Polaris ATV Sportsman Forest 550 User Manual

Download

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,

read the owner’s manual

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

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

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

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.

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: ___________________________________________________________

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.

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.

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.

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.

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.

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.

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.

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.

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

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.

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.

SAFETY

2x4

OUT



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.

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

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.

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

FEATURES AND CONTROLS

2x4

OUT

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.

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

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.

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.

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.

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.

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.

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

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

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 of f 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.

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 spe ed exc eeds 15 mph (25 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

FEATURES AND CONTROLS

Rider Information Center

Directional

Indicator

High Beam

Indicator

Neutral

Indicator

Over-Temperature

Indicator

EPS Warning

Indicator

Instrument Cluster

Your vehicle 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, 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 vehicle components. Wash the

vehicle 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.

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, please see your POLARIS dealer.

The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/o r a 24-hour clock, see page 35.

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.

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

rotational speed when the corresponding display is selected. See page 34.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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 th e 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 36 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 36 for resetting instructions.

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

vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engin e 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 vehicle 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.

13. Directional Indicator - This indicator illuminates when the hazard

switch or a turn signal switch is turned on.

FEATURES AND CONTROLS

MODE Button

SELECT

Button

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 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. 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).

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 switch also acts as the SELECT button when pressed

and released quickly. The transmission cannot be in reverse when using the override switch 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. T oggle through the information area using the SELE CT 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. T oggle through the information area using the SELE CT 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 vehicle.

Trip Meter Mode

The trip meters record the distance traveled by the vehicle 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.

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 position.

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.

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 indi-

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

4. See pages 38-41 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.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load:

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

the electronic control unit is shorted to a wire at battery voltage.

Throttle Position Sensor

Engine Temperature Sensor

Intake Air Temperature Sensor

Manifold Absolute Pressure Sensor Voltage Too High 102 3

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

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

Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5

Fuel Pump Driver Circuit

Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

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

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

SPORTSMAN Forest 550 Diagnostic Codes

Component Condition SPN FMI

Voltage Too High 51 3 Voltage Too Low 51 4 Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Voltage Too High 105 3 Voltage Too Low 105 4

Voltage Too Low 102 4

Voltage Too High 523 3 Signal Fault 523 2

Driver Circuit Short to B+ 651 3

Driver Circuit Short to B+ 1268 3 Driver Circuit Open/Grounded 1347 5 Driver Circuit Short to B+ 1347 3

Driver Circuit Short to B+ 1071 3

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN Forest 550 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 Steering Over Current Shut Down Current Above Normal or

Steering Excessive Current Error Current Above Normal or Steering Torque Sensor T1 Partial

Failure Steering Torque Sensor T2 Partial

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

Steering Position Sensor P1 Partial Failure

Steering Position Sensor P2 Partial Failure

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

EPAS Inverter Temperature Greater than 110 Degrees C 520229 16

EPAS CAN Communications Receive Error

EPAS CAN Communications Transmit Error

Grounded

T1 Shorted to Ground 520223 4

T1 Shorted to Bus 520223 3

T2 Shorted to Ground 520224 4

T2 Shorted to Bus 520224 3

T1 and T2 Shorted to Bus 520225 3

T1 Shorted to Ground & T2

Shorted to Bus

T2 Shorted to Ground & T1

Shorted to Bus

T1 and T2 are Shorted 520225 2

P1 Shorted to Ground 520226 4

P1 Shorted to Bus 520226 3

P2 Shorted to Ground 520227 4

P2 Shorted to Bus 520227 3

P1 and P2 Shorted to bus 520228 3

Greater than 120 Degrees C 520229 0

No RX Message for 2 Seconds 520230 9

No TX Message for 2 Seconds 520231 9

*Assumes unipolar configuration of stepper motor

520221 6 520222 6

520225 16 520225 17

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN Forest 850 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

Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

Idle Air Control Driver Circuit Open/Grounded 634 5

Starter Enable Circuit Driver Circuit Open/Grounded 1321 5

Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3

Driver Circuit Grounded 1347 4

Driver Circuit Short to B+ 1071 3

Driver Circuit Grounded 1071 4

Driver Circuit Short to B+ 634 3

Driver Circuit Grounded 634 4

Position Out of Range 634 7

Driver Circuit Short to B+ 1321 3

Driver Circuit Grounded 1321 4

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN Forest 850 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 Steering Over Current Shut Down Current Above Normal/Grounded 520221 6 Steering Excessive Current Error Current Above Normal/Grounded 520222 6 Steering Torque Sensor T1 Partial

Failure Steering Torque Sensor T2 Partial

Failure Steering Torque Sensor Full

Failure

Steering Position Sensor P1 Partial Failure

Steering Position Sensor P2 Partial Failure

Steering Position Sensor Full Failure

EPAS Inverter Temperature Greater than 110 Degrees C 520229 16

EPAS CAN Comm. Receive Error No RX Message for 2 Seconds 520230 9 EPAS CAN Comm. Transmit Error No TX Message for 2 Seconds 520231 9

T1 Shorted to Ground 520223 4

T1 Shorted to Bus 520223 3

T2 Shorted to Ground 520224 4

T2 Shorted to Bus 520224 3

T1 and T2 Shorted to Ground 520225 4

T1 and T2 Shorted to Bus 520225 3

T1 Shorted to Ground & T2

Shorted to Bus

T2 Shorted to Ground & T1

Shorted to Bus

T1 and T2 are Shorted 520225 2

P1 Shorted to Ground 520226 4

P1 Shorted to Bus 520226 3

P2 Shorted to Ground 520227 4

P2 Shorted to Bus 520227 3

P1 and P2 Shorted to Ground 520228 4

P1 and P2 Shorted to bus 520228 3

Greater than 120 Degrees C 520229 0

520225 16 520225 17

OPERATION

Failure to operate the vehicle 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 vehicle 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.

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 26. 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 familiarize 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 44.

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.

OPERATION

Pre-Ride Checklist

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

Item Remarks Page

Hand brake/lever travel Ensure proper operation 87 Foot brake Ensure proper operation 87 Brake fluid Ensure proper levels 85 Front suspension Inspect, lubricate if necessary 72 Rear suspension Inspect, lubricate if necessary 72 Steering Ensure free operation Tires Inspect condition and pressure 90 Wheels/fasteners Inspect, ensure fastener tightness 90

Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 26

Coolant level Ensure proper level 83 Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 22 Indicator lights/switches Ensure proper operation 20

Engine stop switch Ensure proper operation 21 Air filter, pre-filter Inspect, clean 92 Headlamp Check operation 21 Brake light/tail lamp Check operation 97 Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 78 Mirrors Adjust for best side/rear vision Winch Inspect cable and switch. 62-63

protective clothing

73 84

OPERATION

Starting the Engine

1. Position the vehicle on a level surface

2. Place the transmission in PARK.

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

is in gear and the brake is not engaged.

3. Sit on the vehicle. Move the engine stop switch to RUN.

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

5. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

6. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

Cold Weather Operation

If the vehicle 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. W ater in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

damage. Allow the engine to warm up for several minutes before operating the vehicle.

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 14.

2. Perform the pre-ride inspection. See page 44.

3. Place the transmission in PARK.

4. Mount the vehicle from the left side.

5. Sit upright with both feet on the footrests. Keep both hands on the handlebars.

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

7. Apply the brakes.

8. Shift the transmission into gear.

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

10. Release the brakes.

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

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

Turning the Vehicle

1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn.

2. 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. Use the same leaning technique for turning in reverse.

3. Practice making turns at slow speeds before attempting to turn at faster speeds.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

OPERATION

Sideways

Skid

Turn in direction

of skid

Driving on Slippery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down when entering slippery areas.

2. Engage 4X4 before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while

3. Be alert. Watch the trail. Avoid quick, sharp turns

4. Never apply the brakes during a skid. Correct a skid by turning the

the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.

handlebars in the direction of the skid and shifting your body weight forward.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

OPERATION

Maximum

Depth

Driving Through Water

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Drive slowly. Avoid rocks and obstacles.

4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

NOTICE: If the vehicle stops while fully submerged, major engine damage can

5. Wet brakes may have reduced stopping ability. Dry the brake pads

6. If your vehicle becomes fully immersed, and it's impossible to take

result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

by driving slowly and applying the brakes lightly several times until braking action is normal.

it to a dealer before starting it, follow the steps described on page

103. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Always follow the procedures outlined in this manual for operating over obstacles.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

2. Avoid backing downhill.

3. Drive slowly. Apply the brakes lightly for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use with caution.

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.

Always follow the procedures outlined in this manual for driving in reverse.

OPERATION

25 Maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30.

2. Drive straight uphill.

3. Avoid steep hills (25 maximum).

4. Avoid hills with slippery or loose surfaces.

5. Keep both feet on the footrests.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

OPERATION

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

1. Apply the brakes gradually.

2. When fully stopped, lock the hydraulic parking brake.

3. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

4. Use the K-turn to turn around. See page 56.

Always follow the procedures outlined in this manual for driving on hills. Avoid climbing hills steeper than 25.

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.

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Shift body weight uphill.

3. Keep your feet on the footrests.

4. Avoid hills with slippery or loose surfaces.

5. Avoid crossing the sides of steep hills.

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

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

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

30.

2. Avoid hills with slippery or loose surfaces.

3. Never drive downhill at high speed. Slow down.

4. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.

5. Shift your weight rearward.

6. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

OPERATION

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

OPERATION

2.4 m

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 the vehicle. Keep your weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30.

3. Lock the hydraulic parking brake.

4. Leave the transmission in forward gear. Turn the engine off.

5. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

6. Stay uphill of the vehicle and turn the handlebars full left.

7. Squeeze the brake lever to release the parking brake.

8. Slowly release the brake lever and allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake.

10. Remount from the uphill side. Keep your weight uphill.

11. Apply the foot brake.

12. With the transmission still in forward, start the engine.

13. Squeeze and release the brake lever to release the parking brake.

14. Release the foot brake and drive slowly downhill. Control speed with either the hand or foot brake until the vehicle is on level ground.

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.

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. Always follow these precautions when hauling cargo.

• Read and understand the load distributio n warnings listed on the vehicle warning labels.

• Never exceed the stated load capacity for this vehicle. When determining the weight you are adding to the vehicle, include the wei ght of the ope rator, 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.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• 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.

• TOWING is approved OFF-ROAD ONLY.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

OPERATION

1/3

2/3

Maximum

10 cm

Hauling Cargo

Never exceed the weight capacities specified for your vehicle 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. Use low forward gear when hauling or towing heavy cargo to extend belt life.

Towing Loads

Towing is approved OFF-ROAD ONLY. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.

• Do not tow any trailer on a grade steeper than 15

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

the vehicle 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 car go weight and tongue weight must not exceed the rear rack capacity.

• The total load (operator, accessories, car go an d 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 vehicle warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARISapproved (or equivalent) accessories designed for use on this vehicle.

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. Always block the rear wheels on the downhill side.

WINCH GUIDE

WARNING

DANGER

Danger Zone

The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and operating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people.

Winch Safety Precautions

1. Be alert. Do not operate the winch under the influence of drugs,

alcohol or medication.

2. Practice using the winch so you are prepared to use it in an emer-

gency situation.

Never connect DC powered winches to AC current. Motor damage or fatal shock may occur.

Stand clear of the cable and load during winching. Keep helpers and spectators at a safe distance. If a cable pulls loose or breaks under the load, it can lash back with dangerous force.

3. Beware of the danger zone.

The danger zone is the area of the rotating wire cable drum, the fairlead (if fitted), the cable, the hook and the motor. Before placing hands in or near the danger zone, first relieve tension on load, then disconnect the control switch.

4. If you are within four feet of the winch, do not hold the cable and

the remote (if equipped) at the same time.

WINCH GUIDE

Winch Cable Care

1. The life of a cable is directly related to the care it receives. The wire

cable on a new winch (and any replacement cables) must be respooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage.

2. Inspect all cable before use. Mashed, pinched, frayed or kinked

areas severely reduce the load-carrying capability. Replace damaged cable promptly.

3. Prevent kinks before they occur.

A. This is a start of a kink. Straighten

the cable before using it.

B. The cable was pulled and the loop

has tightened to a kink. The cable is now permanently damaged and should not be used.

C. The result of kinking is that each

strand pulls a different amount of load, causing the strands under the greatest tension to break. This reduces the load capacity of the entire cable.

4. Before re-spooling, remove all load from the cable. Hold the han-

dlebar switch lead in one hand and the cable in the other. Move away from the vehicle as far as the switch will allow. Activate the switch, walk in several feet of cable, then release the switch. Repeat this process until the re-spooling is complete.

CAUTION! To avoid injury, always release the switch before your hand comes within four feet of the fairlead (the physical opening through which the cable passes).

5. Be sure the cable is distributed evenly and tightly on the drum. A

loosely wound drum may allow the cable to work its way down into the layers of cable on the drum and become wedged.

6. Do not grease or oil the cable. Doing so causes dirt contamination

that will reduce the life of the cable.

WINCH GUIDE

DANGER

WARNING

DANGER

Winch Preparation and Inspection

Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.

Inspect the switch and wiring for cracks, pinched spots, frayed wire or loose connections. A damaged, shortened lead could cause the winch to operate as soon as it is plugged in.

Never touch the cable or hook while they are in tension or under load. Even at rest, the winch may have the cable in tension. Never guide a cable under tension onto the drum with your hand.

1. Winch with at least five wraps of cable around

the winch drum. With fewer wraps, the cable could pull loose from the drum under load.

WINCH GUIDE

WARNING

Winch Rigging

Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch.

1. Use a nylon sling to

attach the cable to an anchor point.

CAUTION! Do not attach the hook back onto the cable. Doing so can cause the cable to break.

Always use a handsaver. Do not hold the hook with your hand. This is important not only when reeling cable in but also when removing cable from the winch under power.

2. Run the winch intermittently to take

up cable slack. When using a pulley block, be sure the cable is running properly in all pulleys before applying a load.

CAUTION! Never engage or disengage the clutch if the winch is under load, the cable is in tension or the drum is rotating.

WINCH GUIDE

Winch Operation

NOTICE: This winch is designed for intermittent use. Prolonged use may result

1. Use common sense.

2. Take your time.

3. Think through the situation.

4. Pay attention to what is going on when you are winching.

5. DO NOT overheat the winch motor. During extended winching,

6. Extended winching will discharge your battery. If the low battery

7. DO NOT overload or stall the winch. If the load is greater than the

8. Avoid continuous side pulls.

9. Never tow the vehicle by the winch cable.

10. Never use the winch cable as a tie-down.

11. Use an anchor point that is stronger than what you are pulling.

12. DO NOT hook the cable back onto itself. This will damage the

in damage due to overheating.

stop and feel the winch motor. The motor should be cool enough to touch. If not, allow the motor to cool before continuing.

warning light comes on, stop winching. Make sure the transmission is in neutral or park, then rev the motor for a few minutes until the warning light goes out. Recharge the battery as soon as possible.

winch is capable of pulling, use a snatch block.

cable.

WINCH GUIDE

Winch Operation

13. Use as much cable as possible when pulling. Additional wraps of

cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.

14. Never pull with less than five wraps of cable on the spool.

15. Inspect the condition of the cable prior to pulling. If the cable is

frayed or damaged, replace it as soon as possible.

16. DO NOT submerge the winch in water.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor

Your POLARIS vehicle has a spark arrestor that was designed for onroad and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

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.

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. Non-ionizing Radiation: This vehicle emits some electromagnetic

energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

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 135.

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.

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

 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.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - See Pre-Ride Checklist on 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 Winch - Pre-Ride - See pages 62-63.



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

Coolant - Daily - Check level daily, change

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

 Power steering unit

(if equipped) Headlamp/taillight - Daily - Check operation



Air filter,

main element

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

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



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

 Demand drive fluid 25 H Monthly 250 (400) Inspect level  Demand drive fluid

(extreme use)

 Rear gearcase oil 25 H Monthly 250 (400) Inspect level  Transmission oil 25 H Monthly 250 (400) Inspect level  General

lubrication

 Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

 Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Inspect daily; clean often

- Weekly - Inspect; replace as needed

25 H 1 M 250 (400) Change fluid every 25 hours

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

(Km)

page 44.

as needed

coolant every 2 years

needed

filter change (see page 42)

if ADC is subjected to extreme use. See page 77.

cables, etc.

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval



Throttle Cable/

ETC Switch

E Throttle Body

Intake Duct Drive belt 50 H 6 M 500 (800) Inspect; replace as needed Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength

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

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

(normal use)

 Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid  Transmission oil 100 H 12 M 1000 (1600) Change fluid

Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,

 Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe



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

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



Clutches (drive and driven)



Front wheel bearings



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





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



Valve clearance 1000 H - 10000



Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

(whichever comes first)

Hours Calendar Miles

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

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

100 H 12 M 1000 (1600) Change fluid

100 H 12 M 1000 (1600) Inspect

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

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

(Km)

(16000)

replace if necessary

ing/air leaks

seasonally; pressure test system yearly

surfaces

lines, filter, pump; replace lines every two years

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

parts

Inspect; adjust

when parts are replaced

Remarks

MAINTENANCE

Front Prop Shaft Yoke

Front

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

550 Engine Oil PS-4 PLUS

850 Engine Oil PS-4 PLUS

Transmission Oil

Demand Drive Fluid (Front Gearcase)

Rear Gearcase Oil

Brake Fluid DOT 4 Only --- --- --- Page 85. ADC Fluid Demand Drive

Front Prop Shaft Yoke

A-Arms, Front and Rear

Lubricant

Performance Synthetic 2W-50

AGL PLUS Transmission Fluid

Demand Drive Plus Fluid

ATV Angle Drive Fluid (or GL5 8090 weight gear lube)

Plus Fluid POLARIS

Premium U-Joint Lube

POLARIS Premium AllSeason Grease

Capacity

at Fluid Change

2 qt.

(1.9 l)

2 qt.

(1.9 l)

32 oz.

(950 ml)

9.3 oz.

(275 ml)

7.1 oz.

(210 ml)

--- --- --- Page 78.

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

Grease fittings after extreme use or if suspension becomes squeaky.

Fill Plug

Torque

--- 15-17 ft. lbs.

--- 12 ft. lbs.

10-14 ft. lbs.

(14-19 Nm)

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

10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

Drain Plug

Torque

(20-23 Nm)

(16 Nm)

(14-19 Nm)

11 ft. lbs.

(15 Nm)

(14-19 Nm)

Inspection Procedure

Page 73.

Page 76.

Page 77.

Page 80.

MAINTENANCE

Dipstick

Full

Add

850

Full Add

550

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

Oil Level

Check the oil level when the engine is cold. Never check the

oil with the engine running.

Access the oil dipstick and fill tube from the left side of the vehicle.

1. Position the vehicle on a

2. Remove the dipstick. W ipe it

3. Reinstall and tighten the dip-

4. Remove the dipstick and

5. Add the recommended fluid

6. Reinstall and tighten the

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

level surface. Place the transmission in PARK.

dry with a clean cloth.

stick.

check the oil level.

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

dipstick.

MAINTENANCE

550

Drain

Plug

to front

850

Drain

Plug

Filter Access

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. Place the transmission in

PARK.

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

utes.

3. Stop the engine.

4. Clean the area around the drain plug.

5. Place a drain pan under the crankcase.

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

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.

MAINTENANCE

Oil Filter

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 transmiss ion in PARK.

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

17. Stop the engine.

18. Check for leaks.

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

mark on the dipstick.

20. Dispose of used filter and oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Fill

Level

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 torq ues. 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 vehicle behind the footwell. The drain plug is located on the bottom left side of the gearcase.

Oil Check

1. Remove the footwell (see

page 89).

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.

MAINTENANCE

Drain Plug

Fill

Plug

Fill

Level

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.

Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:

• operation in ADC mode for prolonged periods

• constant ADC operation on hilly or mountainous terrain

• ADC is the primary mode of all-wheel-drive operation

Tip: If the front gearcase is makes excessive noise during ADC operation,

change the demand drive fluid. If the noise continues, please see your POLARIS dealer for service.

Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. 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 sur-

face. Remove the fill plug. Check the fluid level.

2. Add the recommended fluid as

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

3. Reinstall the fill plug. Torque to specification.

Fluid Change

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

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.

plug. Allow the fluid to drain completely.

MAINTENANCE

ADC Fluid Reservoir

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

We recommend the use of POLARIS Demand Drive Plus Fluid. 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

1. Remove the front rack.

2. View the fluid level in the

3. If the level is below the

4. Reinstall the cap.

5. Reinstall the front rack.

extreme use. Extreme use includes operation in ADC mode for prolonged periods or in environments that necessitate primary operation in ADC mode.

the hydraulic system.

reservoir.

minimum mark, remove the cap and add the recommended fluid.

MAINTENANCE

Bleeder

Screw

Cap

Bleeder

Valve

Screw

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 recommended

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 recommended fluid to the reservoir until the level is

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

between the minimum and maximum marks. Make sure the reservoir is free of debris.

MAINTENANCE

Drain Plug

Fill Plug

Fill

Level

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.

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. T orque

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.

MAINTENANCE

Clean

often

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 antifreeze/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.

MAINTENANCE

Recovery

Bottle Cap

Maximum

Mark

Minimum

Mark

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.

MAINTENANCE

Radiator

Cap

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 dr y, check the level in the radiator. Add coolant as needed.

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.

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

Operating the vehicle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the vehicle with spongy-feeling brakes.

If the fluid level is low add DOT 4 brake fluid only . See page 125 for the part numbers of POLARIS products.

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

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.

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 accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

MAINTENANCE

Master

Cylinder

Indicator

Window

Full

Low

Brake Fluid Reservoir

Brake Fluid

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a

level surface. Make sure the handlebars are straight.

2. View the fluid level through

the indicator window (eye) on the top of the master cylinder.

Tip: The eye will appear dark when

the fluid level is full. When fluid is low, the eye will be clear.

3. If the fluid level is low,

remove the cover screws and add fluid to the fill line. Do

not overfill.

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

Foot Brake

The foot brake fluid reservoir is located under the front rack. The brake fluid reservoir cap is black.

NOTICE: Do not use ADC fluid in the

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

MAINTENANCE

1 mm

Brake Inspections

The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.

Perform the following checks to keep the brake systems 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 86.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface condition

of the disc.

MAINTENANCE

String

Stand

2 1

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) toe out.

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

service.

MAINTENANCE

Plastic Rivet

Hex Head Screw

Plastic Rivet

Torx Head

Screw

Steering Assembly

The steering assembly 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.

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).

MAINTENANCE

1/8" (3 mm)

Tires

Operating your vehicle 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.

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. Loosen the wheel nuts slightly.

Do not service axle nuts that have a cotter pin installed. See yo ur POL AR IS dealer.

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

footrest frame.

5. Remove the wheel nuts.

6. Remove the wheel.

MAINTENANCE

Cast Aluminum

Steel

75 ft. lbs.

(102 Nm)

45 ft. lbs.

(61 Nm)

Tires

Wheel Installation

1. Place the transmission in PARK.

2. 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).

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

4. Lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

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)

MAINTENANCE

Main Filter

Pre-Filter

Screws

Air Filter

1. Remove the seat.

2. Remove the air box cover

screws, and remove the air box cover.

3. Remove the filter.

4. Remove the fabric type pre-

filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

5. Reinstall the pre-filter over

the main filter. Install a new main filter if needed.

6. Reinstall the filter into the air

box.

7. Reinstall the air box cover

and the seat.

MAINTENANCE

Fuse Box

850550

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.

MAINTENANCE

7.6 m 5 cm

Screws

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

NOTE: Include rider weight on the seat when measuring.

4. Start the engine.Turn the head-

light switch to high beam.

5. Observe the headlight aim on

the wall. The most intense part of the headlight beam should be 5 cm below the mark on the wall.

6. Tighten or loosen the three (3)

headlight screws to adjust the beam upward or downward or to the left or right.

MAINTENANCE

Position Light

Collar

Socket

Headlamp

Lights

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp.

1. Place the transmission in PARK.

2. Open the front rack cover.

3. Remove the plug at the back of the headlight.

4. Pull the harness plug to disconnect it from the back of the headlight.

5. Position light: Rotate the socket to remove it. Go to step 6. Headlamp: Reach under the bumper and remove the rubber cover from the back of the headlight. Turn the collar counterclockwise and carefully remove the collar and socket.

6. Remove the lamp. Apply dielectric grease to the socket and install a new lamp.

7. Reverse all steps to reassemble the headlight.

MAINTENANCE

Lights

Front T urn Signal Replacement

If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly.

Rear Turn Signal Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the turn signal socket counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the taillight socket counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. T est the lamp for proper operation.

6. Reinstall all components in reverse order.

MAINTENANCE

2-3 mm Gap

Throttle

Arm

Arm Stop Pin

Lock

Nut

Adjuster

Boot

Cable

Adjuster

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment.

Throttle Cable Freeplay

1. Remove the three cover screws from the right handlebar control and remove the cover.

2. With the handlebars

straight ahead, place very light pressure on the throttle lever. A gap of 2-3 mm should be visible between the throttle arm stop pin and the throttle arm.

If adjustment is needed:

1. Locate the throttle cable adjuster. Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut.

2. Loosen the adjuster lock-

nut.

3. Rotate the boot to turn the

adjuster until 2-3 mm of freeplay is achieved between the stop pin and the throttle arm. While

adjusting freeplay, flip the throttle lever back and forth repeatedly.

(continued on next page)

Polaris ATV Sportsman Forest 550 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual