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) and Quadricycles
• RANGER utility vehicles
• Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at www.polarisindustries.com.
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or in acc uracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2009 Sportsman 550/850 XP / 850 XP EPS International Owner’s Manual
P/N 9922173
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
####
VIN
Engine Serial Number
Key
Number
550850
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Failure to follow the warnings in this manual can result in serious injury or death.
This Polaris vehicle is not a toy and can be hazardous to operate. A collision or
rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this Polaris vehicle.
Safety Training
When you purchased your new Polaris vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this information on a regular basis.
If you purchased a used Polaris vehicle from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a
Quadricycle/trailer combination on public roads is prohibited. See your
Polaris dealer about configuring the vehicle to be certified to tow a
trailer on-road.
Equipment Modifications
The warranty on your Polaris Quadricycle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers and large racks may change vehicle handling. Use only
Polaris-approved accessories. Know their function and effect on the vehicle.
6
SAFETY
WARNING
Rider Safety
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Read and understand all warnings, cautions and
operating procedures in this manual and on the
safety labels before operating the vehicle.
Never operate a Quadricycle without proper
instruction. Take a training course. Beginners should
receive training from a certified instructor. Contact an
authorized Polaris dealer or visit the Polaris web site
at www.polarisindustries.com.
Never permit others to operate the vehicle unless
they have read and understand this manual and all
product labels, and have completed a certified safety training course.
Never allow anyone under 16 years of age to
operate this vehicle.
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.
7
SAFETY
Rider Safety
Never carry a passenger on this vehicle.
Always wear an approved helmet that fits
properly. Wear eye protection (goggles or
face shield), gloves, boots, long sleeves and
long pants.
Never consume alcohol or drugs before or
while operating this vehicle.
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
8
Rider Safety
Always inspect your vehicle before each use
to verify that it's in safe operating condition.
See page 44. Follow the inspection and
maintenance procedures outlined in this
manual.
Keep both hands on the handlebars. Keep
both feet on the footrests.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
SAFETY
Always follow the procedures outlined in this
manual for turning. See page 47.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.
If a Quadricycle has been involved in an accident, always have an authorized
Polaris dealer inspect the entire vehicle for possible damage, including (but not
limited to) brake, throttle and steering systems.
9
SAFETY
Rider Safety
Never attempt jumps or other stunts.
Always follow the procedures outlined in this
manual for driving on hills. See page 52.
Never operate on hills too steep for the
vehicle or for your abilities. Practice on
smaller hills before attempting larger hills.
Avoid climbing hills steeper than 25°.
Always move the 4X4 switch to ADC 4X4
before ascending or descending a hill.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills. See page 55.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See
page 54.
Never attempt to turn the vehicle around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual. See page 56.
10
SAFETY
Rider Safety
Always follow the procedures outlined in this
manual for braking if you stall or roll
backwards while climbing a hill. Never back
down a hill. See page 53.
Always follow the procedures outlined in this manual for operating over
obstacles. See page 50.
Always follow the procedures outlined in this
manual for operating on slippery or loose
surfaces. Use extra caution. Always avoid
skidding or sliding. See page 48.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page
49.
Always follow the procedures outlined in this manual for driving in reverse. See
page 51.
11
SAFETY
Rider Safety
Always use the size and type of tires
specified for your vehicle. Maintain the proper
tire pressure.
Never modify this vehicle through improper installation or use of accessories.
Never exceed the stated load capacity for your vehicle. Cargo must be properly
distributed and securely attached. Reduce speed and follow the instructions in
this manual for carrying cargo or towing. Allow a greater distance for braking.
Never operate the vehicle on a frozen body of water.
Operating on paved surfaces may affect the handling and control of the vehicle
and could result in loss of control. Avoid sudden turns or swift movement of the
handlebars.
12
SAFETY
Rider Safety
Always remove the ignition key when the
vehicle is not in use to prevent unauthorized
use or accidental starting.
Always unlock the steering before starting the engine. See page 26.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about Quadricycle safety,
contact an authorized Polaris dealer or visit the Polaris
web site at www.polarisindustries.com.
13
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
14
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.
15
SAFETY
2x4
+
General
Alert
+
+
+
Age 16
Alert
Hill
Operation
Alert
Reverse
Override
Warning
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protec tion.
Read and follow the instructions on each label carefully. If a label
becomes illegible or comes off, contact your Polaris dealer to purchase a
replacement. Replacement safety labels are provided by Polaris at no
charge. The part number is printed on the label.
The following pages repeat the information found on each label.
16
SAFETY
Safety Labels and Locations
General Alert
(Multi-Lingual)
Before you operate this
vehicle, read the owner’s
manual.
7173025
Reverse Override Warning/4X4 Caution
WARNING
Improper use of the override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.
CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
7175512
Hill Operation Alert
• Never operate this vehicle on HILLS steeper than 25 degrees 25°.
• To prevent flip-over on hilly terrain, when going up or down, use throttle and
brakes gradually.
7173026
17
SAFETY
“No Passenger”
Warning
Tire
Pressure/Load
Warning
Safety Labels and Locations
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEAT H.
7175378
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa):
Front: 7.0 psi (48.3 kPa)
Rear: 5.0 psi (34.5 kPa)
MAXIMUM WEIGHT CAPACITY 575 lbs. (261 kg)
INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND
ACCESSORIES.
18
7175820
Safety Labels and Locations
+
Clutch Cover
Warning
(under seat)
+
+
Rack
Warning
Rack
Warning
Clutch Cover Alert
7175826
SAFETY
Rack Warning, Front and Rear
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
• Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg)
7175448
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
7170509
19
FEATURES AND CONTROLS
2x4
Mode/Reverse
Override Switch
Main Key
Switch
Engine
Stop Switch
Headlight
Switch
4X4 Switch
Horn
Switch
Turn Signal
Switch
Hazard
Switch
Switches
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and depress
the override switch.
Pressing the override switch while the throttle is open can cause loss of control,
which may result in serious injury or death. Always release the throttle before
pressing the override switch.
The reverse override switch also acts as a MODE button when held
down for approximately one half second. The transmission cannot be in
reverse when using the override switch as a MODE button.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 30. The
vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.
Hazard Warning Switch
Push the hazard warning switch to cause all turn signal lights to
flash simultaneously . Use this feature to alert others of an emergency or
other situation requiring caution.
20
FEATURES AND CONTROLS
Engine
Stop Switch
Light
Switch
Horn
Switch
Turn Signal
Switch
Switches
Main Key Switch
End all electrical power to the vehicle.
LIGHTS ON position turns the headlights on.
Start the engine. The headlights are not on in this position.
After starting the engine, release the key switch to the POSITION
LIGHTS ON position.
See page 45 for starting procedures.
Engine Stop Switch
The engine will not start or run when
the switch is in the OFF position.
OFF
RUN
Headlight Switch
The lights do not operate unless the
main key switch is on and the engine
stop switch is in the RUN position.
High Beam
Low Beam
Turn Signal Switch
Push the toggle switch either left or right to activate the
corresponding turn signal light. The indicator on the pod will also
flash. Return the toggle to the center position and push it inward
to end the signal.
Horn Switch
Press the horn switch to sound the horn.
21
FEATURES AND CONTROLS
2x4
Electronic Throttle Control
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate the vehicle with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to
increase engine speed and
vehicle movement.
Release the lever to reduce
engine speed and vehicle
movement.
Electronic Throttle Control (ETC)
ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle
system malfunction. Do not modify the ETC system or replace it with other
throttle mechanisms.
22
FEATURES AND CONTROLS
Foot
Brake
Brakes
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems on
this vehicle. Always use caution whenever applying the brakes.
Foot Brake
The all-wheel foot brake is located
on the right footrest. The foot brake
operates both front and rear brakes.
Press the brake pedal down with
your foot to apply the all-wheel
brakes.
If the rear wheels begin to skid or
slide while using the foot brake,
reduce brake pressure.
Hand Brake Lever
The hand brake operates both front
and rear brakes. Squeeze the brake
lever toward the handlebar to apply
the all-wheel brakes.
If the rear wheels begin to skid or
slide while using the brake, reduce
lever pressure.
Operating the vehicle with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the vehicle with a spongy-feeling
brake lever. Always contact your dealer for service before operating the vehicle.
23
FEATURES AND CONTROLS
Brakes
Parking Brake
1. Place the transmission in
PARK.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever.
Operating the vehicle while the parking brake is engaged could result in an
accident and serious injury or death. Always release the parking brake lock
before operating.
24
FEATURES AND CONTROLS
Gear
Selector
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 33 for EPS Warning Indicator information.
Automatic Transmission Gear Selector
The transmission gear selector is
located on the right side of the
vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
Stop the vehicle, release the
throttle and move the shift lever
to the desired gear. See your
dealer if you experience any
shifting problems.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
Whenever the vehicle is left unattended, always place the transmission
in PARK. The transmission is locked when it’s in PARK.
Belt Life
T o extend belt life, use low forward gear in heavy pulling situations and
when operating at less than seven miles per hour (11 km/h) for extended
periods of time.
moving could cause transmission damage.
25
FEATURES AND CONTROLS
Fuel Tank
Cap
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
1. Turn the handlebars to the full left position.
Tip: The handlebars may also be locked in the full left position.
2. Insert the steering lock key and turn it clockwise.
3. Remove the key.
Tip: Place the steering lock keys in a safe place. The lock must be replaced if
the keys are lost.
4. Reverse the procedure to unlock the steering.
The handlebars are locked in the fully turned position when the steering is
locked. Always unlock the steering before starting the engine.
Fuel Tank
Always refuel with the engine stopped,
and outdoors or in a well ventilated area.
Refuel on a level surface.
Remove the fuel tank cap and add fuel.
Use either leaded or unleaded gasoline
with a minimum pump octane number of
87=(R+ M/2) octane. Do not use 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.
26
FEATURES AND CONTROLS
Latches
ADC Fluid
Reservoir
Brake Fluid Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
Front Rack/Compartment
Release the front rack latches
and remove the rack to gain
access to the front compartment. To reinstall the rack,
hold the rack as shown in the
illustration. Position the front
edge in the tabs, then push the
rack downward and secure
the latches.
Access the following components in the front compartment:
• Radiator cap
• Foot brake fluid reservoir
• ADC fluid reservoir
• Coolant recovery bottle cap
• Electrical/fuse/relay components
27
FEATURES AND CONTROLS
2x4
4X4
Switch
ADC 4X4
All Wheel Drive System
The All Wheel Drive system is
controlled by the 4X4 switch.
ADC 4X4 Mode
When the switch is on ADC 4X4,
the ADC system allows engine
braking to all four wheels when
the vehicle descends a hill or
incline. Always move the 4X4
switch to ADC 4X4 before
ascending or descending a hill.
See page 30.
4X4 Mode
When the switch is on 4X4, the
vehicle is in 4X4, and the 4X4
indicator icon in the instrument
cluster display will be visible.
When in 4X4, the demand drive
unit will automatically engage
any time the rear wheels lose
traction. When the rear wheels
regain traction, the demand drive
unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in 4X4.
The vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.
2X4 Mode
When the switch is on 2X4, the vehicle is in two-wheel drive at all
times.
2x4
28
FEATURES AND CONTROLS
All Wheel Drive System
Engaging 4X4
The 4X4 switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable 4X4 until the
engine RPM is below 3100. Once enabled, 4X4 remains enabled until
the 4X4 switch is turned off. If the switch is turned of f while the demand
drive unit is moving, it will not disengage until the rear wheels regain
traction.
Engage the 4X4 switch before getting into conditions where front wheel
drive may be needed. If the rear wheels are spinning, release the throttle
before switching to 4X4.
NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may
cause severe drive shaft and gearcase damage. Always switch to
4X4 or ADC 4X4 while the rear wheels have traction or are at rest.
29
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the
vehicle descends a hill or incline. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the following conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 mph (25 km/h) or less
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the following conditions occur:
• The 4X4 switch is moved out of the ADC 4X4 position
• Vehicle spe ed exc eeds 15 mph (25 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
30
FEATURES AND CONTROLS
Rider Information Center
Directional
Indicator
High Beam
Indicator
Neutral
Indicator
Over-Temperature
Indicator
EPS Warning
Indicator
(if equipped)
Instrument Cluster
Your vehicle is equipped with an instrument cluster that senses vehicle
speed from a gear in the transmission. The instrument cluster measures
distance in miles/kilometers as well as hours of operation.
In addition to showing vehicle speed, the instrument cluster also displays the following items: engine speed, odometer, resettable trip meters
(2), total engine hours of operation, service interval timer and indicator,
gear position, fuel level, AWD status, EPS status (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 vehicle components. Wash the
vehicle by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.
31
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 vehicle to your Polaris dealer for proper diagnosis.
The information center is set to display standard units of measurement
and a 12-hour clock at the factory. T o ch ange to metric an d/or a 24-hour
clock, see page 35.
1. Gear Indicator - This indicator displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
-- = Gear Signal Error (or shifter between gears)
2. Information Display Area - This area displays odometer, tripme-
ters, engine hour meter and programmable service hour interval.
32
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 34.
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 36 for resetting instructions.
7. Engine Overheat Warning - This indicator flashes to indicate an
overheated engine. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will
automatically reduce engine power.
8. Service Indicator - A flashing wrench symbol alerts the operator
that the preset service interval has been reached. The vehicle should
be brought to your dealer for scheduled maintenance. See page 36
for resetting instructions.
9. Under / Over Voltage - This warning usually indicates that the
vehicle is operating at an RPM too low to keep the battery charged.
It may also occur when the engin e is at idle and high electrical load
(lights, cooling fan, accessories) is applied. Drive at a higher RPM
or recharge the battery to clear the warning.
10. Check Engine Warning Indicator - This indicator appears if an
EFI-related fault occurs. Do not operate the vehicle if this warning
appears. Serious engine damage could result. See your dealer.
11. 4X4 Indicator - This indicator illuminates when the 4X4 system is
engaged (switch is on either ADC 4X4 or 4X4).
12. EPS Warning Indicator - This indicator illuminates when the key
is turned to the ON position and goes off when the engine is started.
If the light remains on after starting the engine, the EPS system is
inoperative. See your authorized Polaris dealer for service.
33
FEATURES AND CONTROLS
MODE
Button
SELECT
Button
Instrument Cluster
Rider Information Center
Speed Display Area
Use the MODE button to toggle
through the speed display options.
MODE button operation is locked
out at speeds above approximately
15 MPH (25 km/h).
Tip: The reverse override switch also
acts as a MODE button when held
down for approximately one half
second. The transmission cannot
be in reverse when using the override switch as a MODE button.
This feature does not contain a
vehicle speed lockout function and
can be used at any operating
speed.
Ground Speed Mode
Ground speed is displayed in either miles per hour (MPH) or kilometers
per hour (km/h).
Engine Speed Mode
Engine speed is displayed in revolutions per minute (RPM).
34
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Information Display Area
Use the SELECT button (SEL) to toggle through the information area
options. SELECT button operation is locked out at speeds above
approximately 15 MPH (25 km/h).
Tip: The reverse override switch also acts as the SELECT button when pressed
and released quickly. The transmission cannot be in reverse when using the
override switch as a SELECT button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.
Standard/Metric Display
The display can be viewed in either standard or metric units of measurement. To change units:
1. Press and hold the MODE button until vehicle speed is displayed.
2. T oggle through the information area using the SELE CT button until
the odometer is displayed.
3. Press and hold the MODE button until the displayed units change.
Release the button.
4. New settings remain until changed using the same procedure.
12-Hour/24-Hour Clock Display
1. Press and hold the MODE button until RPM is displayed.
2. T oggle through the information area using the SELE CT button until
the odometer is displayed.
3. Press and hold the MODE button until the clock displays the new
clock format (either 24-hour or 12-hour). Release the button.
4. New settings remain until changed using the same procedure.
Odometer Mode
The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode
The trip meters record the distance traveled by the vehicle on each trip if
reset before each trip. To reset a trip meter , select the trip meter 1 or trip
meter 2 mode. Press and hold the MODE button on the instrument cluster until the total changes to 0. In the Rider Information Center, the trip
meter display contains a decimal point, but the odometer displays without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
35
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Information Display Area
Programmable Service Interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to
change the service interval.
1. Press the SELECT button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the SELECT button
to advance the hours to the desired setting (including OFF). When
the digits stop flashing, the interval has been set.
Clock Mode
Use one of the following two methods to reset the clock.
Method 1
1. Select the Hour Meter Mode.
2. Press and hold the mode button on the instrument cluster until the
hour display flashes. Release the button.
3. Press and release the SELECT button to advance the hours.
4. After the hours are set, press and release the MODE button to move
to the minutes. Use the same procedure to reset the minutes.
5. When the digits stop flashing the clock has been set.
Method 2
1. With the key turned off, press and hold the MODE button.
2. While still holding the MODE button, turn the key to the ON position.
3. Continue to hold the MODE button until the hour display flashes.
Release the button.
4. Set the time as outlined in steps 3-5 of Method 1.
36
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 38-41 for code definitions and failure descriptions.
Tip: More than one fault may be active. Press and hold the MODE button to tog-
gle through all currently active diagnostic codes.
37
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.
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
38
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Sportsman 550 XP Diagnostic Codes
ComponentConditionSPNFMI
Throttle Position Sensor
Engine Temperature Sensor
Intake Air Temperature Sensor
Manifold Absolute Pressure Sensor Voltage Too High1023
Crankshaft Position SensorCircuit Fault6368
Gear Sensor SignalVoltage Too Low (to Calibrate)5234
Fan Relay Driver CircuitDriver Circuit Open/Grounded10715
Idle Air ControlDriver Circuit Grounded5201935
Starter Enable CircuitDriver Circuit Short to B+13213
All Wheel Drive ControlDriver Circuit Short to B+5202073
System PowerVoltage Too High1683
Throttle Safety SignalVoltage Too High5201943
Active Descent Control SystemDriver Circuit Short to B+5202033
Voltage Too High513
Voltage Too Low514
Voltage Too High1103
Voltage Too Low1104
Temperature Too High11016
Engine Overheat Shutdown1100
Voltage Too High1053
Voltage Too Low1054
Voltage Too Low1024
Voltage Too High5233
Signal Fault5232
Driver Circuit Short to B+6513
Driver Circuit Short to B+12683
Driver Circuit Open/Grounded13475
Driver Circuit Short to B+13473
Driver Circuit Short to B+10713
Shorted Load*52019311
Voltage Too low1684
Voltage Too Low5201944
Signal Out of Range5201942
Throttle Stuck5201947
*Assumes unipolar configuration of stepper motor
39
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Sportsman 850 XP / XP EPS Diagnostic Codes
ComponentConditionSPNFMI
Throttle Position SensorVoltage Too High513
Voltage Too Low514
Engine Temperature SensorVoltage Too High1103
Voltage Too Low1104
Temperature Too High11016
Engine Overheat Shutdown1100
Intake Air Temperature SensorVoltage Too High1053
Voltage Too Low1054
Manifold Absolute Pressure SensorVoltage Too High1023
Voltage Too Low1024
Signal Out of Range1022
Crankshaft Position SensorCircuit Fault6368
Plausibility Fault6362
Vehicle Speed SignalSpeed Too High848
Plausibility Fault842
Gear Sensor SignalVoltage Too Low 5234
Voltage too high5233
Signal fault5232
Injector 1 (MAG) (SDI Part Load)Driver Circuit Open/Grounded6515
Driver Circuit Short to B+6513
Driver Circuit Grounded6514
Injector 2 (PTO) (SDI Part Load)Driver Circuit Open/Grounded6525
Driver Circuit Short to B+6523
Driver Circuit Grounded6524
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+12683
Ignition Coil Primary Driver 2 (PTO)Driver Circuit Short to B+12693
Fuel Pump Driver Circuit
Fan Relay Driver CircuitDriver Circuit Open/Grounded10715
Driver Circuit Short to B+5202083
Driver Circuit Grounded5202084
All Wheel Drive ControlDriver Circuit Open/Grounded5202075
Driver Circuit Short to B+5202073
Driver Circuit Grounded5202074
System PowerVoltage Too High1683
Voltage Too low1684
Throttle Safety SignalVoltage Too High5201943
Voltage Too Low5201944
Signal Out of Range5201942
Throttle Stuck5201947
Active Descent Control SystemDriver Circuit Open/Grounded5202035
Driver Circuit Short to B+5202033
Driver Circuit Grounded5202034
Idle SpeedSpeed Too High5202113
Speed Too Low5202114
EPS Models Only
Steering Over Current Shut Down Current Above Normal/Grounded5202216
Steering Excessive Current ErrorCurrent Above Normal/Grounded5202226
Steering Torque Sensor T1 Partial
Failure
Steering Torque Sensor T2 Partial
Failure
Steering Torque Sensor Full
Failure
Steering Position Sensor P1
Partial Failure
Steering Position Sensor P2
Partial Failure
Steering Position Sensor Full
Failure
EPAS Inverter TemperatureGreater than 110 Degrees C52022916
EPAS CAN Comm. Receive Error No RX Message for 2 Seconds5202309
EPAS CAN Comm. Transmit Error No TX Message for 2 Seconds5202319
T1 Shorted to Ground5202234
T1 Shorted to Bus5202233
T2 Shorted to Ground5202244
T2 Shorted to Bus5202243
T1 and T2 Shorted to Ground5202254
T1 and T2 Shorted to Bus5202253
T1 Shorted to Ground & T2
Shorted to Bus
T2 Shorted to Ground & T1
Shorted to Bus
T1 and T2 are Shorted5202252
P1 Shorted to Ground5202264
P1 Shorted to Bus5202263
P2 Shorted to Ground5202274
P2 Shorted to Bus5202273
P1 and P2 Shorted to Ground5202284
P1 and P2 Shorted to bus5202283
Greater than 120 Degrees C5202290
52022516
52022517
41
OPERATION
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new Polaris vehicle is the first ten hours of
operation, or the time it takes to use the first two full tanks of gasoline.
No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive
components will result in more efficient performance and longer life for
these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
42
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 26. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 67. 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 44.
6. Pull only light loads.
7. Change both the oil and the filter at 20 hours, one month or 500
miles (800 km), whichever comes first.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation during the break-in period.
43
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect
the vehicle before each use to make sure it's in safe operating condition.
ItemRemarksPage
Hand brake/lever travelEnsure proper operation81
Foot brakeEnsure proper operation81
Brake fluidEnsure proper levels79
Front suspensionInspect, lubricate if necessary66
Rear suspensionInspect, lubricate if necessary66
SteeringEnsure free operationTiresInspect condition and pressure84
Wheels/fastenersInspect, ensure fastener tightness84
Frame nuts, bolts, fastenersInspect, ensure tightnessFuel and oilEnsure proper levels26
Coolant levelEnsure proper level77
Coolant hosesInspect for leaks-
ADC FluidEnsure proper level74
MirrorsAdjust for best side/rear vision-
protective clothing
85
67
78
112
14
44
OPERATION
Starting the Engine
1. Position the vehicle on a level surface
2. Place the transmission in PARK.
Tip: The starter interlock will prevent the engine from starting if the transmission
is in gear and the brake is not engaged.
3. Sit on the vehicle. Move the engine stop switch to RUN.
4. Do not press the throttle while starting the engine.
5. Turn the ignition key past the POSITION LIGHTS ON position to
engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.
6. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
Cold Weather Operation
If the vehicle is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminates such as water
or excess fuel in the bottom of the crankcase. W ater in the bottom of the
crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.
See your Polaris dealer for engine heater kits, which provide quicker
warm-ups and easier starting in colder weather.
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
45
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 14.
2. Perform the pre-ride inspection. See page 44.
3. Place the transmission in PARK.
4. Mount the vehicle from the left side.
5. Sit upright with both feet on the footrests. Keep both hands on the
handlebars.
6. Start the engine and allow it to warm up.
7. Apply the brakes.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the brakes.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
46
Turning the Vehicle
1. Before turning, activate a
turn signal to alert others of
your intentions. Activate the
left signal before a left turn.
Activate the right signal
before a right turn.
2. Steer in the direction of the
turn, leaning your upper
body to the inside of the
turn while supporting your
weight on the outer footrest.
Use the same leaning technique for turning in reverse.
3. Practice making turns at
slow speeds before attempting to turn at faster speeds.
Always follow the procedures outlined in this
manual for turning. Never turn sharply at
excessive speeds, which can lead to vehicle
overturn.
OPERATION
47
OPERATION
Sideways
Skid
Turn in direction
of skid
Driving on Slippery Surfaces
Whenever driving on slippery or loose surfaces such as wet trails,
gravel, snow or ice, follow these precautions:
1. Slow down when entering slippery areas.
2. Engage 4X4 before wheels begin to lose traction.
NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while
3. Be alert. Watch the trail. Avoid quick, sharp turns
4. Never apply the brakes during a skid. Correct a skid by turning the
the wheels are spinning. Allow the rear wheels to stop spinning
before engaging 4X4, or engage 4X4 before wheels begin to lose
traction.
handlebars in the direction of the skid and shifting your body
weight forward.
Always follow the procedures outlined in this
manual for operating on slippery or loose
surfaces. Use extra caution. Always avoid
skidding or sliding.
48
OPERATION
Maximum
Depth
Driving Through Water
Follow these procedures when
driving through water:
1. Check water depth and current before crossing.
2. Choose a crossing where
both banks have gradual
inclines.
3. Drive slowly. Avoid rocks
and obstacles.
4. Avoid operating in water
deeper than the bottom of
the footrests. If it's unavoidable, travel slowly, balance
your weight carefully and avoid sudden movements. Maintain a
slow and steady forward motion. Do not make sudden turns, stops
or throttle changes.
NOTICE: If the vehicle stops while fully submerged, major engine damage can
5. Wet brakes may have reduced stopping ability. Dry the brake pads
6. If your vehicle becomes fully immersed, and it's impossible to take
result if the machine is not thoroughly inspected. Take the vehicle to
your dealer before starting the engine.
by driving slowly and applying the brakes lightly several times until
braking action is normal.
it to a dealer before starting it, follow the steps described on page
94. Have the vehicle serviced by your dealer promptly.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water.
49
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Be alert. Watch the terrain. Use extra caution.
3. Never operate over large obstacles.
4. Avoid hazards such as logs, rocks and low branches.
Always follow the procedures outlined in this manual for operating over
obstacles.
50
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Avoid backing downhill.
3. Drive slowly. Apply the brakes lightly for stopping.
4. Avoid turning at sharp angles.
5. Never open the throttle suddenly.
6. Do not use the override switch unless additional wheel speed is
required for vehicle movement. Use with caution.
NOTICE: Excessive throttle operation while in the speed limit mode may cause
fuel to build in the exhaust, resulting in engine popping and/or engine
damage.
Always follow the procedures outlined in this manual for driving in reverse.
51
OPERATION
25° Maximum
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 30.
2. Drive straight uphill.
3. Avoid steep hills (25° maximum).
4. Avoid hills with slippery or loose surfaces.
5. Keep both feet on the footrests.
6. Shift body weight uphill.
7. Proceed at a steady rate of speed to avoid stalling.
8. Be alert. Be prepared to take emergency action. This may include
dismounting quickly.
9. Never open the throttle suddenly or make sudden gear changes.
10. Never go over the top of a hill at high speed.
52
OPERATION
Driving Uphill
If all forward speed is lost:
Keep your weight uphill.
If the vehicle begins rolling downhill, never apply engine power. Never
apply the brakes aggressively while rolling backwards.
1. Apply the brakes gradually.
2. When fully stopped, lock the hydraulic parking brake.
3. Dismount on the uphill side, or on the left side if the vehicle is
pointed straight uphill.
4. Use the K-turn to turn around. See page 56.
Always follow the procedures outlined in this
manual for driving on hills. Avoid climbing
hills steeper than 25°.
Always follow the procedures outlined in this
manual for braking if you stall or roll
backwards while climbing a hill. Never back
down a hill.
53
OPERATION
Driving on a Sidehill (Sidehilling)
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Shift body weight uphill.
3. Keep your feet on the footrests.
4. Avoid hills with slippery or loose surfaces.
5. Avoid crossing the sides of steep hills.
6. If the vehicle begins to slide or tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side immediately!
Always follow the procedures outlined in this
manual for crossing the side of a hill.
Never attempt to turn the vehicle around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual.
54
Driving Downhill
When driving downhill, follow
these precautions:
1. Always move the 4X4 switch
to ADC 4X4 before ascending
or descending a hill. See page
30.
2. Avoid hills with slippery or
loose surfaces.
3. Never drive downhill at high
speed. Slow down.
4. Drive straight downhill.
Avoid driving downhill at an
angle, which can cause the
vehicle to pitch sharply to one side.
5. Shift your weight rearward.
6. Apply the brakes slightly to aid in slowing.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills.
OPERATION
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
55
OPERATION
2.4 m
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
1. Stop the vehicle. Keep your weight uphill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 30.
3. Lock the hydraulic parking brake.
4. Leave the transmission in forward gear. Turn the engine off.
5. Dismount on the uphill side, or on the left side if the vehicle is
pointed straight uphill.
6. Stay uphill of the vehicle and turn the handlebars full left.
7. Squeeze the brake lever to release the parking brake.
8. Slowly release the brake lever and allow the vehicle to roll around
to your right until it's pointing across the hill or slightly downward.
56
OPERATION
Turning Around on a Hill (K-Turn)
9. Lock the hydraulic parking brake.
10. Remount from the uphill side. Keep your weight uphill.
11. Apply the foot brake.
12. With the transmission still in forward, start the engine.
13. Squeeze and release the brake lever to release the parking brake.
14. Release the foot brake and drive slowly downhill. Control speed
with either the hand or foot brake until the vehicle is on level
ground.
Always follow the procedures outlined in this
manual for driving on hills. See page 52.
Never operate on hills too steep for the
vehicle or for your abilities. Practice on
smaller hills before attempting larger hills.
Avoid climbing hills steeper than 25°.
Always follow the procedures outlined in this
manual for braking if you stall or roll
backwards while climbing a hill. Never back
down a hill.
57
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo.
• Read and understand the load distributio n warnings listed on the vehicle
warning labels.
• Never exceed the stated load capacity for this vehicle. When determining the
weight you are adding to the vehicle, include the wei ght of the ope rator,
accessories, loads in the rack or box and the load on the trailer tongue. The
combined weight of these items must not exceed the maximum weight capacity.
• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO OR TOWING. Use extreme caution when applying
brakes. Avoid situations that require backing downhill.
• CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.
• CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads
high on the racks raises the center of gravity of the vehicle and creates a less
stable operating condition.
• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
• HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
• USE EXTREME CAUTION when operating with loads that extend over the
rack sides. Stability and maneuverability may be adversely affected, causing
the vehicle to overturn.
• TOWING is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer
combination on public roads is prohibited.
• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when
towing loads in rough terrain, while cornering, or while ascending or descending hills.
58
OPERATION
1/3
2/3
Maximum
10 cm
Hauling Cargo
Never exceed the weight
capacities specified for your
vehicle on warning labels and
in the specifications section of
this manual.
Cargo weight should be evenly
distributed (1/3 on the front
rack and 2/3 on the rear rack)
and mounted as low as possible. When operating over
rough or hilly terrain, reduce
speed and cargo weight to
maintain stable driving conditions. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
Towing Loads
T owing is approved OFF-ROAD ONLY . Operating a Quadricycle/trailer
combination on public roads is prohibited. See your Polaris dealer about
configuring the vehicle to be certified to tow a trailer on-road.
• Do not tow any trailer on a grade steeper than 15°.
• Always attach a towed load to the hitch point. Remove the hitch from
the vehicle when not towing a trailer.
• If towing a load, reduce rear rack cargo weight by the amount of
tongue weight. The combination of rear rack car go weight and tongue
weight must not exceed the rear rack capacity.
• The total load (operator, accessories, car go an d weight on hitch) must
not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding
the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your vehicle
warranty. Never install a hitch longer
than 10 cm. Never install automotive
accessories on your Polaris vehicle.
Always install Polaris-approved (or
equivalent) accessories designed for
use on this vehicle.
59
OPERATION
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Always block the rear wheels on the downhill side.
60
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with governmental noise level requirements.
Spark Arrestor
Your Polaris vehicle has a spark arrestor that was designed for on-road
and off-road operation. It is required that this spark arrestor remain
installed and functional when the vehicle is operated.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not
adjustable.
Electromagnetic Interference
This spark ignition system complies with USA requirements, Canadian
ICES-002 and EMC requirements of European directives 97/24/EC and
2004/108/EC.
61
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 127.
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.
62
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized Polaris dealer perform these services.
Maintenance Chart Key
X Perform these operations more often for vehicles subjected to severe
use.
EEmission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)
Have an authorized Polaris dealer perform these services.
63
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
ItemMaintenance Interval
Steering-Pre-Ride-See Pre-Ride Checklist on
Front suspension-Pre-RideRear suspension-Pre-RideTires-Pre-RideBrake fluid level-Pre-RideBrake lever travel-Pre-RideBrake system-Pre-RideWheels/fasteners-Pre-RideFrame fasteners-Pre-RideEngine oil level-Pre-Ride-
X
Air filter, pre-filter-Daily-Inspect; clean often; replace
X Engine oil change20 H1 Month500 (800)Perform a break-in oil and
Brake pad wear10 HMonthly100 (160) Inspect periodically
X
Battery20 HMonthly200 (320) Check terminals; clean; test
X Demand drive fluid 25 HMonthly250 (400)Inspect level
X Rear gearcase oil25 HMonthly250 (400) Inspect level
X Transmission oil25 HMonthly250 (400) Inspect level
X General
lubrication
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Have an authorized Polaris dealer perform these services.
X Radiator50 H6 M1000 (1600) Inspect; clean external
X Cooling hoses50 H6 M1000 (1600) Inspect for leaks
X Engine oil change100 H6 M1000 (1600) Change the oil and filter
X Demand drive fluid 100 H12 M1000 (1600) Change fluid
X Rear gearcase oil100 H12 M1000 (1600) Change fluid
X Transmission oil100 H12 M1000 (1600) Change fluid
Fuel system100 H12 M1000 (1600) Check for leaks at tank cap,
X Engine mounts100 H12 M1000 (1600) Inspect
Exhaust muffler/
pipe
Q
Spark plug100 H12 M1000 (1600) Inspect; replace as needed
E
X Wiring100 H12 M1000 (1600) Inspect for wear, routing,
Q
Clutches (drive
and driven)
Q
Front wheel
bearings
Q
Brake fluid200 H24 M2000 (3 200) Change every two years
Q
ADC fluid200 H24 M2000 (3200) Change every two years
Spark arrestor300 H36 M3000 (4800) Clean out
Q
Valve clearance1000 H-10000
E
Q
Toe adjustment-Inspect periodically; adjust
Headlight aim-Adjust as needed
(whichever comes first)
Hours CalendarMiles
50 H6 M500 (800)Inspect; adjust; lubricate;
50 H6 M500 (800)Inspect duct for proper seal-
100 H12 M1000 (1600) Inspect
100 H12 M1000 (1600) Inspect; clean; replace worn
100 H12 M1000 (1600) Inspect; replace as needed
(Km)
(16000)
replace if necessary
ing/air leaks
seasonally; pressure test
system yearly
surfaces
lines, filter, pump; replace
lines every two years
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
parts
Inspect; adjust
when parts are replaced
Remarks
65
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 62. Items not listed in the
chart should be lubricated at the General Lubrication interval.
The a-arms and lower control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
Grease fittings (3 pumps maximum) every 500 miles,
before long periods of storage, or after pressure
washing or submerging.
Fill Plug
Torque
---15-17 ft. lbs.
---12 ft. lbs.
10-14 ft. lbs.
(14-19 Nm)
8-10 ft. lbs.
(11-14 Nm)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
10-14 ft. lbs.
Drain Plug
Torque
(20-23 Nm)
(16 Nm)
(14-19 Nm)
11 ft. lbs.
(15 Nm)
(14-19 Nm)
Inspection
Procedure
Page 67.
Page 67.
Page 70.
Page 71.
Page 72.
66
MAINTENANCE
Dipstick
Full
Add
850
FullAdd
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 66 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 119 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. Access the oil dipstick and fill tube from the left
side of the vehicle.
1. Position the vehicle on a
2. Remove the dipstick. W ipe it
3. Reinstall and tighten the dip-
4. Remove the dipstick and
5. Add the recommended fluid
6. Reinstall and tighten the
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
level surface. Place the transmission in PARK.
dry with a clean cloth.
stick.
check the oil level.
as needed. Maintain the oil
level in the safe range
between the FULL and ADD
marks. Do not overfill.
dipstick.
67
MAINTENANCE
550
Drain
Plug
to front
850
Drain
Plug
Filter Access
Engine Oil
Oil and Filter Change
See the table on page 66 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 62. Always change the
oil filter whenever changing oil.
1. Position the vehicle on a level surface. Place the transmission in
PARK.
2. Start the engine. Allow it to warm up at idle for two to three min-
utes.
3. Stop the engine.
4. Clean the area around the drain plug.
5. Place a drain pan under the crankcase.
6. Remove the drain plug. Allow the oil to drain completely.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque to specification.
68
MAINTENANCE
Oil Filter
Engine Oil
Oil and Filter Change
9. Place shop towels beneath the oil
filter. Using an oil filter wrench
(available from your Polaris
dealer), turn the filter counterclockwise to remove it.
10. Using a clean dry cloth, clean the
filter sealing surface on the
crankcase.
11. Lubricate the o-ring on the new
filter with a film of fresh engine
oil. Check to make sure the o-ring
is in good condition.
12. Install the new filter and rotate it
clockwise by hand until the filter
gasket contacts the sealing surface, then turn it an additional 1/2
turn.
13. Remove the dipstick. Add the proper amount of the recommended
oil. Do not overfill.
14. Reinstall the dipstick.
15. Place the transmission in PARK.
16. Start the engine. Allow it to idle for one to two minutes.
17. Stop the engine.
18. Check for leaks.
19. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
20. Dispose of used filter and oil properly.
69
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 66 for fluid
recommendations, capacities and plug torques. Alw ays check and
change the transmission oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 62. See page 119 for the part
numbers of Polaris products.
Maintain the oil level at the bottom of the fill plug hole. The fill
plug is located on the right side of
the vehicle behind the footwell.
The drain plug is located on the
bottom left side of the gearcase.
Oil Check
1. Remove the footwell (see
page 83).
2. Remove the fill plug. Check
the oil level.
3. Add the recommended fluid
as needed to bring the level to
the bottom of the fill hole
threads.
4. Reinstall the fill plug. Torque to specification.
5. Reinstall the footwell.
Oil Change
1. Remove the footwell.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow
the oil to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Remove the fill plug. Add the proper amount of the recommended
oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the footwell.
8. Dispose of used oil properly.
70
MAINTENANCE
Drain Plug
Fill
Plug
Fill
Level
Front Gearcase (Demand Drive) Fluid
See the table on page 66 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 62.
See page 119 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.
71
MAINTENANCE
Drain Plug
Fill Plug
Fill
Level
Rear Gearcase Oil
See the table on page 66 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 62. See
page 119 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.
72
MAINTENANCE
Rear Gearcase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. T orque
to specification.
5. Remove the fill plug. Add the proper amount of the recommended
oil. Do not overfill.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
73
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 71 for demand drive fluid maintenance.
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 62. Maintain the fluid
level between the minimum and maximum marks on the reservoir. We
recommend the use of Polaris ADC Fluid. See page 119 for the part
numbers of Polaris products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
1. Remove the front rack.
2. View the fluid level in the
3. If the level is below the
4. Reinstall the cap.
5. Reinstall the front rack.
the hydraulic system.
reservoir.
minimum mark, remove
the cap and add the
recommended fluid.
74
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 dro ps
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.
75
MAINTENANCE
Clean
Often
Power Steering Unit
If your model is equipped with
power steering, frequently clean
the areas around and on the
power steering unit to allow
proper cooling. Clean these areas
thoroughly.
Cooling System
The engine coolant level is controlled by the recovery system. Recovery
system components are the recovery bottle, the radiator filler neck, the
radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
Polaris recommends the use of Polaris Premium 60/40 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 119 for the part
numbers of Polaris products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
76
MAINTENANCE
Recovery
Bottle Cap
Maximum
Mark
Minimum
Mark
Cooling System
Recovery Bottle Coolant
The recovery bottle fluid level can be viewed from inside the front right
wheel well. Access the recovery bottle cap under the front storage compartment.
1. View the fluid level in the bottle.
2. If the level is low, remove the front rack.
3. Remove the bottle cap and add coolant as needed. Maintain the
coolant level between the minimum and maximum marks on the
bottle (when the fluid is cool).
4. Reinstall the cap.
5. Reinstall the front rack.
77
MAINTENANCE
Radiator
Cap
Cooling System
Radiator Coolant
To ensure that the coolant maintains its ability to protect the engine,
Polaris recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.
Replace the coolant any time the cooling system has been drained for
maintenance or repair . If the recovery bottle has run dr y, check the level
in the radiator. Add coolant as needed.
Escaping steam can cause burns. Never remove the pressure cap while the
engine is warm or hot. Always allow the engine to cool before removing the
pressure cap.
1. Remove the front rack.
2. Remove the pressure cap.
3. Using a funnel, slowly add coolant
through the radiator filler neck.
4. Reinstall the pressure cap. Use of a
non-standard pressure cap will not
allow the recovery system to function properly. Contact your dealer
for the correct replacement part.
5. Reinstall the front rack.
78
MAINTENANCE
Brake Fluid
Check brake fluid levels for both brake systems before each ride.
Always maintain brake fluid at the recommended level. Do not overfill.
The brakes should feel firm when they're applied. Spongy or weak
brakes may indicate a fluid leak or low fluid level. A low fluid level
may also mean that brake pads are worn and need to be replaced. Do not
operate the vehicle with spongy or weak brakes. See your dealer for service.
Operating the vehicle with a spongy brake can result in loss of braking, which
could cause an accident. Never operate the vehicle with spongy-feeling brakes.
If the fluid level is low add DOT 4 brake fluid only. See page 1 19 for the
part numbers of Polaris products.
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in serious injury or death. Maintain brake fluid at the recommended level.
Do not overfill.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of accident or severe injury. After opening a bottle of brake
fluid, always discard any unused portion.
79
MAINTENANCE
Master
Cylinder
Indicator
Window
Full
Low
Brake Fluid Reservoir
Brake Fluid
Hand Brake
The master cylinder is located on
the left handlebar. Maintain the
fluid level 6 mm below the top
edge of the master cylinder. Do
not overfill.
1. Position the vehicle on a
level surface. Make sure the
handlebars are straight.
2. View the fluid level through
the indicator window (eye)
on the top of the master cylinder.
Tip: The eye will appear dark when
the fluid level is full. When fluid
is low, the eye will be clear.
3. If the fluid level is low,
remove the cover screws and
add fluid to the fill line. Do
not overfill.
4. Reinstall the cover. Torque screws to 7 in. lbs. (.8 Nm).
Foot Brake
The foot brake fluid reservoir is
located under the front rack. The
brake fluid reservoir cap is black.
NOTICE: Do not use ADC fluid in the
brake fluid reservoir. ADC
fluid will damage the rubber
components of the brake
system.
80
MAINTENANCE
1 mm
Brake Inspections
The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake
systems are self-adjusting.
Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal
operation.
1. Always keep brake fluid at an adequate
level. See page 80.
2. Check the brake systems regularly for
fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace the pads when
the friction material is worn to 1 mm.
5. Check the security and surface condition
of the disc.
81
MAINTENANCE
String
Stand
2
1
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.
Severe injury or death can result from improper toe alignment and adjustment.
Do not attempt to adjust tie rod alignment. All tie rod adjustments should be
performed by an authorized Polaris dealer.
1. Position the vehicle on a
level surface.
2. Place the handlebars in a
straight-ahead position.
3. Tie a length of string
between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long straightedge instead of string.
4. Measure the distance
from the string to the
rim at the front (1) and
rear (2) of the front rim.
The rear measurement
should be 1/16"-1/8" (2-3 mm) more than the front measurement on
each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6
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.
Steering Assembly
The steering assembly should be checked periodically for loose nuts and
bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.
82
MAINTENANCE
Plastic Rivet
Hex Head Screw
Plastic Rivet
Plastic Rivet
Torx Head
Screw
Seat Removal
1. Grasp one side of the seat
near the rear edge.
2. Pull upward abruptly to
disengage the under-seat
fasteners.
3. Remove the seat.
Side Panel/Footwell Removal
Remove the seat before removing a side panel. Remove the screws and
rivets securing the side panel or footwell (see illustration).
83
MAINTENANCE
1/8" (3 mm)
Tires
Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 120 for recommended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized
Polaris dealer.
Wheel Removal
1. Stop the engine.
2. Place the transmission in PARK.
3. Loosen the wheel nuts slightly.
Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.
4. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
5. Remove the wheel nuts.
6. Remove the wheel.
84
MAINTENANCE
Cast Aluminum
Steel
75 ft. lbs.
(102 Nm)
45 ft. lbs.
(61 Nm)
Tires
Wheel Installation
1. Place the transmission in PARK.
2. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation (if
equipped).
3. Install the wheel nuts and finger-tighten them.
4. Lower the vehicle to the ground.
5. Torque the wheel nuts to specification.
Loose nuts could cause a tire to come off during operation, which could result in
an accident or overturn. Always ensure that all nuts are torqued to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loosened for maintenance service.
Wheel TypeNut TypeNut Torque
AluminumLug Nut75 ft. lbs. (102 Nm)
SteelLug Nut45 ft. lbs. (61 Nm)
85
MAINTENANCE
Main
Filter
Pre-Filter
Screws
Air Filter
1. Remove the seat.
2. Remove the air box cover
screws, and remove the air
box cover.
3. Remove the filter.
4. Remove the fabric type pre-
filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.
5. Reinstall the pre-filter over
the main filter. Install a new
main filter if needed.
6. Reinstall the filter into the air
box.
7. Reinstall the air box cover
and the seat.
86
MAINTENANCE
Fuse Box
850 XP EPS
550 XP850 XP
Fuse Replacement
If the engine stops or will not start, or if you experience other electrical
failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare
fuses are provided in the fuse box.
1. Remove the front rack.
2. Remove the fuse box cover.
3. Remove the suspect fuse from the fuse panel. If the fuse is blown,
install a new fuse with the same amperage rating.
4. Reinstall the fuse box cover.
5. Reinstall the front rack.
87
MAINTENANCE
7.6 m
5 cm
X
X
Screws
Lights
Headlight Beam Adjustment
The headlight beam can be adjusted slightly upward or downward.
1. Position the vehicle on a level surface. The headlight should be
approximately 7.6 m from a wall.
2. Place the transmission in PARK.
3. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
NOTE: Include rider weight on the seat when measuring.
4. Start the engine.Turn the head-
light switch to high beam.
5. Observe the headlight aim on
the wall. The most intense part
of the headlight beam should be
5 cm below the mark on the
wall.
6. Tighten or loosen the three (3)
headlight screws to adjust the
beam upward or downward or
to the left or right.
88
MAINTENANCE
Position Light
Collar
Socket
Headlamp
Lights
Poor lighting can result in loss of control or an accident. Lights become dirty
during normal operation. Wash the headlights and taillights frequently.
Hot components can cause serious burns to skin. Do not service the headlamps
until they've cooled.
Headlight/Position Light Lamp Replacement
When servicing a halogen lamp, do
not touch the lamp with bare fingers.
Oil from your skin leaves a residue,
causing a hot spot that will shorten
the life of the lamp. Hold the plastic
part of the lamp.
1. Place the transmission in PARK.
2. Open the front rack cover.
3. Remove the plug at the back of the
headlight.
4. Pull the harness plug to disconnect
it from the back of the headlight.
5. Position light: Rotate the socket to
remove it. Go to step 6.
Headlamp: Reach under the
bumper and remove the rubber
cover from the back of the
headlight. Turn the collar counterclockwise and carefully remove
the collar and socket.
6. Remove the lamp. Apply dielectric
grease to the socket and install a
new lamp.
7. Reverse all steps to reassemble the
headlight.
89
MAINTENANCE
Screw
Lamp
Lights
Rear Turn Signal Lamp Replacement
1. Place the transmission in PARK.
2. Rotate the turn signal socket
counterclockwise to remove it.
3. Remove the lamp.
4. Apply dielectric grease to the
socket.
5. Install the new lamp. Test the lamp for proper operation.
6. Reinstall all components in reverse order.
Front Turn Signal Lamp Replacement
1. Place the transmission in
PARK.
2. Remove the lens attachment
screw.
3. Rotate the lamp to remove it.
4. Install the new lamp.
5. Reinstall the lens.
90
MAINTENANCE
Lights
Taillight/Brakelight Lamp Replacement
1. Place the transmission in
PARK.
2. Rotate the taillight socket
counterclockwise to remove it.
3. Remove the lamp.
4. Apply dielectric grease to the
socket.
5. Install the new lamp. Test the lamp for proper operation.
6. Reinstall all components in reverse order.
91
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 120 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
Plug Condition
Torque Specification
550 XP850 XP/XP EPS
New Spark Plug9-11 ft. lbs.
(12-15 Nm)
Previously Installed
Spark Plug
17-20 ft. lbs.
(23-27 Nm)
18-20 ft. lbs.
(24-27 Nm)
18-20 ft. lbs.
(24-27 Nm)
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plugs for correct color. See page 93.
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Rotate the spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specifi-
cation.
92
MAINTENANCE
Spark Plugs
Spark Plug Inspection
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
The tip should not be flaky and white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect fuel.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil or incorrect throttle body adjustments.
93
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can resu lt if
the machine is not thoroughly inspected. T ake the vehicle to your dealer
before starting the engine. If it's impossible to take your vehicle to a
dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land or at the very least, to water below the
footrests.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter.
3. Remove the spark plugs.
4. Turn the engine over several times using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying proce-
dure.
7. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
8. If water has been ingested into the PVT, follow the procedure on
page 98 for drying out the PVT.
94
MAINTENANCE
Clean-Out Plug
Spark Arrestor
Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrestor while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrestor clean-
out plug from the bottom of
the muffler.
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and
release the throttle lever
several times to purge carbon from the system.
5. If carbon comes out of the
exhaust, cover or plug the
exhaust outlet(s). Wear
protective gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 4.
7. If particles are still suspected to be in the muffler , elev ate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
8. Place the transmission in PARK. Repeat steps 4 to 6 until no more
particles are expelled.
9. Stop the engine. Allow the arrestor to cool.
10. Reinstall the arrestor clean-out plug and remove the exhaust outlet
cover or plug.
95
MAINTENANCE
PVT System
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer as
outlined in the owner's manual.
• This PVT system is intended for use on Polaris products only. Do not install it
in any other product.
• Always make sure the PVT housing is securely in place during operation.
96
MAINTENANCE
PVT System
The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of pinch applied to the
drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.
The approximate gear ratio diffe re n ce between hig h and low range is
1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the system's dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 km/h) in
low range, the engine speed would be around 3000 RPM. This is well
above the engagement speed of 1600 - 1800 RPM. However, in high
range at 3 MPH (5 km/h), the engine would be running at only 1500
RPM. Whenever operating this close to the engagement speed, the
engine may be running at a speed too low to provide the pinch needed to
prevent belt slip. Belt slip is responsible for creating the excessive heat
that destroys belts, wears clutch components and causes outer clutch
covers to fail.
The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).
97
MAINTENANCE
PVT System
When To Use Low Range and High Range
ConditionRange to Use
Operating at speeds less than 7 MPH (11 km/h)Low
Towing heavy loadsLow
Operating in rough terrain (swamps, mountains, etc.)Low
Operating at speeds greater than 7 MPH (11 km/h)High
PVT Drying
There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before operating.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Rein-
stall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the trans-
mission to the lowest available range.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
98
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