Polaris ATV Sportsman Touring 550 INTL User Manual

Download

PMS 419

Sportsman

550 Touring International 850 Touring International

Owner's Manual

for Maintenance and Safety

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.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

PASSENGER

UNDER

PMS 419

Before you operate or ride this vehicle, read the owner’s manual.

Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahren.

Antes de operar o conducir este vehículo, lea el Manual del propietario.

Lire le Manuel d’utilisation avant d’utiliser ou de conduire ce véhicule.

Prima di usare o guidare il veícolo, leggere il Manuale di istruzioni.

Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista.

Antes de utilizar ou andar neste veículo, leia o Manual do proprietário.

Innan du hanterar eller kör detta fordon, läs Handboken.

For your nearest Polaris dealer, visit www.polarisindustries.com

Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 USA

Part No. 9922825 Rev 01 Printed in USA

*9922825 *

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

• Low emission vehicles (LEVs) 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.

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. 2011 SPORTSMAN 550/850 Touring International Owner’s Manual P/N 9922825

TABLE OF CONTENTS

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . 21

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Emission Control Systems . . . . . . . . . . . . . . . . . . . . 69

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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

POLARIS Products . . . . . . . . . . . . . . . . . . . . . . . . 125

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

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

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

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

INTRODUCTION

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

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.

Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this

2-up vehicle.

SAFETY

Restrictions

Towing is approved OFF-ROAD 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 bee n 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

Rider Safety

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.

Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle.

Never carry more than one passenger on this 2-up vehicle.

Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

Rider Safety

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.

SAFETY

Never attempt jumps or other stunts.

SAFETY

Rider Safety

Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 50.

Keep both hands on the handlebars. Keep both feet on the footrests.

A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

SAFETY

>15

Rider Safety

Always follow the procedures outlined in this manual for turning. See page 54.

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.

Always follow the procedures outlined in this manual for driving on hills. See page 57. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 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 15.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 59.

Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 58.

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

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 60.

Always follow the procedures outlined in this manual for operating over obstacles. See page 63.

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 56.

Rider Safety

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

62.

Always follow the procedures outlined in this manual for driving in reverse. See page 64.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

SAFETY

Never modify the vehicle through improper installation or use of accessories.

SAFETY

Rider Safety

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. See pages 66-68. 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. Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

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 31.

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

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

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

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

Trip 1

RPM

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 any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

SAFETY

Tire Pressure/Load

Alert

Safety Labels and Locations

General Alert (Multi-Lingual)

Before you operate or ride this vehicle, read the owner’s manual.

7174362

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.

Hill Operation Alert

• Never operate this vehicle on HILLS steeper than 15 degrees 15.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

PASSENGER

UNDER

7175512

7174361

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 735 lbs. (333 kg) INCLUDES WEIGHT OF OPERATOR,

PASSENGER, CARGO AND ACCESSORIES. Read Owner’s Manual for more detailed loading

information.

7176783

SAFETY

Clutch Cover

Alert (under

seat)

Rack/Box

Warning

Rack/Box

Warning

Hitch

Capacity

Label

Safety Labels and Locations

Rack/Box Warning

WARNING

• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.

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

7175448

Clutch Cover Alert

Hitch Capacity Label

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

7170509

FEATURES AND CONTROLS

Trip 1

RPM

Main Key

Switch

4X4

Switch

Switches

Main Key Switch

Use the main key switch to start the engine. See page 52.

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.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 35. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

FEATURES AND CONTROLS

2x4

Trip 1

RPM

Override

Switch

Engine

Stop

Switch

Headlight

Switch

Horn

Switch

Hazard

Switch

Turn Signal

Switch

Momentary High-Beam

Switch

Switches

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF

RUN

Push the stop switch down to stop the engine quickly. Pull the stop switch up to the RUN position before attempting to start the engine.

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

Hazard Switch

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emer-

gency or other situation requiring caution.

Turn Signal Switch

Push the toggle switch either left or right to activate the corresponding turn signal light. Return the toggle to the center position to end the signal.

Horn Switch

Press the horn switch to sound the horn.

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.

FEATURES AND CONTROLS

Switches

Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press 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 button also acts as a MODE button when held down for approximately one half second. See the instrument cluster information beginning on page 36.

Tip: The override button will not functi on as a MODE button if the transmission

is in reverse.

Headlight Switch

The main key switch must be on and the engine stop switch must be in the RUN position to operate the headlight switch.

High Beam Low Beam

FEATURES AND CONTROLS

Electronic Throttle Control

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.

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

Brake Lever

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.

Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

FEATURES AND CONTROLS

Master Cylinder

Indicator

Window

Master Cylinder/Brake Fluid

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

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.

Check the brake fluid in the master cylinder before each ride.

1. Position the vehicle on a level

surface.

2. Position the handlebars so the

master cylinder is level.

3. View the brake fluid level

through the indicator window on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low , the eye will be clear.

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

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

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

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

Operating the vehicle while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill. Another option is to park the vehicle in a sidehill position. Never depend on the parking brake alone if the vehicle is parked on a hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

Auxiliary

Foot Brake

Brake Fluid

Reservoir

Auxiliary Foot Brake

Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

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

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

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

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the front storage box. See page 32.

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

NOTICE: Do not use ADC fluid in the

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

FEATURES AND CONTROLS

Gear

Selector

Automatic Transmission Gear Selector

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

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

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

Whenever the vehicle is left unattended, always place the transmission in PARK and lock the parking brake.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed.

moving could cause transmission damage.

FEATURES AND CONTROLS

Tight Position

Less Tight Position

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 37 for EPS Warning Indicator information.

Passenger Seat

Always make sure the passenger seat is installed and securely latched before operating with a passenger. Test the seat latch by attempting to pull the seat upward. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your POLARIS dealer for service.

See pages 89-90 for passenger seat adjustment procedures. See page 89 for passenger seat removal and installation procedures.

Beverage Holders

This vehicle is equipped with beverage holders on each side of the passenger seat. To secure a beverage or other container, remove the rubber retainer strap from one side of the holder. Place the container into the recess and reinstall the strap over the top of the container. Place one of the rubber cylinders through one of the holes to secure a strap.

When trailering the vehicle, and whenever a holder is not in use, always secure the rubber straps in one of the tighter positions to prevent loss of the retainer.

FEATURES AND CONTROLS

Fuel Tank

Cap

Fuel Tank

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

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

content greater than 10%, such as E-85 fuel.

The fuel tank is designed to allow for the normal expansion of fuel. Do not overfill. Do not fill the tank neck.

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full

right 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. Place the steer-

ing 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.

FEATURES AND CONTROLS

Cover Latches Plunger Latches

ADC Fluid

Reservoir

Brake Fluid

Reservoir

Radiator

Cap

Coolant

Bottle Cap

Electrical/Fuse/Relay

Battery

Front Storage Box

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

1. Release the front

box cover latches and lift the cover.

2. Release the plunger

latches that secure the box to the frame.

3. Close the cover and

lift the unlatched edge of the box to disengage the plungers. Pivot the box forward.

4. T o remove the box completel y, disengage the plungers and slide the

box rearward and upward.

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

operating the vehicle.

Access the following components under the front box:

• Radiator cap • Coolant recovery bottle cap

• Brake fluid reservoir • Electrical/fuse/relay components

• ADC fluid reservoir • Battery

FEATURES AND CONTROLS

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 35.

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.

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 (24 km/h) or less

• The throttle must be closed (throttle lever released)

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

Disengaging Active Descent Control

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

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

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

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

FEATURES AND CONTROLS

Trip 1

RPM

88:88

Rider

Information

Center

Speedometer

Indicator Lamps

Instrument Cluster

NOTICE: High water pressure may damage vehicle components. Wash the

Digital/Analog Gauge

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).

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

Digital/Analog Gauge

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

Over Temperature

EPS Warning This indicator illuminates when the key is turned to

Neutral This lamp illuminates when the transmission is in

High Beam This lamp illuminates when the headlamp switch is

Direction Indicators

Check Engine This indicator appears if an EFI-related fault occurs.

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

This lamp 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.

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.

neutral and the ignition key is in the ON position.

set to high beam. A direction indicator flashes when a turn signal is

active. Both indicators flash when the hazard signal is active.

Do not operate the vehicle if this warning appears. Serious engine damage could result. See your dealer.

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Rider Information Center

The rider information center is located in the instrument cluster . All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.

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

Trip 1

RPM

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Rider Information Center

1. Gear Display - This area 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. Fuel Gauge Display - The segments of the fuel gauge show the

level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

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

fuel sensor circuit. See your dealer.

3. Information Display - This area displays odometer, trip meter,

engine hour meter, engine speed and programmable service hour interval.

4. Active Descent Control Display - This icon displays when ADC is

active. See page 35.

5. Clock Display - 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 41 for resetting instructions.

6. Service Reminder Display - 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 41 for resetting instructions.

7. 4X4 Display - This icon displays when the 4X4 system is engaged

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

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Rider Information Center

The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement.

Tip: To exit the set-up mode at any time, wait 10 seconds.The display automati-

cally exits and returns to the odometer display.

Standard Display Metric Display

Distance Miles Kilometers Fuel U.S. Gallons Liters, Imperial Gallons Temperature Fahrenheit Celsius Time 12-Hour Clock 24-Hour Clock

1. Turn the key to the OFF position.

2. Place the transmission in neutral.

3. Press and hold the MODE button while turning the key to the ON

position.

4. When the display flashes the distance setting, tap the MODE button

to advance to the desired setting.

5. Press and hold the MODE button to save the setting and advance to

the next display option.

6. Repeat the procedure to change remaining display settings.

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Rider Information Center

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or dis-

charged.

1. Turn the key to the ON position. Use the MODE button to toggle to

the odometer display.

2. Press and hold the MODE button until the hour segment flashes.

Release the button.

3. With the segment flashing, tap the MODE button to advance to the

desired setting.

4. Press and hold the MODE button until the next segment flashes.

Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.

After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

Odometer Mode

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

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before each trip. T o reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. 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

Digital/Analog Gauge

Rider Information Center

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 MODE button until remaining service hours display.

2. Press and hold the MODE button.

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

advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.

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.

Instrument Cluster

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

Digital/Analog Gauge

Rider Information Center

Engine Error Codes

The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored in the gauge when the key is turned off. The code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

If the CHECK ENGINE light illuminates, retrieve the error codes from the display. Please see your POLARIS dealer for all major repairs.

1. If the error codes are not displayed, use the MODE button to toggle

2. Press and hold the MODE button to enter the diagnostics code

3. Record the numbers displayed in the gear position (if any), clock

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

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

FEATURES AND CONTROLS

until “Ck ENG” displays on the main line of the display.

menu.

and odometer displays.

see your POLARIS dealer for all major repairs.

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

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.

Component Condition SPN FMI

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

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 550 Touring Diagnostic Codes

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

Diagnostic Display Code Definitions

SPORTSMAN 550 Touring Diagnostic Codes

Component Condition SPN FMI

Idle Air Control Driver Circuit Grounded 520193 5

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

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

Voltage Too Low 520194 4

Signal Out of Range 520194 2

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

EPS Models Only

Steering Over Current Shut Down Current Above Normal or 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

Diagnostic Display Code Definitions

SPORTSMAN 850 Touring Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor Voltage Too High 51 3

Voltage Too Low 51 4

Engine Temperature Sensor Voltage Too High 110 3

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

Intake Air Temperature Sensor Voltage Too High 105 3

Voltage Too Low 105 4

Manifold Absolute Pressure Sensor Voltage Too High 102 3

Voltage Too Low 102 4 Signal Out of Range 102 2

Crankshaft Position Sensor Circuit Fault 636 8

Plausibility Fault 636 2

Vehicle Speed Signal Speed Too High 84 8

Plausibility Fault 84 2

Gear Sensor Signal Voltage Too Low 523 4

Voltage too high 523 3 Signal fault 523 2

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

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

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

Driver Circuit Short to B+ 652 3

Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3 Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3 Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3

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

Driver Circuit Short to B+ 1071 3

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

Driver Circuit Short to B+ 634 3

Driver Circuit Grounded 634 4

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

Driver Circuit Short to B+ 1321 3

Driver Circuit Grounded 1321 4

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

SPORTSMAN 850 Touring Diagnostic Codes

Component Condition SPN FMI

Chassis Relay Driver Circuit Open/Grounded 520208 5

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

All Wheel Drive Control Driver Circuit Open/Grounded 520207 5

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

System Power Voltage Too High 168 3

Voltage Too low 168 4

Throttle Safety Signal Voltage Too High 520194 3

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

Active Descent Control System Driver Circuit Open/Grounded 520203 5

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

Idle Speed Speed Too High 520211 3

Speed Too Low 520211 4

EPS Models Only

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

tial Failure Steering Torque Sensor T2 Par-

tial 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 Err No RX Message for 2 Seconds 520230 9 EPAS CAN Comm. Transmit Err No TX Message for 2 Seconds 520231 9 IC CAN Comm. w/EPAS EPAS Offline 520230 31

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

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 31. Always exercise extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 75. Add oil if

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

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

iarize yourself with vehicle operation and handling.

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

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

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

6. Pull only light loads.

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

miles (800 km), whichever comes first.

PVT Break-in (Clutches/Belt)

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

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

Passenger seat latch Ensure latch is secure 30 Brake system/lever travel Ensure proper operation 25

Brake fluid Ensure proper level 26 Auxiliary brake Ensure proper operation 28 Front suspension Inspect, lubricate if necessary 74 Rear suspension Inspect, lubricate if necessary 74 Steering/steering lock Unlock the steering; ensure free oper-

Steering Ensure free operation Tires Inspect condition and pressure 92 Wheels/fasteners Inspect, ensure fastener tightness 94 Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 31

Coolant level Ensure proper level 85 Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 24 Switches Ensure operation 21

Engine stop switch Ensure proper operation 22 Mirrors Adjust for best side/rear vision 24 Turn signals, indicators Ensure operation 22 Air filter, pre-filter Inspect, clean 95 Headlamp Check operation 23

Brake light/taillight Check operation 101 Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 81

ation

protective clothing

75 86

114

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this vehicle. See page 6.

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

Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

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

run in an enclosed area.

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

gency situations (if service brakes become inoperable).

5. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

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

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

7. Never consume alcohol or drugs before or while operating this vehi-

cle.

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

Always maintain proper tire pressure.

9. Never operate a damaged vehicle. After any overturn or accident,

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

10. 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.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

OPERATION

Starting the Engine

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

2. Place the transmission in PARK.

3. Lock the parking brake.

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

is in gear and the brake is not engaged.

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

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

6. Turn the ignition key past the POSITION

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

7. If the engine does not start, return the key to

the OFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

Cold Weather Operation

If the 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.

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 16.

2. Perform the pre-ride inspection. See page 50.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

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

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

8. Shift the transmission into gear.

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

10. Release the parking brake.

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

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

OPERATION

Turning the Vehic le

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.

Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

OPERATION

Driving with a Passenger

1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests.

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

experience with this vehicle.

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

ing an approved helmet with a rigid chin guard. See page 16.

4. Perform the pre-ride inspection. See page 50.

5. Always make sure the passenger seat is installed and securely

latched before operating with a passenger.

6. Lock the parking brake.

7. Mount the vehicle from the left side. After the operator is seated, the

passenger should mount the vehicle from the left side. Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts.

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

9. Do not carry more than one passenger.

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

board. Allow more time and distance for braking.

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

Avoid unexpecte d or aggressive maneuvers that could cause a passenger to fall from the vehicle.

12. Do not cross a hillside with a passenger on board. See page 58.

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

feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

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

riding." When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.

OPERATION

Sideways

skid

Tur n 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. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

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

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

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

5. 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.

OPERATION

15 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 35.

2. Drive straight uphill.

3. Avoid steep hills (15 maximum).

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

5. Avoid hills with slippery or loose surfaces.

6. Keep both feet on the footrests.

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

uphill.

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

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

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

dismounting quickly.

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. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle.

3. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

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

OPERATION

15 Maximum

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 35.

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

descend a hill with the transmission in neutral.

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

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

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

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

uphill.

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

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

OPERATION

8 ft. (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.

OPERATION

Turning Around on a Hill (K-Turn)

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

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

descending a hill. See page 35.

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

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

the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. A passen-

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

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

6. While holding the brake lever, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

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

keeping body weight uphill. A passenger should not remount until the vehicle returns to firm, level ground.

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

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

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

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

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

inspected after operation in water. Perform the services outlined in the maintenance chart. See page 70. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 104, then see your dealer for service at the first opportunity.

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

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.

5. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view.

2. Always avoid backing downhill.

3. 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.

OPERATION

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

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 carry cargo on the rear rack when operating the vehicle in the 2-up

mode with a passenger.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

• Never exceed the stated load capacity for this vehicle. When determining the

weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

• CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on

the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack increases the possibility of vehicle overturn.

• CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads

high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

• HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

• USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

• TOWING is approved OFF-ROAD ONLY.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

• 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

2/3

1/3

Hauling Cargo

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

1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.

2. When operating over rough or

hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.

3. Do not obstruct the headlight beam with cargo.

4. Slow down.

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

extend belt life.

6. Always operate the vehicle with extreme caution whenever hauling

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

OPERATION

Maximum

10 cm

Hauling Cargo

Towing Loads

Towi ng 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, passenger, accessorie s, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or exceeding

Maximum Towing Capacities

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

Maximum Towed Load (Level Ground) 1500 lbs. (680 kg) 1500 lbs. (680 kg) Maximum Vertical Hitch Weight 150 lbs. (68 kg) 150 lbs. (68 kg)

the maximum tongue weight capacity can result in serious damage to the vehicle and will void your POLARIS 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.

550 850

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 on-road 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 standard 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 safe, reliable condition. 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 n 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 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.)

n 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 - Make adjustments as 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 Passenger seat

latch Wheels/fasteners - Pre-Ride Frame fasteners - Pre-Ride Engine oil level - Pre-Ride -



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

Coolant - Daily - Check level daily, change

 ADC fluid - Daily - Check level, add as needed  Power steering unit - Daily - Inspect daily; clean often

Headlight/taillight - Daily - Check operation



Air filter,

main element

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



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

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

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

(extreme use)

 General

lubrication Shift linkage 50 H 6 M 500 (800) Inspect, lubricate

Steering 50 H 6 M 500 (800) Lubricate

 Front suspension 50 H 6 M 500 (800) Lubricate  Rear suspension 50 H 6 M 500 (800) Lubricate

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

E Emission-Related Service

n Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles

-Pre-Ride -

- 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)

needed. See Pre-Ride Checklist on page 50.

as needed coolant every 2 years

change (see page 48)

if ADC is subjected to extreme use. See page 80.

cables, etc.

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

nE Throttle Cable/

ETC Switch

E Throttle Body

Intake Duct Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

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

(normal use) 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

nE 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

nE 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 needed 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 70. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Recommended

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 26. 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.

(946 ml)

9.3 oz.

(275 ml)

7.1 oz.

(210 ml)

--- --- --- Page 81.

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 75.

Page 78.

Page 80.

Page 83.

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 74 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.

1. Position the vehicle on a

2. Access the oil dipstick and

3. Reinstall and tighten the dip-

4. Remove the dipstick and

5. Add the recommended fluid

6. Reinstall and tighten the dip-

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

level surface.

fill tube from the left side of the vehicle. Remove the dipstick. Wipe it 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.

stick.

MAINTENANCE

550 Drain

Plug

to front

850 Drain

Plug

Filter Access

Engine Oil

Oil and Filter Change

See the table on page 74 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 70. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

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

850550

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 counter-clockwise to remove it.

10. Using a clean dry cloth, clean

the filter sealing surface on the crankcase.

11. Lubricate the o-ring on the

new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

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

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

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

oil. Do not overfill.

14. Reinstall the dipstick.

15. Place the transmission in PARK.

16. Lock the parking brake.

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

18. Stop the engine.

19. Check for leaks.

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

mark on the dipstick.

21. Dispose of used filter and oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Fill

Level

Transmission Oil

POLARIS recommends the use of POLARIS AGL PLUS Transmission Fluid for this transmission. See the table on page 74 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. 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 rear side of the gearcase.

Oil Check

1. Remove the footwell (see

page 91).

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.

MAINTENANCE

Transmission Oil

Oil Change

1. Remove the footwell.

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

the oil to drain completely.

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

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

oil.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Reinstall the footwell.

8. Dispose of used oil properly.

MAINTENANCE

Drain Plug

Fill

Plug

Fill

Level

Front Gearcase (Demand Drive) Fluid

See the table on page 74 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 70. 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 make s 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. 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

plug. Allow the fluid to drain completely.

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

4. Add the proper amount of the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

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

MAINTENANCE

ADC Fluid Reservoir

Active Descent Control (ADC) Fluid

Check and change the ADC fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 70.

We recommend the use of POLARIS Demand Drive Plus Fluid for the ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 125 for the part numbers of POLARIS products.

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

Fluid Check

1. Access the reservoir under

2. View the fluid level in the

3. If the level is below the

4. Reinstall the cap.

5. Close and secure the front

the hydraulic system.

the front box. See page 32.

reservoir.

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

box and cover.

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 fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the bleeder valve screws (turn counter-clock-

wise) 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 valve screws 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 bleeder valve screws to 80 in. lbs. (9 Nm). Reinstall the

bleeder valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the

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

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

MAINTENANCE

Drain Plug

Fill Plug

Fill

Level

Rear Gearcase Oil

See the table on page 74 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 70. 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.

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.

Steering Assembly

The steering assembly of the vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.

Cooling System

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases the 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

Maximum

Mark

Minimum

Mark

Recovery

Bottle Cap

Cooling System

Recovery Bottle Coolant

The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. See page

32.

1. View the fluid level in the bottle.

2. If the level is low , remove the bottle cap and add coolant as needed.

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

3. Reinstall the cap.

4. Close and secure the front box and cover.

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. Access the pressure cap under the

front box. See page 32.

2. Remove the pressure cap.

3. Using a funnel, slowly add cool-

ant through the radiator filler neck.

4. Reinstall the pressure cap. Use of

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

5. Close and secure the front box and cover.

MAINTENANCE

3/64" (1 mm)

Brakes

Hand Brake

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

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

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

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

1. Always keep brake fluid at an adequate

level. See page 26.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

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

5. Check the security and surface condition

of the disc.

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. See page 28.

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).

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

Seats

Passenger Seat Removal

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

2. Pivot the rear of the seat upward and

remove the front legs of the seat base from the frame.

3. To reinstall the seat, position the

front legs of the seat base under the frame. Pivot the rear of the seat downward onto the latch. Press down firmly on the seat pad until the latch clicks. Test the seat latch by attempting to pull the seat upward.

Passenger Seat Backrest Adjustments

The passenger backrest can be adjusted horizontally and vertically.

1. Unzip the two zippers at the bot-

tom of the backrest pad. Lift the pad upward to remove it from the backrest frame.

2. To adjust the backrest forward or

rearward, loosen the top adjuster bolt. Pivot the adjuster forward or rearward to one of the three adjustment positions and tighten the bolt.

3. To adjust the backrest upward or

downward, loosen the four vertical adjustment screws on the front side of the backrest frame. Slide the backrest upward or downward to the desired position and tighten the screws.

4. Reinstall the backrest pad.

MAINTENANCE

Seats

Passenger Seat Suspension

1. Remove the passenger seat.

2. Remove the fastener retaining the

passenger seat shock to the passenger seat support.

3. Pivot the seat support upward to

access the lower shock fastener. Remove the lower shock fastener.

4. Remove the shock from the vehicle.

If adjustment is necessary, use a suitable pliers or spanner wrench. Adjust the shock to the desired spring preload. Rotate the adjustment cam to the left to increase preload.

5. Reinstall the shock.

6. Torque the upper and lower shock

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

7. Reinstall the passenger seat.

Operator Seat Removal

1. Remove the passenger

seat. See page 89.

2. Grasp one side of the oper-

ator’s seat near the rear edge.

3. Pull upward abruptly to

disengage the under-seat fasteners.

4. Remove the seat.

MAINTENANCE

Plastic Rivet

Hex Head Screw

Plastic Rivet

Side Panel/Footwell Removal

1. Remove the seat before removing a side panel.

2. To remove a side panel or footwell, remove the fasteners securing it

to the frame. Lift the right side panel upward while removing it to clear the shifter knob

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.

MAINTENANCE

Tires

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

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

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

footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

MAINTENANCE

Cast Aluminum

Steel

75 ft. lbs.

(102 Nm)

45 ft. lbs.

(61 Nm)

Tires

Wheel Installation

1. Place the transmission in PARK.

2. Lock the parking brake.

3. Place the wheel on the hub with the valve stem toward the outside

and rotation arrows on the tire pointing toward forward rotation.

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

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

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 service.

Wheel Type Nut Type Nut Torque

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

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

Air Filter

Main

Filter

Pre-Filter

Screws

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

550 850

Fuse Box

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. Access the fuses under the front box. See page 32.

2. Remove the fuse box cover.

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

install a new fuse with the same amperage rating.

4. Reinstall the fuse box cover.

5. Close and secure the front box and cover.

MAINTENANCE

Lights

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

Headlight Lamp Replacement

When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.

1. Remove the five (5) headlight pod

screws.

2. Lift the pod cover and disconnect

the speedometer harnesses from the speedometer.

Hot components can cause burns to skin. Allow lamps to cool before servicing.

3. Unplug the headlamp from the wiring harness. Be sure to pull on the

connector, not on the wiring.

4. Turn the lamp counter-clockwise to remove it.

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

in the housing.

6. Reassemble the pod.

Polaris ATV Sportsman Touring 550 INTL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Vehicle Identification Numbers

SAFETY

Safety Training

Age Restrictions

Restrictions

Equipment Modifications

Rider Safety

Safe Riding Gear

Safety Labels and Locations

FEATURES AND CONTROLS

Switches

Throttle Lever

Brake Lever

Auxiliary Foot Brake

Automatic Transmission Gear Selector

Electronic Power Steering (EPS)

Passenger Seat

Beverage Holders

Fuel Tank

Steering Lock

Front Storage Box

All Wheel Drive System

Active Descent Control (ADC) System

Instrument Cluster

Starting the Engine

Driving Procedures

Turning the Vehic le

Driving with a Passenger

Driving on Slippery Surfaces

Driving Uphill

Driving Downhill

Driving Through Water

Driving Over Obstacles

Driving in Reverse

Parking on an Incline

Hauling Cargo

Spark Arrestor

Exhaust Emission Control System

Electromagnetic Interference

MAINTENANCE

Periodic Maintenance Chart

Transmission Oil

Rear Gearcase Oil

Power Steering Unit

Steering Assembly

Cooling System

Tires

Air Filter

Fuse Replacement

Lights