Polaris Sportsman 9921973, Sportsman 850 XP EPS, Sportsman 550 XP EPS, Sportsman 550 XP, Sportsman 850 XP User Manual
3
WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342- 3764 for assistance.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
•Snowmobiles
•All-terrain vehicles (ATVs)
•RANGER utility vehicles
•Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2009 Sportsman 550/850 XP/XP EPS Owner’s Manual P/N 9921973
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Emission Control Systems . . . . . . . . . . . . . . . 67
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 125
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 126
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 136
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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
WARNING
Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
•Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV.
•Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are
entitled to take the ATV RiderCoursesm. Contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the
ATV RiderCoursesm.
•This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
•Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.
5
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Engine Serial Number
VIN
|
#### |
|
Key |
550 |
850 |
Number |
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
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SAFETY
Safety Training
ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCoursesm. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV, you can take the ATV RiderCoursesm by calling ATV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342- 3764.
7
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.
Helmet |
Eye Protection |
|
|
Long |
Gloves |
Sleeves |
|
Long Pants
Boots
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
E4
051039
0006.31
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SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.
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SAFETY
Safety Warnings
WARNING
Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.
Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle. See page 7.
Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.
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SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
•Always exercise extreme caution whenever handling gasoline.
•Always refuel with the engine stopped, and outdoors or in a well ventilated area.
•Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
•Do not overfill the tank. Do not fill the tank neck.
•If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident.
Always inspect the ATV before each use to make sure it's in safe operating condition.
Always follow all inspection and maintenance procedures and schedules described in the owner's manual.
11
SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.
Always wear an approved helmet that fits properly and eye protection (goggles or face shield).
Using Alcohol or Drugs
Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.
Never consume alcohol or drugs before or while operating an ATV.
Carrying a Passenger
Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn.
Never carry a passenger on this ATV.
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SAFETY
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and driveways) may adversely affect the
handling of the ATV and could result in loss of control and accident or overturn.
Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads or highways could result in a collision with another vehicle.
Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.
Operating at Excessive Speeds
Operating the ATV at excessive speeds increases the operator's risk of losing control.
Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience.
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SAFETY
Safety Warnings
Physical Control of the ATV
Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.
Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or overturn.
Always follow proper procedures for turning as described in the owner's manual.
Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
Jumps and Stunts
Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn.
Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 57. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
14
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss of control or overturn.
• Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 59.
• Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 36.
•Always check the terrain carefully before descending a hill.
•Shift your weight rearward.
•Never travel down a hill at high speed.
•Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.
Crossing Hillsides
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 58.
Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 60.
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SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.
•Always maintain a steady speed when climbing a hill.
•Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 36.
If all forward speed is lost:
•Keep body weight uphill.
•Apply the brakes.
•Lock the parking brake when fully stopped.
•Dismount on uphill side, or to either side if ATV is pointed straight uphill.
•Turn the ATV around and remount, following the procedure described in the owner's manual. See page 60.
If the ATV begins rolling downhill:
•Keep body weight uphill.
•Never apply engine power.
•Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually.
•When fully stopped, apply the rear brake as well, and then lock the parking brake.
•Dismount on uphill side, or to either side if ATV is pointed straight uphill.
•Turn the ATV around and remount, following the procedure described in the owner's manual. See page 60.
Operating on Steep Hills
Operating on excessively steep hills could cause an overturn.
Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.
16
SAFETY
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.
Do not operate on excessively rough, slippery or loose terrain. Always use extra caution on rough, slippery or loose terrain.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
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SAFETY
Safety Warnings
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 63.
Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.
Improper Tire Maintenance
Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident.
Always use the size and type of tires specified for your ATV.
Always maintain proper tire pressure as described in the owner's manual and on safety labels.
18
SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 62.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.
Operating Through Deep Water
Operating the ATV through deep or fastflowing water could cause the tires to float, causing loss of control or overturn.
Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 61):
• Travel slowly.
• Balance your weight carefully.
•Avoid sudden movements.
•Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.
•Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
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SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.
•Never exceed the stated load capacity for this ATV.
•Cargo should be properly distributed and securely attached.
•Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
•Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice.
Never operate the ATV on a frozen body of water.
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
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SAFETY
Safety Warnings
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use.
21
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:
•without proper training or instruction
•at speeds too fast for your skills or the conditions
•on public roads - a collision can occur with another vehicle
•with a passenger - passengers affect balance and steering and increase risk of losing control
ALWAYS:
•use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns
•avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376
22
SAFETY
Safety Labels and Locations
General Warning |
Discretionary Warning |
Age 16 Warning |
Reverse Override Warning |
|
4X4 Caution |
Discretionary Warning
WARNING
•Never operate this ATV on HILLS steeper than 25 degrees 
25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill.
•REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.
7175511
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 16.
7175374
Reverse Override Warning/4X4 Caution
WARNING
Improper use of the override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.
CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.
7175512
23
SAFETY
Safety Labels and Locations
“No Passenger”
Warning
Tire
Pressure/Load
Warning
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
7175378
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 7.0 psi (48.3 kPa) Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 575 lbs. (261 kg)
7175440
24
Safety Labels and Locations |
SAFETY |
|
|
Rack |
Rack |
Warning |
Warning |
+ |
+ |
+
Clutch
Cover
Warning (under seat)
Clutch Cover Warning
WARNING
•Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.
•Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
7175488
Rack Warning, Front and Rear
WARNING
•DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.
•Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg)
7175448
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
7170509
25
FEATURES AND CONTROLS
Switches
Headlight
Switch
2x4
Mode/Reverse |
4X4 Switch |
|
|
Override |
|
Button |
Main Key |
Engine |
|
Stop Switch |
Switch |
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button.
WARNING! Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override button.
The reverse override button also acts as a MODE button when held down for approximately one half second. The transmission cannot be in reverse when using the override button as a MODE button.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 36. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.
26
FEATURES AND CONTROLS
Switches
Engine Stop Switch
Move the stop switch either left or right to the OFF position to stop the engine quickly.
Move the stop switch to the OFF RUN position before attempt-
ing to start the engine. The engine will not start or run when the switch is off.
Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 53 for starting procedures.
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.
27
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