Polaris ATV Sportsman Touring 550 INTL User Manual
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
12
PMS 419
GB
D
E
F
I
FI
P
S
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
1
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
2
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
3
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
####
VIN
Engine Serial Number
Key
Number
550 850
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________________
Frame VIN: ____________________________________________________________________
Engine Serial Number: ____________________________________________________________
Key Number: ___________________________________________________ ________________
5
SAFETY
WARNING
Failure to follow the warnings in this manual can result in serious injury or death.
This POLARIS vehicle is not a toy and can be hazardous to operate. A collision
or rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this POLARIS vehicle.
Safety Training
When you purchased your new POLARIS vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this information on a regular basis.
If you purchased a used POLARIS vehicle from a party other than a
POLARIS dealer, please request free safety training from any authorized POLARIS dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
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.
6
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.
7
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.
8
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.
9
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.
10
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.
11
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.
12
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.
13
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.
14
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.
15
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
16
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.
17
SAFETY
2x4
Trip 1
km
mi
RPM
F
E
88
:
88
H
General
Alert
H
H
H
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.
18
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
12
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
19
SAFETY
H
Clutch Cover
Alert (under
seat)
H
H
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)
20
7170509
FEATURES AND CONTROLS
Trip 1
km
mi
RPM
F
E
88
:
88
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.
21
FEATURES AND CONTROLS
2x4
Trip 1
km
mi
RPM
F
E
88
:
88
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.
22
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
23
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.
24
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.
25
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).
26
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.
27
Loading...