Polaris Sportsman 550 Touring EPS, Sportsman 850 Touring EPS, Sportsman 9922090 User Manual

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 1-800­342-3764 for assistance.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Pant

one

426C

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE GEAR

FOR DRIVER

AND PASSENGER

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

MORE THAN

1 PASSENGER

NEVER USE

WITH DRUGS

OR ALCOHOL

NEVER operate:

without proper ATV 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 unless passenger seat is securely in place

THE OPERATOR MUST 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

reduce speed and use extra caution at all times when carrying a
passenger - dismount passenger when conditions require

make sure passenger reads and understands this label and
passenger safety label

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9922090 Rev 02
Printed in USA

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

• Victory Motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experi­ence have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we’ve ever produced.

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
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!

®

utility vehicles

®

®

(MSD)

1

POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris
Industries Inc.

Copyright 2009 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.
2010 SPORTSMAN 550/850 Touring EPS Owner’s Manual
P/N 9922090

2

TABLE OF CONTENTS

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Emission Control Systems . . . . . . . . . . . . . . . 75

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 131

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 135

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 136

Declaration of Conformity . . . . . . . . . . . . . . . 140

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 149

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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.

• 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

####

VIN

Engine Serial Number

Key

Number

550 850

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: ___________________________________________________________

6

SAFETY

Safety Training

ATV safety training is a top priority for Polaris. Polaris strongly
encourages you and any family members who will be riding the ATV to
take a training course.

If you purchased a new Polaris ATV in the United States, your dealer
provided instruction to you about the authorized ATV RiderCourse
that is available to you and your eligible family members. This training
is included in the purchase price of your ATV. 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 in the United States, you can enroll

sm

in the ATV RiderCourse

for a fee. Call ATV Enrollment Express at

[phone] or visit www.atvsafety.org.
If you purchased a Polaris ATV outside the United States, please contact

your dealer or local law enforcement agencies for information about
safety 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 in the United
States, call the Consumer Product Safety Commission at 1-800­638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.

sm

7

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.

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.

8

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.

9

SAFETY

WARNING

Safety Warnings

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

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 or ride on this ATV safely and could be susceptible to accident or injury.

10

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.

Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).

Carrying a Passenger

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

Carrying More Than One
Passenger

Carrying more than one passenger greatly
reduces the operator's ability to balance and
control the ATV, which may result in an
accident or overturn.

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

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.

12

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.

Never operate at excessive speeds.
Travel at speeds appropriate for
your skills, your passenger's skills,
and operating conditions.

SAFETY

13

SAFETY

Safety Warnings

Physical Control of the ATV

Removing even one hand or foot can reduce
ability to control the vehicle or could cause loss
of balance and ejection from the ATV.

If a person's feet are not firmly planted on the
footrests, they could come into contact with the
wheels or other moving parts and lead to
accident or injury.

Always keep both hands on the handlebars
and both feet on the footrests of the ATV during
operation. 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.

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.

Practice turning at slow speeds before
attempting to turn at faster speeds.

Never turn at excessive speed.

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.

14

Safety Warnings

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 63. Always move the 4X4 switch to
ADC 4X4 before ascending or descending a hill.

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.
See page 65.

• 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 39.

• 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.

SAFETY

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 64.

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 66.

15

SAFETY

>15°

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 39.

If all forward speed is lost:

• Lean forward to keep body weight uphill. A
passenger should also lean uphill.

• Apply the single lever brakes.

• Lock the parking brake when fully stopped.

• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 66.

If the ATV begins rolling backwards:

• Keep operator and passenger 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 foot brake as well, and then lock the parking
brake.

• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 66.

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 15 degrees.

16

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 until you've learned and
practiced the skills necessary to control the
ATV on such 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.

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 70.

Before shifting into reverse gear, always
check for obstacles or people behind the ATV.
When it's safe to proceed, back slowly.

SAFETY

17

SAFETY

Safety Warnings

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.

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 69.

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.

18

SAFETY

Safety Warnings

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

68):

• 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. The friction will help dry
out the pads.

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.

• Always follow the instructions in the owner's manual for operating with a

passenger. See page 60.

19

SAFETY

Safety Warnings

Operating on Frozen Bodies of
Water

Operating on frozen bodies of water may
result in serious injury or death if the ATV
and/or riders 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.

20

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. Never secure a
passenger to the vehicle or to the operator with a belt, rope or similar device.

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

Reverse Override Warning

AWD Caution

Age 16

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.

Reverse Override Warning/AWD Caution

WARNING
Improper use of 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

Age 16 Warning

WARNING
Operating this ATV if you are under the age of 16 increases the chances of

severe injury or death to both operator and passenger.
NEVER operate this ATV if you are under age 16.

7175375

22

SAFETY

General Warning

Safety Labels and Locations

General Warning

WARNING
Improper ATV use can result in SEVERE

INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR FOR DRIVER AND
PASSENGER

NEVER USE ON PUBLIC ROADS
NEVER CARRY MORE THAN 1 PASSENGER
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:

• without proper ATV 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 unless passenger seat is securely in place
THE OPERATOR MUST ALWAYS:

• use proper riding techniques to avoid overturns on hills and rough terrain and

in turns

• avoid paved surfaces - pavement may seriously affect handling and control

• reduce speed and use extra caution at all times when carrying a passenger -

dismount passenger when conditions require

• make sure passenger reads and understands this label and passenger safety

label
LOCATE AND READ OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175844

23

SAFETY

Passenger Warning

Discretionary Warning

Tire Pressure/Load

Warning

Safety Labels and Locations

Passenger Warning/Discretionary Warning

WARNING
PASSENGER SAFETY
To reduce the risk of SEVERE INJURY or

DEATH
NEVER CARRY MORE THAN ONE

PASSENGER
NEVER RIDE AFTER USING DRUGS OR

ALCOHOL
NEVER carry a passenger too small to firmly

plant feet on footrests and securely grasp
hand holds.

THE PASSENGER MUST ALWAYS:

• use an approved helmet and protective gear

• securely grasp hand holds and plant feet firmly on footrests while seated in
the passenger seat

• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require

WARNING

• Never operate this ATV on HILLS steeper than 15 degrees 15°. 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.

7175845

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: 735 lbs. (333 kg)

• Lug nut torque values:

Steel rims 45 ft-lbs. (61 Nm)
Aluminum rims 75 ft-lbs. (102 Nm)

7175846

24

SAFETY

+

Clutch Cover

Warning

+

+

Rack/Box

Warning

Rack/Box

Warning

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 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

25

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key

Switch

Engine

Stop Switch

Headlight

Switch

4X4

Switch

Switches

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain
additional wheel speed while backing, depress the override switch.

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 39. The
vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.

26

FEATURES AND CONTROLS

OFF OFFRUN

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
RUN position before attempt­ing 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 57.

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.

27

FEATURES AND CONTROLS

WARNING

Throttle Lever

Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.

Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Always check the lever
for free movement and return before starting the engine. Also check
occasionally during operation.

Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.

Engine speed and vehicle movement are controlled by pressing the
throttle lever. The throttle lever is spring loaded. Engine speed returns to
idle when the lever is released.

This ATV is equipped with
Polaris Electronic Throttle Con­trol (ETC), which is designed to
reduce the risk of a frozen or
stuck throttle.

If the throttle cable should stick
in an open position when the
operator releases the throttle
lever, engine speed will be lim­ited, and power to the rear
wheels will be reduced.

28

FEATURES AND CONTROLS

WARNING

Brake Lever

Operating the ATV with a spongy brake lever can result in loss of braking, which
could cause an accident. Never operate the ATV 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.

29

FEATURES AND CONTROLS

WARNING

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 ATV 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).

30

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PAR K.

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.

WARNING! Operating the ATV 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 ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.

31

FEATURES AND CONTROLS

WARNING

Auxiliary

Foot Brake

Brake Fluid

Reservoir

Auxiliary Foot Brake

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

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. Access the reservoir under the
front box. See page 36.

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.

32

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

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and
when operating at less than seven miles per hour for extended periods of
time.

moving could cause transmission damage.

33

FEATURES AND CONTROLS

Tight Position

Less Tight Position

Electronic Power Steering (EPS)

Electronic power steering (if equipped) engages when the ignition key is
turned to the ON position. EPS remains engaged whether the vehicle is
moving or idle. See page 42 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 95-96 for passenger seat adjustment procedures.
See page 95 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.

34

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.

35

FEATURES AND CONTROLS

Cover Latches Plunger Latches

ADC Fluid

Reservoir

Brake Fluid

Reservoir

Radiator

Cap

Coolant

Bottle Cap

Electrical/Fuse/Relay

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. To remove the box completely, 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

36

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 39.

4X4 Mode

When the switch is on 4X4, the
ATV 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 ATV is in two-wheel drive at all times.

37

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 off 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.

38

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

39

FEATURES AND CONTROLS

Rider Information Center

Directional

Indicator

High Beam

Indicator

Neutral

Indicator

Over-Temperature

Indicator

EPS Warning

Indicator

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle
speed from a gear in the transmission. The instrument cluster measures
distance in miles/kilometers as well as hours of operation.

In addition to showing vehicle speed, the instrument cluster also dis­plays the following items: engine speed, odometer, resettable trip meters
(2), total engine hours of operation, service interval timer and indicator,
gear position, fuel level, AWD status, EPS status (if equipped), high
beam status, battery voltage warning, temperature warning and diagnos­tic display mode. These features are outlined on the following pages.

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

40

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

1

3

4

8

6

5

9

7

10

11

2

12

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All seg­ments will light up for one second at start-up. If the instrument cluster
fails to illuminate, a battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the electronic speedome­ter. If this occurs, take the ATV 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 44.

1. Gear Indicator - This indicator displays gear shifter position.

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

-- = Gear Signal Error (or shifter between gears)

2. Information Display Area - This area displays odometer, tripme-

ters, engine hour meter and programmable service hour interval.

41

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

rotational speed when the corresponding display is selected. See
page 43.

4. Fuel Gauge - The segments of the fuel gauge show the level of fuel

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

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

fuel sensor circuit. See your dealer.

5. High Beam Indicator - This indicator appears when the lights are

set to high beam.

6. Clock - The clock displays time in a 12-hour or 24-hour format. If

the engine is turned off, press the MODE button. The time will dis­play for 5-10 seconds. See page 46 for resetting instructions.

7. Engine Overheat Warning - This indicator flashes to indicate an

overheated engine. If the indicator stops flashing but remains illu­minated, the overheating condition remains, and the system will
automatically reduce engine power.

8. Service Indicator - A flashing wrench symbol alerts the operator

that the preset service interval has been reached. The vehicle should
be brought to your dealer for scheduled maintenance. See page 46
for resetting instructions.

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

ATV is operating at an RPM too low to keep the battery charged. It
may also occur when the engine is at idle and high electrical load
(lights, cooling fan, accessories) is applied. Drive at a higher RPM
or recharge the battery to clear the warning.

10. Check Engine Warning Indicator - This indicator appears if an

EFI-related fault occurs. Do not operate the ATV if this warning
appears. Serious engine damage could result. See your dealer.

11. 4X4 Indicator - This indicator illuminates when the 4X4 system is

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

12. EPS Warning Indicator - This indicator illuminates when the key

is turned to the ON position and goes off when the engine is started.
If the light remains on after starting the engine, the EPS system is
inoperative. See your authorized Polaris dealer for service.

42

FEATURES AND CONTROLS

MODE
Button

SELECT

Button

Instrument Cluster

Rider Information Center

Speed Display Area

Use the MODE button to toggle
through the speed display options.
MODE button operation is locked
out at speeds above approximately
15 MPH (25 km/h).

Tip: The reverse override 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.
This feature does not contain a
vehicle speed lockout function and
can be used at any operating
speed.

Ground Speed Mode

Ground speed is displayed in either miles per hour (MPH) or kilometers
per hour (km/h).

Engine Speed Mode

Engine speed is displayed in revolutions per minute (RPM).

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Use the SELECT button (SEL) to toggle through the information area
options. SELECT button operation is locked out at speeds above
approximately 15 MPH (25 km/h).

Tip: The reverse override button also acts as the SELECT button when pressed

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

Standard/Metric Display

The display can be viewed in either standard or metric units of measure­ment. To change units:

1. Press and hold the MODE button until vehicle speed is displayed.

2. Toggle through the information area using the SELECT button until

the odometer is displayed.

3. Press and hold the MODE button until the displayed units change.

Release the button.

4. New settings remain until changed using the same procedure.

12-Hour/24-Hour Clock Display

1. Press and hold the MODE button until RPM is displayed.

2. Toggle through the information area using the SELECT button until

the odometer is displayed.

3. Press and hold the MODE button until the clock displays the new

clock format (either 24-hour or 12-hour). Release the button.

4. New settings remain until changed using the same procedure.

44

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Odometer Mode

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

Trip Meter Mode

The trip meters record the distance traveled by the ATV on each trip if
reset before each trip. To reset a trip meter, select the trip meter 1 or trip
meter 2 mode. Press and hold the MODE button on the instrument clus­ter until the total changes to 0. In the Rider Information Center, the trip
meter display contains a decimal point, but the odometer displays with­out a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

45

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Programmable Service Interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is pro­grammed at 50 hours at the factory. Use the following procedure to
change the service interval.

1. Press the SELECT button until remaining service hours display.

2. Press and hold the MODE button.

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

to advance the hours to the desired setting (including OFF). When
the digits stop flashing, the interval has been set.

Clock Mode

Use one of the following two methods to reset the clock.

Method 1

1. Select the Hour Meter Mode.

2. Press and hold the mode button on the instrument cluster until the

hour display flashes. Release the button.

3. Press and release the SELECT button to advance the hours.

4. After the hours are set, press and release the MODE button to move

to the minutes. Use the same procedure to reset the minutes.

5. When the digits stop flashing the clock has been set.

Method 2

1. With the key turned off, press and hold the MODE button.

2. While still holding the MODE button, turn the key to the ON posi-

tion.

3. Continue to hold the MODE button until the hour display flashes.

Release the button.

4. Set the time as outlined in steps 3-5 of Method 1.

46

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Information Display Area

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only.
Please see your Polaris dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if
you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and
on and the warning indicator is no longer active. This allows the deter­mination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit. Please see your
Polaris dealer to retrieve inactive codes.

Use the following procedure to view active codes that occur when the
key is on.

1. Place the transmission in PARK.

2. Press and release the SELECT button until the flashing check

engine warning indicator appears in the display.

3. A set of two numbers will also appear in the display.

• The 2-6 digit suspect parameter number (SPN) in the information area
indicates which component is generating the fault code.

• The 1-2 digit failure mode indicator (FMI) number in the clock area indi­cates the fault mode, such as open or short circuit.

4. See pages 48-51 for code definitions and failure descriptions.

Tip: More than one fault may be active. Press and hold the MODE button to tog-

gle through all currently active diagnostic codes.

47

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load:

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

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

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

Throttle Position Sensor

Engine Temperature Sensor

Intake Air Temperature Sensor

Manifold Absolute Pressure Sensor Voltage Too High 102 3

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

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

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

Fuel Pump Driver Circuit

Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

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

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

SPORTSMAN 550 Touring EPS Diagnostic Codes

Component Condition SPN FMI

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

Voltage Too Low 102 4

Voltage Too High 523 3
Signal Fault 523 2

Driver Circuit Short to B+ 651 3

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

Driver Circuit Short to B+ 1071 3

48

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN 550 Touring EPS 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

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

49

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN 850 Touring EPS Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor Voltage Too High 51 3

Voltage Too Low 51 4

Engine Temperature Sensor Voltage Too High 110 3

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

Intake Air Temperature Sensor Voltage Too High 105 3

Voltage Too Low 105 4

Manifold Absolute Pressure Sensor Voltage Too High 102 3

Voltage Too Low 102 4
Signal Out of Range 102 2

Crankshaft Position Sensor Circuit Fault 636 8

Plausibility Fault 636 2

Vehicle Speed Signal Speed Too High 84 8

Plausibility Fault 84 2

Gear Sensor Signal Voltage Too Low 523 4

Voltage too high 523 3
Signal fault 523 2

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

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

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

Driver Circuit Short to B+ 652 3

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

Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

Idle Air Control Driver Circuit Open/Grounded 634 5

Starter Enable Circuit Driver Circuit Open/Grounded 1321 5

Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3

Driver Circuit Grounded 1347 4

Driver Circuit Short to B+ 1071 3

Driver Circuit Grounded 1071 4

Driver Circuit Short to B+ 634 3

Driver Circuit Grounded 634 4

Position Out of Range 634 7

Driver Circuit Short to B+ 1321 3

Driver Circuit Grounded 1321 4

50

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

SPORTSMAN 850 Touring EPS 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 Par­tial Failure

Steering Torque Sensor Full
Failure

Steering Position Sensor P1
Partial Failure

Steering Position Sensor P2
Partial Failure

Steering Position Sensor Full
Failure

EPAS Inverter Temperature Greater than 110 Degrees C 520229 16

EPAS CAN Comm. Receive 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

51

OPERATION

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. 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 ATV 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.

52

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 35. Always exercise
extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 81. 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 54.

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.

53

OPERATION

Pre-Ride Checklist

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.

Item Remarks Page

Passenger seat latch Ensure latch is secure 34

Brake system/lever travel Ensure proper operation 29

Brake fluid Ensure proper level 30

Auxiliary brake Ensure proper operation 32

Front suspension Inspect, lubricate if necessary 80

Rear suspension Inspect, lubricate if necessary 80

Steering Ensure free operation -

Tires Inspect condition and pressure 98

Wheels/fasteners Inspect, ensure fastener tightness 98

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 35

Coolant level Ensure proper level 91

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 28

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 27

Air filter, pre-filter Inspect, clean 101

Headlamp Check operation 27

Brake light/taillight Check operation 107

Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 88

protective clothing

93

100

81

92

122

103

8

54

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this
vehicle. See page 7.

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. Operate this vehicle off-road only. Never operate the vehicle on

pavement or on any public street, road or highway, including dirt
and gravel roads.

6. 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.

7. 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.

8. Never consume alcohol or drugs before or while operating an ATV.

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

Always maintain proper tire pressure.

10. Never operate a damaged ATV. After any overturn or accident, have

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

11. Never operate the ATV on a frozen body of water.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

55

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera­tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con­tacting your Polaris dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

56

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.

Tip: Do not press the throttle while starting the engine.

5. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.

6. If the engine does not start, return the key to the OFF position and

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

NOTICE: Operating the vehicle immediately after starting could cause engine

Cold Weather Operation

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

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

57

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 54.

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.

58

OPERATION

Turning the Vehicle

Both rear wheels drive
equally at all times. This
means that the outside wheel
must travel a greater distance
than the inside wheel when
turning, and the inside tire
must slip traction slightly.

1. Slow down.

2. Never turn quickly when
carrying a passenger or
cargo.

3. Steer in the direction of
the turn.

4. Keep both feet on the
footrests.

5. Lean your upper body to the inside of the turn while supporting your
weight on the outer footrest. This technique alters the balance of
traction between the rear wheels, allowing the turn to be made
smoothly. The same leaning technique should be used for turning in
reverse.

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

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

59

OPERATION

Driving with a Passenger

1. Never allow anyone under 12 years of age to ride as a passenger on
this 2-up ATV. 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 8.

4. Perform the pre-ride

inspection. See page 54.

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.

60

OPERATION

Driving with a Passenger

11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected 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 64.

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.
Never secure a passenger to the vehicle or to the operator with a
belt, rope or similar device.

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.

61

OPERATION

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, 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. Maintain a high level of alertness, reading the trail and avoiding

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.

quick, sharp turns, which can cause skids.

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

62

OPERATION

15° Maximum

Driving Uphill

Braking and handling are greatly affected when operating in hilly ter­rain. Improper procedure could cause loss of control or overturn. When­ever traveling uphill, follow these precautions:

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

descending a hill. See page 39.

2. Drive straight uphill.

3. Avoid steep hills (15° maximum).

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

5. Never climb hills with excessively 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 and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.

9. Never go over the top of any hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.

10. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.

63

OPERATION

Driving on a Sidehill (Sidehilling)

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 sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

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

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

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

64

OPERATION

15° Maximum

Driving Downhill

When driving downhill, follow these precautions:

1. Always check the terrain carefully before descending a hill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 39.

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

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

5. Drive straight downhill. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.

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

7. 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.

65

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.

66

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 39.

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.

67

OPERATION

Maximum Depth

Driving Through Water

Your ATV can operate
through water with a
maximum recommended
depth equal to the bottom of
the footrests. Follow these
procedures when operating
through water:

1. Determine water depths
and current before
entering water.

2. Choose a crossing

where both banks have
gradual inclines.

3. Avoid operating

through deep or fast­flowing water.

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

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

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 76. 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 110,
then see your dealer for service at the first opportunity.

.

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

68

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

2. Look ahead and learn to read the terrain. Be constantly alert for haz­ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.

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

69

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. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

7. Do not use the override switch unless additional wheel speed is

required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.

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.

70

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.

71

OPERATION

WARNING

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:

Never carry cargo on the rear rack when operating the ATV in the 2-up mode
with a passenger.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the 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.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The
vehicle should never exceed 10 mph (16 kph) while towing a load on a level
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.

72

OPERATION

2/3

1/3

Hauling Cargo

Never exceed the weight capacities
specified for your ATV 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.

73

OPERATION

Maximum

4" (10 cm)

Hauling Cargo

Towing Loads

Always attach a towed load to the hitch point. Remove the hitch from
the ATV 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 cargo weight and tongue weight must
not exceed the rear rack capacity.

• The total load (operator, passenger, accessories, 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 ATV
warranty. Never install a hitch longer
than 4" (10 cm). Never install
automotive accessories on your
Polaris ATV. Always install Polaris­approved (or equivalent) accessories
designed for ATV use.

550 EFI 850 EFI

74

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to
be in accordance with the USFS standard 5100-1c. Federal law requires
that this spark arrestor be installed and functional when the vehicle is
operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.

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.

The vehicle compliance labels can be found on the frame tubing of the
vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

75

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on
page 149.

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.

76

MAINTENANCE

WARNING

Periodic Maintenance Chart

Improperly performing the procedures marked with a Q 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

X Perform these operations more often for vehicles subjected to severe

use.

E Emission-related service

(Failure to conduct this maintenance will not void the emissions
warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

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 -

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

Coolant - Daily - Check level daily, change

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

X Power steering unit - Daily - Inspect daily; clean often

Headlight/taillight - Daily - Check operation

(whichever comes first)

Hours Calendar Miles

-Pre-Ride -

(Km)

needed. See Pre-Ride
Checklist on page 54.

as needed

coolant every 2 years

needed

Remarks

77

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

XEAir filter,

main element

X 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

X

Q

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

Q

ADC fluid 25 H - - Change fluid if extreme use

X Rear gearcase oil

(if equipped)

X Transmission oil 25 H Monthly 250 (400) Inspect level
X Demand drive fluid 25 H Monthly 250 (400) Inspect level
X General

lubrication

Q

Throttle Cable/

E

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

X Radiator

(if applicable)

X Cooling hoses

(if applicable)

X Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter
X Rear gearcase oil

(if equipped)

X Transmission oil 100 H 12 M 1000 (1600) Change fluid
X Demand drive fluid 100 H 12 M 1000 (1600) Change fluid

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

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

Exhaust muffler/
pipe

(whichever comes first)

Hours Calendar Miles

- Weekly - Inspect; replace as needed

25 H Monthly 250 (400) Inspect level

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

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

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

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

50 H 6 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Change fluid

100 H 12 M 1000 (1600) Inspect

(Km)

change (see page 52)

conditions (see page 88)

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test
system yearly

surfaces

lines, filter, pump; replace
lines every two years

Remarks

78

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Q

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

E

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

Q

Clutches (drive
and driven)

Q

Front wheel
bearings

Q

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

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

X

Q

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

Q

Valve clearance 1000 H - 10000

E

Q

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

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

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

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

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

(Km)

(16000)

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

parts

every 25 hours if extreme use
conditions (see page 88)

Inspect; adjust

when parts are replaced

Remarks

79

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 76. 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 30.

ADC Fluid Demand Drive

Front Prop
Shaft Yoke

Lubricant

Performance
Synthetic 2W-50

Performance
Synthetic 2W-50

Synthetic
SPORTSMAN
XP Transmission
Fluid

Demand Drive
PLUS Fluid

ATV Angle Drive
Fluid (or GL5 80­90 weight gear
lube)

PLUS Fluid

Polaris Premium
U-Joint Lube

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 88.

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

Fill Plug

Tor que

--- 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.

10-14 ft. lbs.

Drain Plug

Tor que

(20-23 Nm)

(16 Nm)

(14-19 Nm)

11 ft. lbs.

(15 Nm)

(14-19 Nm)

Inspection
Procedure

Page 81.

Page 81.

Page 84.

Page 86.

Page 87.

80

MAINTENANCE

Dipstick

Full

Add

850

Full Add

550

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn­thetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on
page 80 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 135 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 ATV. 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.

81

MAINTENANCE

550 Drain

Plug

to front

850 Drain

Plug

Filter Access

Engine Oil

Oil and Filter Change

See the table on page 80 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 76. 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.

CAUTION! 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.

82

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.

83

MAINTENANCE

Drain Plug

Fill Plug

Fill

Level

Transmission Oil

Polaris recommends the use of Polaris Synthetic SPORTSMAN XP
Transmission Fluid for this transmission. See the table on page 80 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 76. See page 135 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 ATV behind the footwell. The
drain plug is located on the bottom
left side of the gearcase.

Oil Check

1. Remove the footwell (see

page 97).

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.

84

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.

85

MAINTENANCE

Drain Plug

Fill

Plug

Fill

Level

Front Gearcase (Demand Drive) Fluid

See the table on page 80 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 76.
See page 135 for the part numbers of Polaris products.

Use the recommended fluid. Use of other fluids may result in improper
operation of components.

Maintain the fluid level at the bottom of the fill hole threads. See below
for capacity.

The fill plug is located on
the right side of the
demand drive unit. The
drain plug is located on the
bottom right side of the
unit.

Fluid Check

1. Position the vehicle on

a level surface.
Remove the fill plug.
Check the fluid level.

2. Add the recom-

mended 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.

86

MAINTENANCE

Drain Plug

Fill Plug

Fill

Level

Rear Gearcase Oil

See the table on page 80 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 76. See
page 135 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. Torque

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.

87

MAINTENANCE

ADC Fluid

Reservoir

Active Descent Control (ADC) Fluid

If your vehicle is equipped with Active Descent Control, there are two
fluid levels that must be maintained (demand drive fluid and ADC
fluid). See page 86 for demand drive fluid maintenance.

Check and change the ADC fluid at the intervals outlined in the Periodic
Maintenance Chart beginning on page 76.

NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to

We recommend the use of Polaris Demand Drive Plus Fluid for the
ADC unit. Maintain the fluid level between the minimum and maximum
marks on the reservoir. See page 135 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

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

the hydraulic system.

the front box. See page 36.

reservoir.

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

box and cover.

88

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 ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the screws (turn counter-clockwise) and allow

fluid and trapped air to flow from the fitting. Tighten the screw
when clean fluid begins to flow. Repeat this step for the remaining
valve.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops
below the minimum fill line. Adding fluid to an empty reservoir will result in
trapped air. If the level drops below the minimum line, add fluid to the maximum
line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

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

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

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

89

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 ATV 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 anti-freeze/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 135 for the part
numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.

90

MAINTENANCE

Recovery

Bottle Cap

Maximum

Mark

Minimum

Mark

Cooling System

Recovery Bottle Coolant

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

36.

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.

91

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 dry, check the level
in the radiator. Add coolant as needed.

CAUTION! 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 36.

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.

92

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.

WARNING! An over-full master cylinder may cause brake drag or brake lock­up, 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 30.

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 32.

93

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).

WARNING! 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 ser-

vice.

94

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.

95

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 95.

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.

96