Polaris ATV Sportsman Forest 550 User Manual

Sportsman Forest 550
Sportsman Forest 850
for Maintenance and Safety
Owner's Manual
Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
This is an adult vehicle only.
Before you operate this vehicle,
For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923176 Rev 01 Printed in USA
*9923176 *
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit­ing line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
RANGER
• Victory Motorcycles Always follow the instructions and recommendations in this manual.
The 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 needs during (and after) the warranty period.
For more information about POLARIS, visit us online at www.polaris­industries.com.
®
utility vehicles
®
®
(MSD) technician. Please see your dealer for all of your service
1
POLARIS, THE WAY OUT and SPOR TSMAN are registered trademarks of POLARIS Industries Inc.
MAXXIS
®
is a registered trademark of Maxxis International.
Copyright 2010 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 in acc uracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.
Printed in U.S.A. SPORTSMAN Forest 550 / SPORTSMAN Forest 850 Owner’s Manual P/N 9923176
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls. . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Emission Control Systems . . . . . . . . . . . . . . . 67
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 125
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 126
Declaration of Conformity. . . . . . . . . . . . . . . 130
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3
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.
DANGER
A DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
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.
4
INTRODUCTION
####
VIN
Engine Serial Number
Key
Number
550 850
As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protec­tion of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the opera­tion of this vehicle in your area.
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: ___________________________________________________________
5
SAFETY
WARNING
Failure to follow the warnings in this manual can result in serious injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.
Read and understand your owner's manual and all warnings before operating this POLARIS vehicle.
Safety Training
When you purchased your new POLARIS vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this informa­tion on a regular basis.
If you purchased a used POLARIS vehicle from a party other than a POLARIS dealer, please request free safety training from any autho­rized POLARIS dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a trailer with this vehicle on public roads is prohibited. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.
Equipment Modifications
The warranty on your POLARIS vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only POLARIS-approved accessories. Know their function and effect on the vehicle.
6
SAFETY
WARNING
Rider Safety
Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. See the OPERATION section of the owner’s manual for proper operating procedures.
Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.
Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com.
Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
Never allow anyone under 16 years of age to operate this vehicle.
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel 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.
Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.
7
SAFETY
Rider Safety
Never carry a passenger on this vehicle.
Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.
Never consume alcohol or drugs before or while operating this vehicle.
Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
8
Rider Safety
Always inspect your vehicle before each use to verify that it's in safe operating condition. See page 44. Follow the inspection and maintenance procedures outlined in this manual.
Keep both hands on the handlebars. Keep both feet on the footrests.
Always travel slowly when operating on unfamiliar terrain. Use extra caution.
SAFETY
Always follow the procedures outlined in this manual for turning. See page 47.
Never turn sharply at excessive speeds, which can lead to vehicle overturn.
If the vehicle has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
9
SAFETY
Rider Safety
Never attempt jumps or other stunts.
Always follow the procedures outlined in this manual for driving on hills. See page 52. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25.
Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 55.
Always follow the procedures outlined in this manual for crossing the side of a hill. See page 54.
Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. See page 56.
10
SAFETY
Rider Safety
Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 53.
Always follow the procedures outlined in this manual for operating over obstacles. See page 50.
Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 48.
Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page
49.
Always follow the procedures outlined in this manual for driving in reverse. See page 51.
11
SAFETY
Rider Safety
Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.
Never modify this vehicle through improper installation or use of accessories.
Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.
Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.
Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.
12
SAFETY
Rider Safety
Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.
Always unlock the steering before starting the engine. See page 26.
Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
For more information about safety, contact an authorized
POLARIS dealer or visit the POLARIS web site at
www.polarisindustries.com.
13
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
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.
14
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.
15
SAFETY
2x4
OUT
IN
General
Alert
Age 16
Alert
Hill
Operation
Alert
Reverse Override Warning
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 a 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.
The following pages repeat the information found on each label.
16
SAFETY
Safety Labels and Locations
General Alert (Multi-Lingual)
Before you operate this vehicle, read the owner’s manual.
7173025
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
Hill Operation Alert
• Never operate this vehicle on HILLS steeper than 25 degrees 25.
• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.
7173026
17
SAFETY
“No Passenger”
Warning
Tire
Pressure/Load
Warning
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
DEAT H.
7175378
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa):
Front: 7.0 psi (48.3 kPa)
Rear: 5.0 psi (34.5 kPa) MAXIMUM WEIGHT CAPACITY 575 lbs. (261 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND
ACCESSORIES.
18
7175820
Safety Labels and Locations
Clutch Cover
Warning
(under seat)
Rack
Warning
Rack
Warning
Clutch Cover Alert
7175826
SAFETY
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
19
FEATURES AND CONTROLS
2x4
OUT
IN
Mode/Reverse
Override Switch
Main Key
Switch
4X4 Switch
Winch
Switch
Momentary High-Beam
Switch
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 switch.
Pressing the override switch 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 switch.
The reverse override switch also acts as a MODE button when held down for approximately one half second. The transmission cannot be in reverse when using the override switch as a MODE button.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 30. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.
Momentary High Beam Switch
Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released.
Winch Switch
See page 61 for winch information.
20
FEATURES AND CONTROLS
Override
Switch
Engine
Stop
Switch
Headlight
Switch
Horn
Switch
Hazard
Switch
Turn
Signal
Switch
Switches
Main Key Switch
End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position.
After starting the engine, release the key switch to the POSITION
LIGHTS ON position. See page 45 for starting procedures.
Engine Stop Switch
The engine will not start or run when the switch is in the OFF position.
OFF RUN
Headlight Switch
The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.
High Beam
Turn Signal Switch
Horn Switch
Hazard Warning Switch
flash simultaneously . Use this feature to alert others of an emergency or other situation requiring caution.
Low Beam
Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also
flash. Return the toggle to the center position to end the signal.
Press the horn switch to sound the horn
Push the hazard warning switch to cause all turn signal lights to
21
FEATURES AND CONTROLS
2x4
Electronic Throttle Control
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.
Do not start or operate the vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to increase engine speed and vehicle movement.
Release the lever to reduce engine speed and vehicle movement.
Electronic Throttle Control (ETC)
ETC causes the engine to stop if the throttle cable sticks in an open posi­tion when the operator releases the throttle lever.
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.
22
FEATURES AND CONTROLS
Foot
Brake
Brakes
Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.
Foot Brake
The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes.
If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.
Hand Brake Lever
The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.
If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.
Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.
23
FEATURES AND CONTROLS
Brakes
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 for-
ward to engage the lock.
4. Release the brake lever.
5. To release the parking brake
lock, squeeze and release the brake lever.
Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.
24
FEATURES AND CONTROLS
Gear
Selector
Electronic Power Steering (EPS)
Electronic power steering engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 33 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
Stop the vehicle, release the throttle and move the shift lever to the desired gear. See your dealer if you experience any shifting problems.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at less than 11 km/h for extended periods and when operating uphill at a slow speed.
moving could cause transmission damage.
25
FEATURES AND CONTROLS
Fuel Tank
Cap
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
1. Turn the handlebars to the full left position.
Tip: The handlebars may also be locked in the full left position.
2. Insert the steering lock key and turn it clockwise.
3. Remove the key.
Tip: Place the ste ering lock keys in a safe place. The lock must be replaced if
the keys are lost.
4. Reverse the procedure to unlock the steering.
The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.
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 th an 10 per­cent, 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.
26
FEATURES AND CONTROLS
Latches
ADC Fluid Reservoir
Brake Fluid Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
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
• Foot brake fluid reservoir
• ADC fluid reservoir
• Coolant recovery bottle cap
• Electrical/fuse/relay components
27
FEATURES AND CONTROLS
2x4
4X4
Switch
ADC 4X4
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 30.
4X4 Mode
When the switch is on 4X4, the vehicle 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 vehicle is in two-wheel drive at all times.
2x4
28
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