circuit Open/Grounded 651 5

Driver Circuit Short to B+ 651 3
Driver Circuit Grounded 651 4

Injector 2 (PTO) (SDI Part Load) Driver Circuit Open/Grounded 652 5

Driver Circuit Short to B+ 652 3

Driver Circuit Grounded 652 4
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3
Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3
Fuel Pump Driver Circuit

Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3

Driver Circuit Grounded 1347 4
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

Driver Circuit Short to B+ 1071 3

Driver Circuit Grounded 1071 4
Idle Air Control Driver Circuit Open/Grounded 634 5

Driver Circuit Short to B+ 634 3

Driver Circuit Grounded 634 4

Position Out of Range 634 7
Starter Enable Circuit Driver Circuit Open/Grounded 1321 5

Driver Circuit Short to B+ 1321 3

Driver Circuit Grounded 1321 4

47

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Sportsman 850 XP / XP EPS Diagnostic Codes

Component Condition SPN FMI

Chassis Relay Driver Circuit Open/Grounded 520208 5

Driver Circuit Short to B+ 520208 3
Driver Circuit Grounded 520208 4

All Wheel Drive Control Driver Circuit Open/Grounded 520207 5

Driver Circuit Short to B+ 520207 3
Driver Circuit Grounded 520207 4

System Power Voltage Too High 168 3

Voltage Too low 168 4

Throttle Safety Signal Voltage Too High 520194 3

Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7

Active Descent Control System Driver Circuit Open/Grounded 520203 5

Driver Circuit Short to B+ 520203 3
Driver Circuit Grounded 520203 4

Idle Speed Speed Too High 520211 3

Speed Too Low 520211 4

EPS Models Only

Steering Over Current Shutdown Current Above Normal/Grounded 520221 6
Steering Excessive Current Error Current Above Normal/Grounded 520222 6
Steering Torque Sensor T1 Par-

tial Failure

T1 Shorted to Ground 520223 4
T1 Shorted to Bus 520223 3

Steering Torque Sensor T2 Par­tial Failure

T2 Shorted to Ground 520224 4
T2 Shorted to Bus 520224 3

Steering Torque Sensor Full
Failure

T1 and T2 Shorted to Ground 520225 4
T1 and T2 Shorted to Bus 520225 3
T1 Short to Ground & T2 Short to Bus 520225 16
T2 Short to Ground & T1 Short to Bus 520225 17
T1 and T2 are Shorted 520225 2

Steering Position Sensor P1
Partial Failure

P1 Shorted to Ground 520226 4
P1 Shorted to Bus 520226 3

Steering Position Sensor P2
Partial Failure

P2 Shorted to Ground 520227 4
P2 Shorted to Bus 520227 3

Steering Position Sensor Full
Failure

P1 and P2 Shorted to Ground 520228 4
P1 and P2 Shorted to bus 520228 3

EPAS Inverter Temperature Greater than 110 Degrees C 520229 16

Greater than 120 Degrees C 520229 0
EPAS CAN Comm. Receive Err No RX Message for 2 Seconds 520230 9
EPAS CAN Comm. Transmit Err No TX Message for 2 Seconds 520231 9
IC CAN Comm. w/EPAS EPAS Offline 520230 31

48

FEATURES AND CONTROLS

Front Rack/Compartment

Release the front rack latches
and remove the rack to gain
access to the front compart­ment. To reinstall the rack,
hold the rack as shown in the
illustration. Position the front
edge in the tabs, then push the
rack downward and secure
the latches.

Access the following
components in the front
compartment:

• Radiator cap

• Brake fluid reservoir

• ADC fluid reservoir

• Battery

• Coolant recovery bottle cap

• Electrical/fuse/relay components

Latches

ADC Fluid

Reservoir

Brake Fluid

Reservoir

Radiator

Cap

Coolant

Bottle Cap

Electrical/Fuse/Relay

Battery

49

OPERATION

Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.

Break-In Period

The break-in period for your new Polaris ATV is the first 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 proce­dures for a proper break-in. Careful treatment of a new engine and drive
components will result in more efficient performance and longer life for
these components.

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 33. Always exercise
extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 73. Add oil if

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

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

iarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 50.

6. Pull only light loads.

7. Change both the oil and the filter at 20 hours, one month or 500

miles (800 km), whichever comes first.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur­ing the break-in period.

WARNING

50

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/lever travel Ensure proper operation 29

85

Brake fluid Ensure proper level 30

Auxiliary brake Ensure proper operation 32

Front suspension Inspect, lubricate if necessary 72

Rear suspension Inspect, lubricate if necessary 72

Steering Ensure free operation -

Tires Inspect condition and pressure 88

Wheels/fasteners Inspect, ensure fastener tightness 88

90

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 33

73

Coolant level Ensure proper level 83

84

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 28

118

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 27

Air filter, pre-filter Inspect, clean 91

Headlamp Check operation 27

93

Brake light/tail lamp Check operation 97

Riding gear Wear approved helmet, goggles, and

protective clothing

8

ADC Fluid Ensure proper level 80

51

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 oper­ate this vehicle.

3. Never carry a passenger on this ATV.

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

run in an enclosed area.

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

gency situations (if service brakes become inoperable).

6. 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.

7. 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.

8. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handle­bars while operating, and always keep both feet on the footrests.

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

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

Always maintain proper tire pressure.

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

a qualified service dealer inspect the entire machine for possible
damage.

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

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

52

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera­tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con­tacting 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 vehi­cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

53

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti­lated area.

2. Place the transmission in PARK.

3. Lock the parking brake.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

4. Sit on the vehicle and move the engine stop switch to RUN.

5. Do not press the throttle while starting the engine.

6. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.

7. 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 accu­mulation increases as outside temperature decreases.

54

OPERATION

Driving Procedures

1. Wear a helmet and eye protection.

2. Sit upright with both feet on the footrests and both hands on the
handlebars.

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

4. Shift the transmission into gear.

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

6. Release the parking brake.

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

8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.

55

OPERATION

Turning the Vehicle

Your ATV is equipped with a
solid rear axle, which drives
both rear wheels equally at all
times. This means that the
wheel on the outside of the turn
must travel a greater distance
than the inside wheel when
turning and the inside tire must
slip traction slightly.

To turn, steer in the direction of
the turn, leaning your upper
body to the inside of the turn
while supporting your weight
on the outer footrest. This 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.

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.

56

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.

Sideways

Skid

Turn in

direction of

skid

57

OPERATION

Driving Uphill

Braking and handling are greatly affected when operating in hilly ter­rain. Improper procedure could cause loss of control or overturn. When­ever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 36.

2. Drive straight uphill.

3. Avoid climbing steep hills (25° 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.

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.

25° Maximum

58

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. Shift body weight uphill.

3. Keep your feet on the footrests.

4. If the vehicle begins to slide or tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side immediately!

59

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 36.

2. Avoid steep hills (25° maximum).

3. Shift body weight uphill.

4. Drive straight downhill.

5. Slow down. Excessive speed when traveling downhill can cause

loss of control.

6. Squeeze the brake lever gradually. Applying the brakes too firmly

may cause the rear wheels to lock, which could result in loss of con­trol.

60

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.

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 36.

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

4. Dismount on the uphill side of the vehicle, or on the left if the vehi­cle is pointing straight uphill.

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

6. While holding the service brake, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's point­ing across the hill or slightly downward.

7. Lock the parking brake and remount the vehicle from the uphill
side, keeping body weight uphill.

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

9. Release the parking brake and proceed slowly, controlling speed
with the service brake, until the vehicle is on more level ground.

8 ft. (2.4 m)

61

OPERATION

Driving Through Water

Your ATV can operate through
water with a maximum recom­mended depth equal to the bot­tom of the footrests. Follow
these precautions when operat­ing through water:

1. Determine water depths and
current before entering
water.

2. Choose a crossing where

both banks have gradual
inclines.

3. Avoid operating through

deep or fast-flowing water.

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

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 68. The following areas need
special attention: engine oil, transmission oil, demand drive fluid, rear
gearcase oil, and all grease fittings

.

If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 100,
then see your dealer for service at the first opportunity.

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

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

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

• 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.

Maximum

Depth

62

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 haz­ards 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.

63

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

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 button unless additional wheel speed is
required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.

NOTICE: Excessive throttle operation while in the speed limit mode may cause

fuel to build in the exhaust, resulting in engine popping and/or engine
damage.

64

OPERATION

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high
on the racks raises the center of gravity of the vehicle and creates a less stable
operating condition.

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. 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.

WARNING

65

OPERATION

Hauling Cargo

Never exceed the weight
capacities specified for your
ATV on warning labels and in
the specifications section of
this manual.

Cargo weight should be evenly
distributed (1/3 on the front
rack and 2/3 on the rear rack)
and mounted as low as possi­ble. When operating over
rough or hilly terrain, reduce
speed and cargo weight to
maintain stable driving condi­tions. Do not obstruct the headlight beam with cargo. Use low forward
gear when hauling or towing heavy cargo to extend belt life.

Towing Loads

Always attach a towed load to the hitch point. Remove the hitch from
the ATV when not towing a trailer. If towing a load, reduce rear rack
cargo weight by the amount of tongue weight.

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

not exceed the rear rack capacity.

• The total load (operator, accessories, cargo and weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or exceeding

the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your ATV
warranty. Never install a hitch longer
than 4" (10 cm). Never install
automotive accessories on your
Polaris ATV. Always install Polaris­approved (or equivalent) accessories
designed for ATV use.

1/3

2/3

Maximum

4" (10 cm)

66

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.

67

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. 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 com­ponents 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.

68

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic 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 139.

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 crank­case. 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.

69

MAINTENANCE

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to severe

use.

E Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

 Have an authorized Polaris dealer perform these services.

WARNING

70

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

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

E Emission-Related Service

 Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Steering - Pre-Ride - See Pre-Ride Checklist on

page 50.

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

Engine oil level - Pre-Ride -

XEAir filter, pre-filter - Daily - Inspect; clean often; replace

as needed

Coolant - Daily - Check level daily, change

coolant every 2 years

X ADC fluid - Daily - Check level daily, add as

needed

X Power steering unit

(if equipped)

- Daily - Inspect daily; clean often

Headlamp/taillight - Daily - Check operation

XEAir filter,

main element

- Weekly - Inspect; replace as needed

X Engine oil change 20 H 1 Month 500 (800) Perform a break-in oil and

filter change (see page 49)

X

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

Q

ADC fluid 25 H - - Change fluid if extreme use

conditions (see page 80)

X Demand drive fluid 25 H Monthly 250 (400) Inspect level
X Rear gearcase oil 25 H Monthly 250 (400) Inspect level
X Transmission oil 25 H Monthly 250 (400) Inspect level
X General

lubrication

50 H 3 M 500 (800) Lubricate all fittings, pivots,

cables, etc.

71

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Q

E

Throttle Cable/
ETC Switch

50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

E Throttle Body

Intake Duct

50 H 6 M 500 (800) Inspect duct for proper seal-

ing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; replace as needed

Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength

seasonally; pressure test
system yearly

X Radiator 50 H 6 M 1000 (1600) Inspect; clean external

surfaces

X Cooling hoses 50 H 6 M 1000 (1600) Inspect for leaks
X Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter
X Demand drive fluid 100 H 12 M 1000 (1600) Change fluid
X Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid
X Transmission oil 100 H 12 M 1000 (1600) Change fluid

Fuel system 100 H 12 M 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

100 H 12 M 1000 (1600) Inspect

Q

E

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

security; apply dielectric
grease to connectors
subjected to water, mud, etc.

Q

Clutches (drive
and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn

parts

Q

Front wheel
bearings

100 H 12 M 1000 (1600) Inspect; replace as needed

Q

Brake fluid 200 H 24 M 2000 (3200) Change every two years

X

Q

ADC fluid 200 H 24 M 2000 (3200) Change every two years;

every 25 hours if extreme use
conditions (see page 80)

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Q

E

Valve clearance 1000 H - 10000

(16000)

Inspect; adjust

Q

Toe adjustment - Inspect periodically; adjust

when parts are replaced

Headlight aim - Adjust as needed

72

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 68. Items not listed in the
chart should be lubricated at the General Lubrication interval.

The a-arms and lower control arms are lubricated at the 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

Lubricant

Capacity

at Fluid
Change

Fill Plug

Torque

Drain Plug

Torque

Inspection
Procedure

550 Engine Oil PS-4 PLUS

Performance
Synthetic 2W-50

2 qt.

(1.9 l)

--- 15-17 ft. lbs.
(20-23 Nm)

Page 73.

850 Engine Oil PS-4 PLUS

Performance
Synthetic 2W-50

2 qt.

(1.9 l)

--- 12 ft. lbs.

(16 Nm)

Page 73.

Transmission
Oil

Synthetic
SPORTSMAN
XP Transmission
Fluid

32 oz.

(950 ml)

10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

(14-19 Nm)

Page 76.

Demand Drive
Fluid (Front
Gearcase)

Demand Drive
Plus Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.
(11-14 Nm)

11 ft. lbs.

(15 Nm)

Page 77.

Rear
Gearcase Oil

ATV Angle Drive
Fluid (or GL5 80­90 weight gear
lube)

7.1 oz.

(210 ml)

10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

(14-19 Nm)

Page 78.

Brake Fluid DOT 4 Only --- --- --- Page 30.

ADC Fluid Demand Drive

Plus Fluid

--- --- --- Page 80.

Front Prop
Shaft Yoke

Polaris Premium
U-Joint Lube

Grease fittings (3 pumps maximum) every 500 miles,
before long periods of storage, or after pressure
washing or submerging.

Front Prop Shaft Yoke

Front

73

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn­thetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on
page 72 for fluid recommendations, capacities and plug torques.

Oil may need to be changed more frequently if Polaris oil is not used.
Always use 2W-50 oil. Follow the manufacturer's recommendations for
ambient temperature operation. See page 125 for the part numbers of
Polaris products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. Always use the recommended oil. Never substitute
or mix oil brands.

Oil Level

Check the oil level when the
engine is cold. 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
the ATV. Remove the dip­stick. Wipe it dry with a
clean cloth.

3. Reinstall and tighten the dip-

stick.

4. Remove the dipstick and

check the oil level.

5. Add the recommended fluid

as needed. Maintain the oil
level in the safe range
between the FULL and ADD
marks. Do not overfill.

6. Reinstall and tighten the

dipstick.

Dipstick

Full

Add

850

Full Add

550

74

MAINTENANCE

Engine Oil

Oil and Filter Change

See the table on page 72 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 68. Always change the
oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to warm up at idle for two to three min­utes.

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.

550

Drain

Plug

to front

850

Drain

Plug

Filter Access

75

MAINTENANCE

Engine Oil

Oil and Filter Change

9. Place shop towels beneath the oil
filter. Using an oil filter wrench
(available from your Polaris
dealer), turn the filter counter­clockwise to remove it.

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.

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.

Oil Filter

76

MAINTENANCE

Transmission Oil

Polaris recommends the use of Polaris Synthetic Sportsman XP Trans­mission Fluid for this transmission. See the table on page 72 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 68. See page 125 for the part
numbers of Polaris products.

Maintain the oil level at the bot­tom of the fill plug hole. The fill
plug is located on the right side of
the ATV behind the footwell. The
drain plug is located on the bottom
left side of the gearcase.

Oil Check

1. Remove the footwell (see
page 87).

2. Remove the fill plug. Check

the oil level.

3. Add the recommended fluid

as needed to bring the level to
the bottom of the fill hole
threads.

4. Reinstall the fill plug. Torque to specification.

5. Reinstall the footwell.

Oil Change

1. Remove the footwell.

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.

Drain Plug

Fill Plug

Fill

Level

77

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

See the table on page 72 for fluid recommendations, capacities and plug
torques. Always check and change the demand drive fluid at the inter­vals outlined in the Periodic Maintenance Chart beginning on page 68.
See page 125 for the part numbers of Polaris products.

Use the recommended fluid. Use of other fluids 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
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.

2. Add the recom-

mended fluid as
needed to bring the
level to the bottom of the fill hole threads.

3. Reinstall the fill plug. Torque to specification.

Fluid Change

1. Position the vehicle on a level surface. Remove the fill plug.

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.

Drain Plug

Fill

Plug

Fill

Level

78

MAINTENANCE

Rear Gearcase Oil

See the table on page 72 for fluid recommendations, capacities and plug
torques. Always check and change the rear gearcase oil at the intervals
outlined in the Periodic Maintenance Chart beginning on page 68. See
page 125 for the part numbers of Polaris products.

The fill plug is located on the
rear of the gearcase. The drain
plug is located on the bottom
of the gearcase.

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.

2. Remove the fill plug.

Check the oil level.

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.

Drain Plug

Fill Plug

Fill

Level

79

MAINTENANCE

Rear Gearcase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain hole.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug with a new sealing 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.

80

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 77 for demand drive fluid maintenance.

Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 68.

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 125 for the part numbers of Polaris
products.

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

the hydraulic system.

1. Remove the front rack.

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. Reinstall the front rack.

ADC Fluid

Reservoir

81

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level
surface. Before performing the
fluid change, allow the vehicle
to sit for at least 30 minutes.

2. Thoroughly clean the areas

around and on the ADC
reservoir and bleeder valves
(one on each side of the
differential).

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.

Bleeder

Screw

Cap

Bleeder

Valve

Screw

82

MAINTENANCE

Power Steering Unit

If your model is equipped with
power steering, frequently clean
the areas around and on the
power steering unit to allow
proper cooling. Clean these areas
thoroughly.

Cooling System

The engine coolant level is controlled by the recovery system. Recovery
system components are 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 con­tracting (cooled) coolant is drawn back up from the bottle, past the pres­sure 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/cool­ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. Polaris Premium 60/40 is already premixed
and ready to use. Do not dilute with water. See page 125 for the part
numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.

Clean

Often

83

MAINTENANCE

Cooling System

Recovery Bottle Coolant

The recovery bottle fluid level can be viewed from inside the front right
wheel well. Access the recovery bottle cap under the front storage com­partment.

1. View the fluid level in the bottle.

2. If the level is low, remove the front rack.

3. Remove the bottle cap and add coolant as needed. Maintain the

coolant level between the minimum and maximum marks on the
bottle (when the fluid is cool).

4. Reinstall the cap.

5. Reinstall the front rack.

Recovery

Bottle Cap

Maximum

Mark

Minimum

Mark

84

MAINTENANCE

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine,
Polaris recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for
maintenance or repair. If the recovery bottle has run dry, check the level
in the radiator. Add coolant as needed.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.

1. Remove the front rack.

2. Remove the pressure cap.

3. Using a funnel, slowly add cool­ant through the radiator filler
neck.

4. Reinstall the pressure cap. Use of
a non-standard pressure cap will
not allow the recovery system to
function properly. Contact your
dealer for the correct replacement
part.

5. Reinstall the front rack.

Radiator

Cap

85

MAINTENANCE

Brakes

Hand Brake

The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self­adjusting.

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 lock­up, which could result in serious injury or death. Maintain brake fluid at the
recommended level. Do not overfill.

The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.

1. Always keep brake fluid at an adequate
level. See page 30.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).

5. Check the security and surface condition

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.

3/64" (1 mm)

86

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.

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 straight­edge 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.

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.

String

Stand

2

1

87

MAINTENANCE

Seat Removal

1. Grasp one side of the seat
near the rear edge.

2. Pull upward abruptly to

disengage the under-seat
fasteners.

3. Remove the seat.

Side Panel/Footwell Removal

Remove the seat before removing a side panel.
Remove the screws and rivets securing the side panel or footwell (see

illustration).

Plastic Rivet

Hex Head Screw

Plastic Rivet

Plastic Rivet

Tor x He ad

Screw

88

MAINTENANCE

Tires

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 126 for recom­mended tire type, size and pressure.

Tire Tread Depth

Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.

WARNING

1/8" (3 mm)

89

MAINTENANCE

Tires

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical com­ponent 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.

90

MAINTENANCE

Tires

Wheel Installation

1. Place the transmission in PARK.

2. Lock the parking brake.

3. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation (if
equipped).

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

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or overturn. Always ensure that all nuts are torqued to
specification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos­ened for maintenance service.

Wheel Type Nut Type Nut Torque

Aluminum Lug Nut 75 ft. lbs. (102 Nm)

Steel Lug Nut 45 ft. lbs. (61 Nm)

Cast Aluminum

Steel

75 ft. lbs.

(102 Nm)

45 ft. lbs.

(61 Nm)

91

MAINTENANCE

Air Filter

1. Remove the seat.

2. Remove the air box cover
screws, and remove the air
box cover.

3. Remove the filter.

4. Remove the fabric type pre­filter 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.

6. Reinstall the filter into the air
box.

7. Reinstall the air box cover
and the seat.

Main

Filter

Pre-Filter

Screws

92

MAINTENANCE

Fuse Replacement

If the engine stops or will not start, or if you experience other electrical
failures, a fuse may need replacement. Locate and correct any short cir­cuits that may have caused the blown fuse, then replace the fuse. Spare
fuses are provided in the fuse box.

1. Remove the front rack.

2. Remove the fuse box cover.

3. 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. Reinstall the front rack.

Fuse Box

550 XP EPS

850 XP EPS

550 XP 850 XP

93

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.

Headlight Lamp Replacement

When servicing a halogen lamp, avoid touching the lamp with bare fin­gers. 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 speedom­eter 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 wir­ing.

4. Turn the lamp counterclockwise to remove it.

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

in the housing.

6. Reassemble the pod.

94

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 approxi­mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.

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 screw is

located on the right side of
the headlight pod. To adjust
the beam, loosen the screw.
Adjust the headlamp to the
desired position, then
tighten the screw.

2" (5 cm)

Lamp Center Height

25 ft. (7.6 m)

Adjustment

Screw

95

MAINTENANCE

Lights

Low Beam Adjustment

The low beam can be adjusted
slightly upward or downward.

1. Loosen the phillips screw
located at the rear of the
headlamp.

2. Tilt the headlamp upward

or downward.

3. Tighten the screw.

Phillips Screw

96

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.