PMS 419
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Sportsman Forest 550
Sportsman Forest 850
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
•RZR® sport vehicles
• VICTORY® motorcycles
• GEM® electric vehicles
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.
2
POLARIS® and SPORTSMAN® are registered trademarks of POLARIS Industries Inc.
MAXXIS® is a registered trademark of Maxxis International.
Copyright 2013 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
SPORTSMAN Forest 550 / SPORTSMAN Forest 850 Owner’s Manual
P/N 9924662
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls. . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Emission Control Systems . . . . . . . . . . . . . . . 73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 127
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 131
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 132
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 140
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4
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.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could 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.
5
INTRODUCTION
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the
protection of our environment. Read and understand your owner's
manual, which includes valuable information about all aspects of your
vehicle, including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the
operation of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key
Number
550 850
6
SAFETY
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
Never operate this vehicle without proper instruction. Take a training
course.
For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polarisindustries.com.
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. Towing a
trailer with this vehicle on public roads is prohibited. See your
POLARIS dealer about configuring the vehicle to be certified to tow a
trailer on-road.
Equipment Modifications
The warranty on your POLARIS vehicle may be terminated if any
equipment has been added, or if any modifications have 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.
WARNING
7
SAFETY
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 this vehicle without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor.
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.
WARNING
8
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.
9
SAFETY
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.
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 the vehicle has been involved in an accident, always have an authorized
POLARIS dealer inspect the entire vehicle for possible damage, including (but
not limited to) brake, throttle and steering systems.
10
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.
11
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.
12
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 unless you have
independently verified that the ice is sufficiently thick to support the weight and
moving force of the vehicle, you and your cargo, together with any other
vehicles in your party.
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.
13
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 safety, contact an authorized
POLARIS dealer or visit the POLARIS web site at
www.polarisindustries.com.
14
SAFETY
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.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
15
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.
16
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If 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.
2x4
OUT
IN
General
Alert
Age 16
Alert
Hill
Operation
Alert
Reverse
Override
Warning
17
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
18
SAFETY
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
DEATH.
7175378
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa): FRONT: 7.0 (48.3) REAR: 7.0 (48.3)
MAXIMUM WEIGHT CAPACITY 575 lbs. (261 kg)
INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND
ACCESSORIES.
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg).
NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs.
(91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
7177981
“No Passenger”
Warning
Tire
Pressure/Load
Warning
19
SAFETY
Safety Labels and Locations
Clutch Cover Alert
7175826
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
Clutch Cover
Warning
(under seat)
Rack
Warning
Rack
Warning
20
FEATURES AND CONTROLS
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.
Momentary High Beam Switch
Press this switch with your left forefinger to activate the headlight high
beam. The lights will return to low beam when the switch is released.
Winch Switch
See page 61 for winch information.
2x4
OUT
IN
Mode/Reverse
Override Switch
Main Key
Switch
4X4 Switch
Winch
Switch
Momentary High-Beam
Switch
21
FEATURES AND CONTROLS
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 to end the signal.
Horn Switch
Press the horn switch to sound the horn.
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.
Override
Switch
Engine
Stop
Switch
Headlight
Switch
Horn
Switch
Hazard
Switch
Turn
Signal
Switch
22
FEATURES AND CONTROLS
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.
Throttle Release Switch
The throttle release switch causes the engine to stop if the throttle cable
sticks in an open position when the operator releases the throttle lever.
The throttle release switch stops the engine in the event of a throttle system
malfunction. Do not modify the throttle release switch or replace it with other
throttle mechanisms.
2x4
23
FEATURES AND CONTROLS
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.
Foot
Brake
24
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.
25
FEATURES AND CONTROLS
Electronic Power Steering (EPS)
Electronic power steering engages when the ignition key is turned to the
ON position. EPS remains engaged whether the vehicle is moving or
idle. See page 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
moving could cause transmission damage.
Whenever the vehicle is left unattended, always place the transmission
in PARK. The transmission is locked when it’s in PARK.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at
less than 11 km/h for extended periods and when operating uphill at a
slow speed.
Gear
Selector
26
FEATURES AND CONTROLS
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 right 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 fuel
with ethanol content greater than 10
percent, 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.
Extreme Use 30 AH Battery
If your factory-installed 18 AH battery cannot maintain a charge
because of operation in extreme cold or with multiple electrical
accessories, please see your POLARIS dealer to purchase a 30 AH
battery.
1. Fully charge the new battery before installing it. See page 118.
2. To install the 30 AH battery, remove the 18 AH battery. See page
115.
3. Remove the plastic spacer at the bottom of the battery compartment.
Save the spacer for future use.
4. Install the new battery. See page 116.
Fuel Tank
Cap
27
FEATURES AND CONTROLS
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
Latches
ADC Fluid Reservoir
Brake Fluid Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
28
FEATURES AND CONTROLS
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 (in forward or reverse).
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
2x4
4X4
Switch
ADC 4X4
29
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.
30
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 speed exceeds 15 mph (25 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
31
FEATURES AND CONTROLS
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, 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.
Rider Information Center
Directional
Indicator
High Beam
Indicator
Neutral
Indicator
Over-Temperature
Indicator
EPS Warning
Indicator
32
FEATURES AND CONTROLS
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, please see your POLARIS dealer.
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 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,
tripmeters, engine hour meter and programmable service hour
interval.
3. Speed Display - This area displays vehicle ground speed or engine
rotational speed when the corresponding display is selected. See
page 34.
1
3
4
8
6
5
9
7
10
11
2
12
13
33
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
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 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 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.
13. Directional Indicator - This indicator illuminates when the hazard
switch or a turn signal switch is turned on.
34
FEATURES AND CONTROLS
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).
MODE
Button
SELECT
Button
35
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. 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.
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.
36
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.
37
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
toggle through all currently active diagnostic codes.
38
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Display Code Definitions
Open Load:
There is a break in the wires that lead to the item listed in
the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground:
The wire is shorted to ground between the electronic
control unit and the item listed in the chart.
Shorted Load:
The wires leading to the item listed in the chart are
shorted together, or the item has shorted internally.
Short-to-Battery:
The wire leading from the item listed in the chart to
the electronic control unit is shorted to a wire at battery voltage.
SPORTSMAN Forest 550 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
Crankshaft Position Sensor Circuit Fault 636 8
Gear Sensor Signal Voltage Too Low (to Calibrate) 523 4
Voltage Too High 523 3
Signal Fault 523 2
Injector 1 (MAG) Driver Circuit Open/Grounded 651 5
Driver Circuit Short to B+ 651 3
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5
Driver Circuit Short to B+ 1268 3
Fuel Pump Driver Circuit
Driver Circuit Open/Grounded 1347 5
Driver Circuit Short to B+ 1347 3
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5
Driver Circuit Short to B+ 1071 3
39
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
*Assumes unipolar configuration of stepper motor
SPORTSMAN Forest 550 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
Steering Over Current Shut Down Current Above Normal or
Grounded
520221 6
Steering Excessive Current Error Current Above Normal or
Grounded
520222 6
Steering Torque Sensor T1 Partial
Failure
T1 Shorted to Ground 520223 4
T1 Shorted to Bus 520223 3
Steering Torque Sensor T2 Partial
Failure
T2 Shorted to Ground 520224 4
T2 Shorted to Bus 520224 3
Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4
T1 and T2 Shorted to Bus 520225 3
T1 Shorted to Ground & T2
Shorted to Bus
520225 16
T2 Shorted to Ground & T1
Shorted to Bus
520225 17
T1 and T2 are Shorted 520225 2
Steering Position Sensor P1 Partial
Failure
P1 Shorted to Ground 520226 4
P1 Shorted to Bus 520226 3
Steering Position Sensor P2 Partial
Failure
P2 Shorted to Ground 520227 4
P2 Shorted to Bus 520227 3
Steering Position Sensor Full Failure P1 and P2 Shorted to Ground 520228 4
P1 and P2 Shorted to bus 520228 3
EPAS Inverter Temperature Greater than 110 Degrees C 520229 16
Greater than 120 Degrees C 520229 0
EPAS CAN Communications
Receive Error
No RX Message for 2 Seconds 520230 9
EPAS CAN Communications
Transmit Error
No TX Message for 2 Seconds 520231 9
40
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
SPORTSMAN Forest 850 Diagnostic Codes
Component Condition SPN FMI
Throttle Position Sensor Voltage Too High 51 3
Voltage Too Low 51 4
Engine Temperature Sensor Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0
Intake Air Temperature Sensor Voltage Too High 105 3
Voltage Too Low 105 4
Manifold Absolute Pressure Sensor Voltage Too High 102 3
Voltage Too Low 102 4
Signal Out of Range 102 2
Crankshaft Position Sensor Circuit Fault 636 8
Plausibility Fault 636 2
Vehicle Speed Signal Speed Too High 84 8
Plausibility Fault 84 2
Gear Sensor Signal Voltage Too Low 523 4
Voltage too high 523 3
Signal fault 523 2
Injector 1 (MAG) (SDI Part Load) Driver Circuit Open/Grounded 651 5
Driver Circuit Short to B+ 651 3
Driver Circuit Grounded 651 4
Injector 2 (PTO) (SDI Part Load) Driver Circuit Open/Grounded 652 5
Driver Circuit Short to B+ 652 3
Driver Circuit Grounded 652 4
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3
Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3
Fuel Pump Driver Circuit
Driver Circuit Open/Grounded 1347 5
Driver Circuit Short to B+ 1347 3
Driver Circuit Grounded 1347 4
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5
Driver Circuit Short to B+ 1071 3
Driver Circuit Grounded 1071 4
Idle Air Control Driver Circuit Open/Grounded 634 5
Driver Circuit Short to B+ 634 3
Driver Circuit Grounded 634 4
Position Out of Range 634 7
Starter Enable Circuit Driver Circuit Open/Grounded 1321 5
Driver Circuit Short to B+ 1321 3
Driver Circuit Grounded 1321 4
41
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
SPORTSMAN Forest 850 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
Steering Over Current Shut Down Current Above Normal/Grounded 520221 6
Steering Excessive Current Error Current Above Normal/Grounded 520222 6
Steering Torque Sensor T1 Partial
Failure
T1 Shorted to Ground 520223 4
T1 Shorted to Bus 520223 3
Steering Torque Sensor T2 Partial
Failure
T2 Shorted to Ground 520224 4
T2 Shorted to Bus 520224 3
Steering Torque Sensor Full
Failure
T1 and T2 Shorted to Ground 520225 4
T1 and T2 Shorted to Bus 520225 3
T1 Shorted to Ground & T2
Shorted to Bus
520225 16
T2 Shorted to Ground & T1
Shorted to Bus
520225 17
T1 and T2 are Shorted 520225 2
Steering Position Sensor P1
Partial Failure
P1 Shorted to Ground 520226 4
P1 Shorted to Bus 520226 3
Steering Position Sensor P2
Partial Failure
P2 Shorted to Ground 520227 4
P2 Shorted to Bus 520227 3
Steering Position Sensor Full
Failure
P1 and P2 Shorted to Ground 520228 4
P1 and P2 Shorted to bus 520228 3
EPAS Inverter Temperature Greater than 110 Degrees C 520229 16
Greater than 120 Degrees C 520229 0
EPAS CAN Comm. Receive Error No RX Message for 2 Seconds 520230 9
EPAS CAN Comm. Transmit Error No TX Message for 2 Seconds 520231 9
42
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 20 hours
of operation. 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.
43
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 79. 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
familiarize 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 25 hours.
8. Check the fluid level of the transmission after the first 25 hours of
operation and every 100 hours thereafter.
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.
If a belt fails, always clean away all debris when replacing the belt.
44
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the vehicle is in safe operating
condition before operating increases the risk of an accident. Always
inspect the vehicle before each use to make sure it's in safe operating
condition.
Item Remarks Page
Hand brake/lever travel Ensure proper operation 93
Foot brake Ensure proper operation 93
Brake fluid Ensure proper levels 91
Front suspension Inspect, lubricate if necessary 78
Rear suspension Inspect, lubricate if necessary 78
Steering Ensure free operation -
Tires Inspect condition and pressure 96
Wheels/fasteners Inspect, ensure fastener tightness 96
97
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 26
79
Coolant level Ensure proper level 89
90
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 22
104
Indicator lights/switches Ensure proper operation 20
Engine stop switch Ensure proper operation 21
Air filter, pre-filter Inspect, clean 98
Headlamp Check operation 21
Brake light/tail lamp Check operation 103
Riding gear Wear approved helmet, goggles, and
protective clothing
14
ADC Fluid Ensure proper level 84
Mirrors Adjust for best side/rear vision -
Winch Inspect cable and switch. 61-72
45
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
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
Cold Weather Operation
If the vehicle is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminates such as water
or excess fuel in the bottom of the crankcase. Water 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.
46
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.
47
OPERATION
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.
48
OPERATION
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
the wheels are spinning. Allow the rear wheels to stop spinning
before engaging 4X4, or engage 4X4 before wheels begin to lose
traction.
3. Be alert. Watch the trail. Avoid quick, sharp turns
4. Never apply the brakes during a skid. Correct a skid by turning the
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.
Sideways
Skid
Turn in direction
of skid
49
OPERATION
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
result if the machine is not thoroughly inspected. Take the vehicle to
your dealer before starting the engine.
5. Wet brakes may have reduced stopping ability. Dry the brake pads
by driving slowly and applying the brakes lightly several times until
braking action is normal.
6. If your vehicle becomes fully immersed, and it's impossible to take
it to a dealer before starting it, follow the steps described on page
109. 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.
Maximum
Depth
50
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.
51
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.
52
OPERATION
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.
25° Maximum
53
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.
54
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.
55
OPERATION
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.
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
56
OPERATION
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.
2.4 m
57
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.
58
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 distribution 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 weight of the operator,
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.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs.
(91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
• TOWING is approved OFF-ROAD ONLY.
• 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.
59
OPERATION
Hauling Cargo
1. Never exceed the weight
capacities specified for your
vehicle on warning labels and in
the specifications section of this
manual.
2. 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.
3. When operating over rough or
hilly terrain, reduce speed and
cargo weight to maintain stable
driving conditions.
4. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above
75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
5. NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above
200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
6. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
1/3
2/3
60
OPERATION
Hauling Cargo
Towing Loads
Towing is approved OFF-ROAD ONLY. See your POLARIS dealer
about configuring the vehicle to be certified to tow a trailer on-road.
• Do not tow any trailer on a grade steeper than 15°.
• Always attach a towed load to the hitch point. Remove the hitch from
the vehicle when not towing a trailer.
• If towing a load, reduce rear rack cargo weight by the amount of
tongue weight. The combination of rear rack cargo weight and tongue
weight must not exceed the rear rack capacity.
• The total load (operator, accessories, cargo and weight on hitch) must
not exceed the maximum weight capacity of the vehicle.
• FOREST 550 Unbraked Trailer Towing Capacity is 1786 lbs. (810
kg) based on EU Directive 76/432/EC.
• FOREST 850 Unbraked Trailer Towing Capacity is 1914 lbs. (868
kg) based on EU Directive 76/432/EC.
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.
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.
Maximum
10 cm
61
WINCH GUIDE
These safety warnings and instructions apply if your vehicle came
equipped with a winch or if you choose to add an accessory winch to
your vehicle.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially
designed synthetic rope. The term “winch cable” will be used for either
unless noted otherwise.
Winch Safety Precautions
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the
winch.
5. Always keep body, hair, clothing and jewelry clear of the winch
cable, fairlead and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving
vehicle. See the Shock Loading section on page 70.
7. Always keep the area around the vehicle, winch, winch cable and
load clear of people (especially children) and distractions while
operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch
are not being used.
9. Always be sure that at least five (5) full turns of winch cable are
wrapped around the winch drum at all times. The friction provided
by this wrapped cable allows the drum to pull on the winch cable
and move the load.
10. Always apply your vehicle’s park brake and/or park mechanism to
hold the vehicle in place during winching. Use wheel chocks if
needed.
WARNING
62
WINCH GUIDE
Winch Safety Precautions
11. Always align the vehicle and winch with the load directly in front of
the vehicle as much as possible. Avoid winching with the winch
cable at an angle to the winching vehicle’s centerline whenever
possible.
12. If winching at an angle is unavoidable, follow these precautions:
A. Look at the winch drum occasionally. Never let the winch cable “stack”
or accumulate at one end of the winch drum. Too much winch cable at
one end of the winch drum can damage the winch and the winch cable.
B. If stacking occurs, stop winching. Follow step 15 on page 68 to feed
and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the
winching vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s
rated capacity.
15. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation,
stop winching and permit the winch to cool down for 10 minutes
before using it again.
16. Never touch, push, pull or straddle the
winch cable while winching a load.
17. Never let the winch cable run through
your hands, even if wearing heavy
gloves.
18. Never release the clutch on the winch
when the winch cable is under load.
19. Never use the winch for lifting or
transporting people.
63
WINCH GUIDE
Winch Safety Precautions
20. Never use the winch to hoist or suspend a vertical load.
21. Never immerse or submerse your winch in water. Take your winch
to your dealer for service if this occurs.
22. Always inspect your winch and winch cable before each use.
23. Never winch the hook fully into the winch. This can cause damage
to winch components.
24. Unplug the remote control from the vehicle when the winch is not in
use to prevent inadvertent activation and use by unauthorized
persons.
25. Never grease or oil the winch cable. This will cause the winch cable
to collect debris that will shorten the life of the cable.
64
WINCH GUIDE
Winch Operation
Read the Winch Safety Precautions in the preceding pages before using
your winch.
Tip: Consider practicing the operation and use of your winch before you actually
need to use it in the field.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able
to deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls
for any signs of damage or parts in need of repair or replacement
before each use. Pay particular attention to the first 3 feet (1 meter)
of winch cable if the winch is being used (or has been used) for lift-
ing an accessory plow assembly. Promptly replace any worn or
damaged cable.
2. Never operate a winch or a vehicle in need of repair or service.
3. Always apply your vehicle’s
park brake and/or park
mechanism to hold the vehicle
in place during winching. Use
wheel chocks if needed.
WARNING
Hook Strap
65
WINCH GUIDE
Winch Operation
4. Always use the hook strap when
handling the hook.
WARNING! Never put your fingers into
the hook. This could lead to SEVERE
INJURY.
A. Attach the hook itself onto the
load or use a tow strap or chain
to secure the load to the winch
cable.
Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to
stretch.
WARNING! Never use a recovery strap when winching due to the excessive
energy that can be released if the winch cable breaks. This can result in
SEVERE INJURY or DEATH. See the Shock Loading section on page 70.
B. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.
WARNING! Replace the winch cable at the first sign of damage to prevent
SEVERE INJURY or DEATH in the event of failure. For your safety, always
replace POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer.
C. If possible, keep the winch cable aligned with the centerline of the
winching vehicle. This will help the spooling of the winch cable and
reduce the load on the fairlead.
D. If freeing a stuck vehicle by attaching to a tree, use an item such as a
tow strap to avoid damaging the tree during winch operation. Sharp
cables and chains can damage and even kill trees. Please remember
to TreadLightly® (treadlightly.org).
E. Before operating the winch, be sure
that the safety latch on the winch
cable hook is fully seated when the
load is attached.
F. Never operate your winch with a
damaged hook or latch. Always
replace damaged parts before using
the winch.
NO YES
NO
YES
66
WINCH GUIDE
Winch Operation
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the winch’s pulling
capacity. Always be sure that at least five (5) full turns of winch
cable are wrapped around the winch drum at all times. The friction
provided by this wrapped cable allows the drum to pull on the
winch cable and move the load.
8. Read and adhere to the following information for winch damping to
ensure safe winch use.
A. In order to absorb energy that could be released by a winch cable
failure, always place a “damper” on the winch cable. A damper can be
a heavy jacket, tarp, or other soft, dense object. A damper can absorb
much of the energy released if a winch cable breaks when winching.
Even a tree limb can help as a damper if no other items are available to
you.
B. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
C. On a long pull, it may be necessary to stop winching so that the
damper can be repositioned to the new mid-point of the winch cable.
Always release the tension on the winch cable before repositioning the
damper.
D. Avoid being directly in line with the winch cable whenever possible.
Also, never permit others to stand near or in line with the winch cable
during winch operation.
9. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or
worn.
67
WINCH GUIDE
Winch Operation
11. The ONLY time a winch-equipped vehicle should be moving when
using the winch is when that vehicle itself is stuck. The winch-
equipped vehicle should NEVER be in motion to “shock” load the
winch cable in an attempt to move a second stuck vehicle. See the
Shock Loading section on page 70. For your safety, always follow
these guidelines when winching a vehicle free:
A. Release the winch clutch and spool out the necessary length of winch
cable.
B. Align the winch cable as close as possible to the winching vehicle’s
centerline.
C. Attach the winch cable hook to the anchor point or the stuck vehicle’s
frame following instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle gear to propel the stuck vehicle in the
direction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free
the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself
without the help of the winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12. Never attempt to winch another stuck vehicle by attaching the
winch cable to a suspension component, brush guard, bumper or
cargo rack. Vehicle damage may result. Instead, attach the winch to
a strong portion of the vehicle frame or hitch.
68
WINCH GUIDE
Winch Operation
13. Extensive winching will run down the battery on the winching
vehicle. Let the winching vehicle’s engine run while operating the
winch to prevent the battery from running low if winching for long
periods.
14. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation,
stop winching and permit the winch to cool down for 10 minutes
before using it again.
15. After winching is complete, especially if winching at an angle, it
may be necessary to re-distribute the winch cable across the winch
drum. You will need an assistant to perform this task.
A. Release the clutch on the winch.
B. Feed out the winch cable that is unevenly bunched up in one area.
C. Re-engage the winch clutch.
D. Have an assistant pull the winch cable tightly with about 100 lbs. (45
kg) of tension using the hook strap.
E. Slowly winch the cable in while your assistant moves the end of the
winch cable back and forth horizontally to evenly distribute the winch
cable on the drum.
F. Doing this reduces the chances of the winch cable “wedging” itself
between lower layers of winch cable.
69
WINCH GUIDE
Winch Cable Care
For your safety, always replace POLARIS winch parts (including the
cable) with genuine POLARIS replacement parts available at your
authorized POLARIS dealer.
WARNING! Use of worn or damaged cable could lead to sudden failure and
SEVERE INJURY.
1. Always inspect your winch before each use. Inspect for worn or
loose parts including mounting hardware. Never use the winch if
any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn
or kinked winch cable.
A. A kinked winch cable made of
wire rope is shown at right. Even
after being “straightened out,”
this cable has already been
permanently and severely
damaged. Promptly discontinue
use of a winch cable in this
condition.
B. A kinked winch cable made of
wire rope that has been
“straightened out” is shown at
right. Even though it may look
usable, the cable has been
permanently and severely damaged. It can no longer transmit the load
that it could prior to kinking. Promptly discontinue use of a winch cable
in this condition.
C. A winch cable made of
synthetic rope should be
inspected for signs of fraying.
Replace the cable if fraying is
observed (shown at right).
Promptly discontinue use of a
winch cable in this condition.
D. Also replace the winch cable if there are fused or melted fibers. Such
an area of the synthetic rope will be stiff and appear smooth or glazed.
Promptly discontinue use of a winch cable in this condition.
A
B
C
70
WINCH GUIDE
Shock Loading
WARNING! Your winch cable is very strong but it is NOT designed for dynamic,
or “shock” loading. Shock loading may tension a winch cable beyond its strength
and cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both
wire-rope and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never
take up slack in the winch cable by moving the winching vehicle in
an attempt to move an object. This is a dangerous practice. It gener-
ates high winch cable loads that may exceed the strength of the
cable. Even a slowly moving vehicle can create large shock loads in
a winch cable.
WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).
This puts extra load on the winch, winch cable, and generates
excessive heat from the motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an
object with a winch produces shock loading of the cable even when
towing at slow speeds. Towing from a winch also positions the
towing force high on the vehicle. This can cause instability of the
vehicle and possibly lead to an accident.
71
WINCH GUIDE
Shock Loading
4. Never use recovery straps with your winch. Recovery straps are
designed to stretch and can store energy. This stored energy in the
recovery strap is released if a winch cable fails making the event
even more hazardous. Similarly, never use elastic “bungie” cords
for winching.
5. Never use the winch to tie down a vehicle to a trailer or other
transportation vehicle. This type of use also causes shock loading
that can cause damage to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads
produced by the winch motor when operated from a stationary
vehicle. Always remember that the winch and winch cable are NOT
designed for shock loading.
72
WINCH GUIDE
Winch Maintenance and Service Safety
WARNING! Improper or lack of winch maintenance and service could lead to
SEVERE INJURY or DEATH. Always follow all winch instructions and warnings
in this manual.
1. Always inspect your winch before each use. Inspect for worn or
kinked winch cable. Also inspect for worn or loose parts including
mounting hardware.
2. Permit your winch motor to cool down prior to servicing your
winch.
3. Never work on your winch without first disconnecting the battery
connections to prevent accidental activation of the winch
4. For your safety, always replace POLARIS winch parts (including
the cable) with genuine POLARIS replacement parts available at
your authorized POLARIS dealer.
5. Some winch models use wire rope as the winch cable. Other
winches use a specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade
polymer rope such as can be purchased in a hardware store.
Although they may look similar, they are NOT alike. A polymer
rope not designed for winch use will stretch and store excessive
energy when winching.
WARNING! Failure of a stretched rope under winching conditions will release
all of the stored energy. This will increase the chances of SEVERE INJURY or
DEATH.
73
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 Arrester
Your POLARIS vehicle has a spark arrester that was designed for on-
road and off-road operation. It is required that this spark arrester 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 vehicle complies with the EMC requirements of European
directives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the
limitations of their device and the applicable electromagnetic standards
and directives that apply to this vehicle.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration
levels of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was
controlled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
74
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 140.
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.
75
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
Improperly performing the procedures marked with a “D” could result in
component failure and lead to serious injury or death. Have an authorized
POLARIS dealer perform these services.
Perform all services at whichever maintenance interval is reached first.
Symbol Description
► Perform these operations more often for vehicles subjected to severe use.
E Emission-related service.
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
See Pre-Ride Checklist on
page 44.
Front suspension - -
Rear suspension - -
Tires - -
Brake fluid level - -
Brake lever travel - -
Brake system - -
Wheels/fasteners - -
Frame fasteners - -
Engine oil level - -
Winch - - See pages 61-72.
►
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Coolant - Daily - Check level daily, change
coolant every 2 years
► ADC fluid - Daily - Check level daily, add as
needed
► Power steering unit
(if equipped)
- Daily - Inspect daily; clean often
Headlamp/taillight - Daily - Check operation
►
E
Air filter, main
element
- Weekly - Inspect; replace as needed
76
MAINTENANCE
Periodic Maintenance Chart
► Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
► Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
► Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change
(see page 42)
► Demand drive fluid
(extreme use)
25 H 1 M 250 (400) Change fluid every 25 hours
if ADC is subjected to
extreme use. See page 83.
► Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check
► Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check
► Transmission oil 25 H 1 M 250 (400) Break-in oil level check
► General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Shift linkage 50 H 6 M 500 (800) Inspect, lubricate
D Steering 50 H 6 M 500 (800) Lubricate
► Front suspension 50 H 6 M 500 (800) Lubricate
► Rear suspension 50 H 6 M 500 (800) Lubricate
D
E
Throttle Cable/
Throttle Release
Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 H 6 M 500 (800) Inspect duct for proper seal-
ing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; replace as needed
Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
► Radiator 50 H 6 M 1000 (1600) Inspect; clean external
surfaces
► Cooling hoses 50 H 6 M 1000 (1600) Inspect for leaks
77
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
► Oil lines and
fasteners
100 6 M 1000 (1600) Inspect for leaks and loose
fittings
► Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter
► Demand drive fluid
(normal use)
100 H 12 M 1000 (1600) Change fluid
► Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid
► Transmission oil 100 H 12 M 1000 (1600) Change fluid
Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
► Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
D
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
► Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
D Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
D Brake fluid 200 H 24 M 2000 (3200) Change every two years
►
D
ADC fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrester 300 H 36 M 3000 (4800) Clean out
D
E
Valve clearance 1000 H - 10000
(16000)
Inspect; adjust
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
78
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 74. 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.
Item Recommended
Lubricant
Capacity
at Fluid
Change
Fill Plug
Torque
Drain Plug
Torque
Inspection
Procedure
550 Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt.
(1.9 l)
--- 15-17 ft. lbs.
(20-23 Nm)
Page 79.
850 Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt.
(1.9 l)
--- 12 ft. lbs.
(16 Nm)
Page 79.
Transmission
Oil
AGL Gearcase
Lubricant &
Transmission
Fluid
37 oz.
(1100 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 82.
Demand Drive
Fluid (Front
Gearcase)
Demand Drive
Fluid
9.3 oz.
(275 ml)
8-10 ft. lbs.
(11-14 Nm)
11 ft. lbs.
(15 Nm)
Page 83.
Rear
Gearcase Oil
ATV Angle Drive
Fluid (or GL5 80-
90 weight gear
lube)
7.1 oz.
(210 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 86.
Brake Fluid DOT 4 Brake
Fluid
--- --- --- Page 91.
ADC Fluid Demand Drive
Fluid
--- --- --- Page 84.
Front Prop
Shaft Yoke
U-Joint Grease Grease fittings (3 pumps maximum) every 500 miles,
before long periods of storage, or after pressure
washing or submerging.
A-Arms, Front
and Rear
POLARIS All
Season Grease
Grease fittings after extreme use or if suspension
becomes squeaky.
Front Prop Shaft Yoke
Front
79
MAINTENANCE
Engine Oil
Oil Recommendations
POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-
50 4-cycle oil or a similar oil for this engine. Oil may need to be
changed more frequently if POLARIS oil is not used. Always use 5W-
50 oil. Follow the manufacturer's recommendations for ambient
temperature operation. See page 131 for the part numbers of POLARIS
products.
See the table on page 78 for fluid recommendations, capacities and plug
torques.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
Oil Level
Check the oil level when the
engine is cold. Never check the
oil with the engine running.
Access the oil dipstick and fill
tube from the left side of the
vehicle.
1. Position the vehicle on a
level surface. Place the
transmission in PARK.
2. Remove the dipstick. Wipe it
dry with a clean cloth.
3. Reinstall and tighten the
dipstick.
4. Remove the dipstick and
check the oil level.
5. Add the recommended fluid
as needed. Maintain the oil
level in the safe range
between the FULL and ADD
marks. Do not overfill.
6. Reinstall and tighten the
dipstick.
Dipstick
Full
Add
850
Full Add
550
80
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 78 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 74. 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
minutes.
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.
550 Drain Plug
Front
Filter Access
850 Drain Plug
Top View
81
MAINTENANCE
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.
12.
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.
Install the new filter and rotate it
clockwise by hand until the filter
gasket contacts the sealing
surface, then turn it an additional
3/4 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.
Oil Filter
550 850
82
MAINTENANCE
Transmission Oil
See the table on page 78 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 74. See
page 131 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 95).
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.
Drain Plug
Fill Plug
Fill
Level
83
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 78 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
74. See page 131 for the part numbers of POLARIS products.
Change the front gearcase fluid every 25 hours if the ADC unit is
exposed to extreme use. Extreme use includes any of the following:
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation
Tip: If the front gearcase is makes excessive noise during ADC operation,
change the demand drive fluid. If the noise continues, please see your
POLARIS dealer for service.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. Maintain the fluid level at the bottom of the
fill hole threads. 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 recommended fluid as
needed to bring the level to the
bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.
Fluid Change
1. Position the vehicle on a level surface. Remove the fill plug.
2. Place a drain pan under the demand drive unit. Remove the drain
plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Dispose of used fluid properly.
Drain Plug
Fill
Plug
Fill
Level
84
MAINTENANCE
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 83 for demand drive fluid maintenance.
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 74.
NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to
extreme use. Extreme use includes operation in ADC mode for
prolonged periods or in environments that necessitate primary
operation in ADC mode.
We recommend the use of POLARIS Demand Drive Fluid. Maintain the
fluid level between the minimum and maximum marks on the reservoir.
See page 131 for the part numbers of POLARIS products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
1. Remove the front rack.
2. View the fluid level in the
reservoir.
3. If the level is below the
minimum mark, remove
the cap and add the
recommended fluid.
4. Reinstall the cap.
5. Reinstall the front rack.
ADC Fluid Reservoir
85
MAINTENANCE
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 recommended
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 recommended fluid to the reservoir until the level is
between the minimum and maximum marks. Make sure the
reservoir is free of debris.
9. Reinstall the cap securely. Clean up any drips or spills.
Bleeder
Screw
Cap
Bleeder
Valve
Screw
86
MAINTENANCE
Rear Gearcase Oil
See the table on page 78 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 74. See
page 131 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.
Drain Plug
Fill Plug
Fill
Level
87
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. 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.
88
MAINTENANCE
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 Antifreeze 60/40 premix
or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. POLARIS Antifreeze is already premixed
and ready to use. Do not dilute with water. See page 131 for the part
numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Clean
often
89
MAINTENANCE
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.
Recovery
Bottle Cap
Maximum
Mark
Minimum
Mark
90
MAINTENANCE
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.
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.
Radiator
Cap
91
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 131 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.
92
MAINTENANCE
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.
Master
Cylinder
Indicator
Window
Full
Low
Brake Fluid Reservoir
93
MAINTENANCE
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 92.
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. Clean any grease using a
recommended brake cleaner or alcohol. Do not use spray lubricants
or other petroleum-based products. If you discover any damage
(cracks, excessive corrosion, warping) see your dealer for service
before operating.
1 mm
94
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/4-1/2 inch (6-12 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 straight-
edge 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 3-6 mm more than the front measurement on each side of
the vehicle to obtain the recommended 6-12 mm toe out alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for
service.
String
Stand
2
1
95
MAINTENANCE
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.
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).
Plastic Rivet
Hex Head Screw
Plastic Rivet
Plastic Rivet
Torx Head
Screw
96
MAINTENANCE
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 132 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.
1/8" (3 mm)
97
MAINTENANCE
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 Type Nut Type Nut Torque
Aluminum Lug Nut 75 ft. lbs. (102 Nm)
Steel Lug Nut 45 ft. lbs. (61 Nm)
Cast Aluminum
Steel
75 ft. lbs.
(102 Nm)
45 ft. lbs.
(61 Nm)
98
MAINTENANCE
Air Filter
1. Remove the seat.
2. Remove the air box cover
strap, 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.
Main
Filter
Pre-Filter
Strap
99
MAINTENANCE
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.
Fuse Box
850550
100
MAINTENANCE
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
headlight 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.
7.6 m
5 cm
X
X
Screws
101
MAINTENANCE
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 counter-
clockwise 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.
Position Light
Collar
Socket
Headlamp
102
MAINTENANCE
Lights
Front Turn Signal Replacement
If a front turn signal light becomes
inoperable, the lamps cannot be
replaced. Replace the entire signal lamp
assembly.
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.
103
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.
104
MAINTENANCE
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer for adjustment.
Throttle Cable Freeplay
1. Remove the three cover
screws from the right
handlebar control and
remove the cover.
2. With the handlebars
straight ahead, place very
light pressure on the
throttle lever. A gap of 2-3
mm should be visible
between the throttle arm
stop pin and the throttle
arm.
If adjustment is needed:
1. Locate the throttle cable
adjuster. Squeeze the end
of the rubber boot and slide
it back far enough to
expose the inline cable
adjuster locknut.
2. Loosen the adjuster
locknut.
3. Rotate the boot to turn the
adjuster until 2-3 mm of
freeplay is achieved
between the stop pin and
the throttle arm. While
adjusting freeplay, flip the
throttle lever back and
forth repeatedly.
(continued on next page)
2-3 mm Gap
Throttle
Arm
Arm Stop Pin
Lock
Nut
Adjuster
Boot
Cable
Adjuster
105
MAINTENANCE
Throttle Cable Freeplay
4. Place the transmission in PARK.
5. Start the engine and allow the idle to stabilize. If necessary, tap the
throttle lever to ensure the idle speed settles.
6. If idle speed remains above or below the recommended setting (see
specification pages), verify the correct gap. If gap is correct and idle
speed is still not satisfactory, please see your POLARIS dealer for
service.
7. With the engine running, turn the handlebars fully to the left and
right. Tap the throttle lever at each turn, verifying that idle RPM
returns to the recommended setting. If idle speed increases, it may
be necessary to increase the gap between the stop pin and throttle
arm, but do not exceed the recommended 2-3 mm gap.
8. When adjustments are complete, tighten the locknut.
9. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.
10. Ensure the control cover seal is in place, then reinstall the cover and
screws.
106
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Front and Rear Springs
The front and rear shock absorber
springs are adjusted by rotating the
adjuster either clockwise or
counterclockwise to increase or
decrease spring tension. Accessory
springs are available through your
POLARIS dealer.
Handlebars
The handlebars can be adjusted for rider preference.
Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the handlebars,
resulting in loss of control and serious injury or death. Follow the adjustment
procedures exactly, or see your POLARIS dealer for service.
1. Remove the upper headlight
pod.
2. Loosen the four handlebar
bolts.
3. Adjust the handlebar to the
desired height. Be sure the
handlebars do not contact the
gas tank or any other part of
the machine when turned fully
to the left or right.
4. Torque the front two bolts to
10-12 ft. lbs. (14-17 Nm), then
torque the rear two bolts. A
gap of up to 1/8" (3 mm) will
remain at the rear of the clamp
blocks.
5.
Adjuster
Handlebar
Bolts
107
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 132 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.
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 108.
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
specification.
Plug Condition
Torque Specification
550 850
New Spark Plug 9-11 ft. lbs.
(12-15 Nm)
18-20 ft. lbs.
(24-27 Nm)
Previously Installed
Spark Plug
17-20 ft. lbs.
(23-27 Nm)
18-20 ft. lbs.
(24-27 Nm)
108
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.
109
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take 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. If
equipped, remove the air box drain
plug to drain water. Make sure the
E-ring is on the drain plug and
reinstall the drain plug.
NOTICE: Serious damage could occur if
the air box drain plug is not
reinstalled and tightened
properly
.
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
procedure.
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 113 for drying out the PVT.
Drain Plug (850)
110
MAINTENANCE
Spark Arrester
Failure to heed the following warnings while servicing the spark arrester 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
arrester 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 arrester 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, elevate 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 arrester to cool.
10. Reinstall the arrester clean-out plug and remove the exhaust outlet
cover or plug.
Clean-Out Plug
111
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. Always look for
and remove debris inside and around the clutch and vent system when
replacing the belt.
• 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.
112
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 difference between high 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.).
113
MAINTENANCE
PVT System
When To Use Low Range and High Range
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.
Reinstall 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
transmission 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.
Condition Range to Use
Operating at speeds less than 7 MPH (11 km/h) Low
Towing heavy loads Low
Operating in rough terrain (swamps, mountains, etc.) Low
Operating at speeds greater than 7 MPH (11 km/h) High
114
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be
identified by its flat covers on the top of the battery. A conventional
battery has six filler caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into a conventional battery.
115
MAINTENANCE
Battery
Battery Removal
1. Remove the seat.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Disconnect the battery hold-down strap.
5. On conventional batteries, remove the battery vent tube.
6. Lift the battery out of the vehicle. Be careful not to tip a
conventional battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
116
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the
battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging instructions on page 118
before installing the battery.
If your factory-installed 18 AH battery cannot maintain a charge
because of operation in extreme cold or with multiple electrical
accessories, please see your POLARIS dealer to purchase a 30 AH
battery. Before installing the 30 AH battery, remove the plastic spacer at
the bottom of the battery compartment. Save the spacer for future use.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed
batteries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
Battery gases could accumulate in an improperly installed vent tube and cause
an explosion, resulting in serious injury or death. Always ensure that the vent
tube is free of obstructions and is securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Secure the battery hold-down strap.
6. Connect and tighten the red (positive) cable first.
7. Connect and tighten the black (negative) cable last.
8. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
9. Install the seat.
117
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 131 for the
part numbers of POLARIS products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. Maintain the fluid
level between the upper and lower
level marks.
Add only distilled water. Tap water
contains minerals that are harmful to
a battery.
Lower
Mark
Upper
Mark
118
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from
leaking or spilled electrolyte during charging. See page 115.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific
gravity to 1.270 or greater.
3. Reinstall the battery. See page 116. Make sure the positive terminal
polarity is properly connected.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very warm
to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. The battery should be disconnected from a load or charger for at
least two hours before checking voltage. Check the battery voltage
with a voltmeter or multimeter. A fully charged battery will register
12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger
manufacturer's instructions for recharging. When using a constant
current charger, use the guidelines on the next page for recharging.
119
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
120
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its
appearance but it can also extend the life of various components.
NOTICE: High water pressure may damage components. POLARIS
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a
garden hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
121
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the
following items:
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.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
• Wheel bearings • Electrical components
• Radiator • Switches and controls
• Transmission seals • Fuel system components
• Cab and body panels • Labels and decals
122
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion,
preserve wheel life and ensure a "like new" appearance for many years.
Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean chrome
wheels more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each
polished chrome wheel. Choose a product suitable for chrome
finishes. Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as
outlined above.
123
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and then clean the vehicle as recommended.
See page 120.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the
recommended amount. Carbon Clean removes water from fuel
systems, stabilizes fuel and removes carbon deposits from pistons,
rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel delivery system.
Oil and Filter
Change the oil and filter. See page 80.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
124
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the following fluid levels. Change fluids as recommended in the
Periodic Maintenance Chart beginning on page 74.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength)
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean, following the
instructions on the container. Run the engine for several minutes so
the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To
access the plug holes, use a section of clear 1/4" hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap and
reinstall the caps onto the plugs.
5. Turn the engine over several times using electric start. Oil will be
forced in and around the piston rings and ring lands, coating the
cylinder with a protective film of fresh oil.
6. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and injectors should be completely drained of gasoline.
125
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 74.
Battery Maintenance
Remove the battery and recharge it as outlined on page 118. Store the
battery in a cool, dry place.
Storage Area/Covers
Set the tire pressure and safely support the vehicle with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine POLARIS cover. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent
condensation, and may promote corrosion and oxidation.
Accessories
Auxiliary power outlets provide 12-volt power for operating
accessories. Accessory outlets are available for all models. POLARIS
also has a wide range of additional accessories available for your
vehicle. Always install accessories that are approved by POLARIS for
use on this vehicle.
126
MAINTENANCE
Transporting the Vehicle
1. Stop the engine.
2. Place the transmission in PARK.
3. Secure the fuel cap, oil cap and seat.
4. Always tie the frame of the vehicle to the transporting unit securely
with suitable straps or rope. Do not attach tie straps to the front A-
arm bolt pockets, racks or handlebars.
5. Remove the key to prevent loss during transporting.
127
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range during loading.
Starting out going up a
steep incline
Use low range or turn around using the K-turn (see page
56).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 113.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of
control and vehicle overturn.
Climbing over large
objects from a stopped
position
Shift the transmission to low range and carefully use fast,
brief, aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of
control and vehicle overturn.
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT. See page 113. Inspect clutch seals for
damage if repeated leaking occurs.
Clutch malfunction See your POLARIS dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 43.
128
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Clogged fuel filter See your dealer
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plugs Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Water or fuel in crankcase Immediately see your POLARIS dealer
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
129
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Possible Cause Solution
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank vent line Inspect and replace
Low octane fuel Replace with recommended fuel
Clogged fuel filter See your dealer
Incorrect fuel Replace with recommended fuel
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Stopping/starting without adequate
warm-up
Allow engine to warm up before operat-
ing and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
130
TROUBLESHOOTING
Engine Stops or Loses Power
Engine Overheating
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plugs Inspect, clean and/or replace spark plug
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Overheated engine Clean radiator screen and core, clean
engine exterior, see your dealer
Possible Cause Solution
Debris lodged in screen Clean the screen.
Plugged Radiator Use a garden hose to flush any debris
from the radiator fins. NOTE: High pres-
sure washers can deform the radiator fins
and reduce cooling efficiency.
131
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(gal./3.8 l)
2877922 Demand Drive Fluid (qt./.95 l)
2877923 Demand Drive Fluid (gal./3.8 l)
2870465 Pump for Gallon (3.8 l) Jug
Coolant
2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l)
2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, All Season Grease
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
2876160 ATV Angle Drive Fluid (qt./.95 l)
2872276 ATV Angle Drive Fluid (2.5 gal./9.5 l)
2871460 Premium Starter Grease
2871515 U-Joint Grease (3 oz./89 ml cartridge)
2871551 U-Joint Grease (14 oz./414 ml cartridge)
2871329 Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326 Carbon Clean
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956 Loctite™ 565 Thread Sealant
2859044 POLARIS Battery Tender™ Charger
132
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN Forest 550
Maximum Weight Load Capacity 575 lbs. (261 kg)
Dry Weight 342 kg +/- 7 % , based on configuration
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Rear Gearcase Oil Capacity 7.1 oz. (210 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Transmission Oil Capacity 37 oz. (1100 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Rack Capacity 240 lbs. (109 kg)
Unbraked Trailer Towing
Capacity*
1786 lbs. (810 kg)
Overall Length 83.25 in. (211 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 50.75 in. (129 cm)
Wheelbase 53 in. (134.6 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 84 in. (213 cm) unloaded
Engine ES550PLE 4-Stroke (Low Torque Capacity)
Displacement 549.7 cc
Engine Power 30 kW
Bore x Stroke 96.6 x 75
Alternator Output 490w @ 1350 RPM/Peak 630w
Compression Ratio 9.6:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM 1425 +/- 50
Ignition Timing 13 +/- 3 BTDC @ 1350 RPM, Engine warm
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
Lubrication System Wet Sump
Seat Single Seat, length 650 mm
Steering System Akerman Principle, with handlebar controls
Transmission Power System Shaft drive on all wheels
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Front Suspension Dual a-arm with 9.2" (23 cm) travel
Rear Suspension Progressive rate with 10.2" (26 cm) travel
133
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN Forest 550
Transmission and Gears High/Low/Neutral/Reverse/Parking
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.693:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tires Type Front Off Road Style, Deep Tread Design, size 26x8-14
AT / 7 psi (48.3 kPa) Pressure
Tires Type Rear Off Road Style, Deep Tread Design, size 26x10-
14 AT / 7 psi (48.3 kPa) Pressure
Brakes, Front/Rear Single-Control handlebar hydraulic disc on all
wheels
Brakes, Auxiliary Foot-Activated Hydraulic Disc on all wheels
Brake, Parking Hydraulic lock on all wheels, Mechanical Lock in
Park
Hitch Rear mounting for attachment of coupling
devices
Winch Front permanent installed winch with 2500 lbs.
(1125 kg) capacity
Headlight 2 Hi/Lo beam on bumper (55/60 watt)
Taillights 7 watts
Brake Light 27 watts
Instrument Cluster Digital LCD/LED
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
23-54G
PN 1322914
Dark Blue
PN 7043803
Red/White
PN 3235088
105-165
BA3
PN 3235092
1800-3700
(6000-12000)
23-51
PN 1322915
Dark Blue
PN 7043803
Red/White
PN 3235088
105-165
BA3
PN 3235092
134
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN Forest 850
Maximum Weight Load Capacity 575 lbs. (261 kg)
Dry Weight 360 kg +/- 7 % , based on configuration
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Rear Gearcase Oil Capacity 7.1 oz. (210 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Transmission Oil Capacity 37 oz. (1100 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Rack Capacity 240 lbs. (109 kg)
Unbraked Trailer Towing
Capacity*
1914 lbs. (868 kg)
Overall Length 83.25 in. (211 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 50.75 in. (129 cm)
Wheelbase 53 in. (134.6 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 84 in. (213 cm) unloaded
Engine EHO850LE 4-Stroke (Low Torque Capacity)
Displacement 850 cc
Engine Power 51.5 kW
Bore x Stroke 87 x 71.5
Alternator Output 475w @1200 RPM/Peak 575w
Compression Ratio 11:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM 1200 +/- 50
Ignition Timing 6 +/- 5 BTDC @ 1200 RPM, Engine warm
Spark Plug Type / Gap REA6MCX / .035 in. (0.9 mm)
Lubrication System Wet Sump
Seat Single Seat, length 650 mm
Steering System Akerman Principle, with handlebar controls
Transmission Power System Shaft drive on all wheels
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Front Suspension Dual a-arm with 9.2" (23 cm) travel
Rear Suspension Progressive rate with 10.2" (26 cm) travel
135
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN Forest 850
Transmission and Gears High/Low/Neutral/Reverse/Parking
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.367:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tires Type Front Off Road Style, Deep Tread Design, size 26x8-14
AT / 7 psi (48.3 kPa) Pressure
Tires Type Rear Off Road Style, Deep Tread Design, size 26x10-
14 AT / 7 psi (48.3 kPa) Pressure
Brakes, Front/Rear Single-Control handlebar hydraulic disc on all
wheels
Brakes, Auxiliary Foot-Activated Hydraulic Disc on all wheels
Brake, Parking Hydraulic lock on all wheels, Mechanical Lock in
Park
Hitch Rear mounting for attachment of coupling
devices
Winch Front permanent installed winch with 2500 lbs.
(1125 kg) capacity
Headlight 2 Hi/Lo beam on bumper (55/60 watt)
Taillights 7 watts
Brake Light 27 watts
Instrument Cluster Digital LCD/LED
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
24-63
PN 5632215
Red/White
PN 7043349
Red/White
PN 3235088
105-165
BA3
PN 3235092
1800-3700
(6000-12000)
24-60
PN 5632216
Red/White
PN 7043349
Red/White
PN 3235088
105-165
BA3
PN 3235092
136
WARRANTY
LIMITED WARRANTY
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX
MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against
defects in material or workmanship. POLARIS further warrants that the spark arrestor in
this product will meet the efficiency requirements of USFS standard 5100-1C for at least
1000 hours when subjected to normal use and when maintenance and installation are in
accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective parts
and begins on the date of purchase by the original retail purchaser. This warranty is
transferable to another owner during the warranty period through a POLARIS dealer,
but any such transfer will not extend the original term of the warranty. The duration of
this warranty may vary by international region based upon local laws and regulations.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days of purchase. Upon receipt of this
registration, POLARIS will record the registration for warranty. No verification of
registration will be sent to the purchaser as the copy of the Warranty Registration Form
will be your proof of warranty coverage. If you have not signed the original registration
and received the customer copy, please contact your dealer immediately. NO
WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS
REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is
very important in ensuring trouble-free operation. Purchasing a machine in the crate or
without proper dealer set-up will void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
This POLARIS limited warranty excludes any failures that are not caused by a defect in
material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF
DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental
damage, normal wear and tear, abuse or improper handling. This warranty also does not
cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained, or used for purposes other than for which it was
designed.
This warranty excludes damages or failures resulting from: improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external stress,
heat, cold or contamination; operator error or abuse; improper component alignment,
tension, adjustment or altitude compensation; snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket or unapproved components, accessories, or attachments; unauthorized
repairs; or repairs made after the warranty period expires or by an unauthorized repair
center.
137
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty excludes damages or failures caused by abuse, accident, fire, or any other
cause other than a defect in materials or workmanship and provides no coverage for
consumable components, general wear items, or any parts exposed to friction surfaces,
stresses, environmental conditions and/or contamination for which they were not
designed or not intended, including but not limited to the following items:
Lubricants and Fluids
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is
not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage,
transportation costs, hotels, meals, shipping or handling fees, product pick-up or
delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or
personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,
AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN
THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON
FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY
TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR
IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR
OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL
SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS
ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL
EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO
NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION
OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY
TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components and fluids
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps • Spark plugs
• Filter • Sealants
• Lubricants • Coolants
• Bushings • Bearings
138
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS Servicing
Dealer. When requesting warranty service you must present your copy of the Warranty
Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use
your original selling dealer; however, you may use any POLARIS Servicing Dealer to
perform warranty service.
In the country where your product was purchased:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If
you move or are traveling within the country where your product was purchased,
Warranty and Service Bulletin repairs may be requested from any authorized POLARIS
dealer that sells the same line as your product.
Outside the country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased,
you should take your product to an authorized POLARIS dealer. You must show the
dealer photo identification from the country of the selling dealer’s authorized location as
proof of residence. Upon residence verification, the servicing dealer will be authorized
to perform the warranty repair.
If you move:
If you move to another country, be sure to contact POLARIS Customer Assistance and
the customs department of the destination country before you move. Product
importation rules vary considerably from country to country. You may be required to
present documentation of your move to POLARIS in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS in order to
register your product in your new country. You should warranty register your product at
a local POLARIS dealer in your new country immediately after you move to continue
your warranty coverage and to ensure that you receive information and notices regarding
your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside of
the country in which the product was originally purchased, all warranty coverage will be
denied. You must nonetheless register your product under your name and address with a
local POLARIS dealer in your country to ensure that you receive safety information and
notices regarding your product.
139
WARRANTY
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS
SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED
LOCATION. This policy does not apply to products that have received authorization for
export from POLARIS. Dealers may not give authorization for export. You should
consult an authorized dealer to determine this product’s warranty or service coverage if
you have any questions. This policy does not apply to products registered to government
officials or military personnel on assignment outside the country of the selling dealer’s
authorized location. This policy does not apply to Safety Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and you have
not followed the procedure set above, your product will no longer be eligible for
warranty or service bulletin coverage of any kind, other than safety bulletins. Products
registered to Government officials or military personnel on assignment outside of the
country where the product was purchased will continue to be covered by the Limited
Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance, they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state or in different countries. If any of the above terms are void
because of federal, state, local law, all other warranty terms will remain in effect.
140
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and
services performed.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
141
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
142
INDEX
0-9
4X4 Switch . . . . . . . . . . . . . . . . 20, 28
A
Access, Front Compartment . . . . . . 27
Accessories . . . . . . . . . . . . . . . . . . 125
Active Descent Control Fluid . . . 84-85
Active Descent Control System. . . . 30
ADC System . . . . . . . . . . . . . . . . . . 30
Age Restrictions. . . . . . . . . . . . . . . . . 6
Air Filter . . . . . . . . . . . . . . . . . . . . . 98
All Wheel Drive System . . . . . . . 28-29
B
Battery . . . . . . . . . . . . . . . . . . 114-119
Charging (Conventional) . . . . . 118
Charging (Sealed Battery) . . . . 119
Charging (Sealed) . . . . . . . . . . . 118
Extreme Use 30 AH . . . . . . . . . . 26
Fluid (Conventional Battery) . . 117
Installation . . . . . . . . . . . . . . . . 116
Removal . . . . . . . . . . . . . . . . . . 115
Storage . . . . . . . . . . . . . . . . . . . 117
Belt Life. . . . . . . . . . . . . . . . . . . . . . 25
Boots . . . . . . . . . . . . . . . . . . . . . . . . 15
Brake Fluid . . . . . . . . . . . . . . . . . 91-92
Brake Inspections. . . . . . . . . . . . . . . 93
Brake Lever . . . . . . . . . . . . . . . . . . . 23
Brake, Foot . . . . . . . . . . . . . . . . 23, 92
Brake, Hand Lever. . . . . . . . . . . . . . 92
Brake, Parking . . . . . . . . . . . . . . . . . 24
Brakelight . . . . . . . . . . . . . . . . . . . 103
Brakes . . . . . . . . . . . . . . . . . . . . . 23-24
Break-In Period . . . . . . . . . . . . . . 42-43
C
Camber Adjustment. . . . . . . . . . . . 106
Cargo . . . . . . . . . . . . . . . . . . . . . . 58-60
Caster Adjustment . . . . . . . . . . . . . 106
Chrome Wheel Care . . . . . . . . . . . 122
Cleaning and Storage. . . . . . . . 120-125
Clothing . . . . . . . . . . . . . . . . . . . . . . 15
Clutching
550 XP . . . . . . . . . . . . . . . . . . . 133
850 XP . . . . . . . . . . . . . . . . . . . 135
C
Cold Weather Operation . . . . . . . . . . 45
Coolant Bottle . . . . . . . . . . . . . . . . . . 89
Coolant, Radiator. . . . . . . . . . . . . . . . 90
Cooling System . . . . . . . . . . . . . . 88-90
Corrosion Removal, Chrome. . . . . . 122
D
Demand Drive Fluid . . . . . . . . . . . . . 83
Diagnostic Codes, 550 XP EPS. . 38-39
Diagnostic Codes, 850 XP EPS. . 40-41
Disengaging Active Descent Control 30
Display, Standard/Metric. . . . . . . . . . 35
Drive Belt Wear/Burn . . . . . . . . . . . 127
Drivetrain Break-In . . . . . . . . . . . . . . 43
Driving Downhill. . . . . . . . . . . . . . . . 55
Driving in Reverse. . . . . . . . . . . . . . . 51
Driving on a Sidehill . . . . . . . . . . . . . 54
Driving on Slippery Surfaces . . . . . . 48
Driving Over Obstacles . . . . . . . . . . . 50
Driving Procedures . . . . . . . . . . . . . . 46
Driving Through Water . . . . . . . . . . . 49
Driving Uphill . . . . . . . . . . . . . . . 52-53
E
Electromagnetic Interference. . . . . . . 73
Electronic Power Steering . . . . . . . . . 25
Engaging 4X4 . . . . . . . . . . . . . . . . . . 29
Engaging Active Descent Control. . . 30
Engine Break-In. . . . . . . . . . . . . . . . . 43
Engine Fogging . . . . . . . . . . . . . . . . 124
Engine Oil . . . . . . . . . . . . . . . . . . 79-81
EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EPS Warning Indicator . . . . . . . . . . . 33
Equipment Modifications . . . . . . . . . . 6
European Vibration and Noise . . . . . 73
Exhaust Emission Control System . . 73
Extreme Use 30 AH Battery . . . . . . . 26
Eye Protection . . . . . . . . . . . . . . . . . . 15
F
Fluid
ADC . . . . . . . . . . . . . . . . . . . . 84-85
Brake. . . . . . . . . . . . . . . . . . . . 91-92
Demand Drive. . . . . . . . . . . . . . . . 83
143
INDEX
F
Fluid Change
ADC . . . . . . . . . . . . . . . . . . . . . . . 85
Demand Drive . . . . . . . . . . . . . . . 83
Foot Brake, Auxiliary . . . . . . . . . . . . 23
Footwell Removal. . . . . . . . . . . . . . . 95
Front Compartment. . . . . . . . . . . . . . 27
Front Gearcase (Demand Drive). . . . 83
Front Rack/Compartment . . . . . . . . . 27
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 26
Fuse Replacement. . . . . . . . . . . . . . . 99
G
Gear Selector. . . . . . . . . . . . . . . . . . . 25
Gearcase Oil, Rear . . . . . . . . . . . 86-87
Gloves. . . . . . . . . . . . . . . . . . . . . . . . 15
H
Hand Brake . . . . . . . . . . . . . . . . . . . . 92
Handlebar Adjustment . . . . . . . . . . 106
Hauling Cargo. . . . . . . . . . . . . . . 58-60
Hazard Warning Switch . . . . . . . . . . 21
Headlight Lamp . . . . . . . . . . . . . . . 101
Headlight Switch. . . . . . . . . . . . . . . . 21
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 14
High Beam Switch, Momentary . . . . 20
High Range Use . . . . . . . . . . . . . . . 113
Horn Switch . . . . . . . . . . . . . . . . . . . 21
I
Idle RPM Adjustment . . . . . . . . . . . 104
Immersion . . . . . . . . . . . . . . . . . . . . 109
Instrument Cluster. . . . . . . . . . . . 31-41
K
Key Switch . . . . . . . . . . . . . . . . . . . . 21
K-Turn . . . . . . . . . . . . . . . . . . . . 56-57
L
Light Switch . . . . . . . . . . . . . . . . . . . 20
Lights
Front Turn Signal Replacement. 102
Headlight Beam Adjustment . . . 100
Headlight Lamp . . . . . . . . . . . . . 101
Momentary High Beam Switch . . 20
Position Light Lamp. . . . . . . . . . 101
Rear Turn Signal . . . . . . . . . . . . 102
Taillight/Brakelight/Worklight . 103
L
Low Beam Adjustment. . . . . . . . . . 100
Low Range Use. . . . . . . . . . . . . . . . 113
Lubrication Guide. . . . . . . . . . . . . . . 78
M
Maintenance Chart . . . . . . . . . . . 74-77
Metric/Standard Display. . . . . . . . . . 35
Mirrors . . . . . . . . . . . . . . . . . . . . . . . 22
Mode Switch. . . . . . . . . . . . . . . . . . . 20
Modifications . . . . . . . . . . . . . . . . . . . 6
N
Noise Emission Control System . . . . 73
O
Oil
Engine . . . . . . . . . . . . . . . . . . 79-81
Rear Gearcase . . . . . . . . . . . . 86-87
Transmission . . . . . . . . . . . . . . . . 82
Oil and Filter Change . . . . . . . . . 80-81
Oil Level, Engine . . . . . . . . . . . . . . . 79
Oil Recommendations . . . . . . . . . . . 79
Override Switch . . . . . . . . . . . . . . . . 20
P
Parking Brake . . . . . . . . . . . . . . . . . . 24
Parking on an Incline . . . . . . . . . . . . 60
Periodic Maintenance Chart . . . . 74-77
Polaris Product List. . . . . . . . . . . . . 131
Polishing the Vehicle . . . . . . . . . . . 121
Position Light Lamp . . . . . . . . . . . . 101
Power Steering . . . . . . . . . . . . . . . . . 25
Power Steering Unit (Cleaning) . . . . 88
Pre-Ride Checklist . . . . . . . . . . . . . . 44
PVT Break-In . . . . . . . . . . . . . . . . . . 43
PVT Drying . . . . . . . . . . . . . . . . . . 113
PVT System . . . . . . . . . . . . . . 111-113
R
Rack/Compartment, Front . . . . . . . . 27
Reverse Operation . . . . . . . . . . . . . . 51
Reverse Override Switch . . . . . . . . . 20
Rider Information Center . . . . . . 32-41
Rider Safety . . . . . . . . . . . . . . . . . 7-13
Riding Gear. . . . . . . . . . . . . . . . . 14-15
144
INDEX
S
Safety Labels . . . . . . . . . . . . . . . . 16-19
Safety Training . . . . . . . . . . . . . . . . . 6
Safety, Winch Maintenance. . . . . . . 72
Severe Use . . . . . . . . . . . . . . . . . . . . 74
Shock Loading the Winch . . . . . . 70-71
Side Panel Removal. . . . . . . . . . . . . 95
Sidehilling . . . . . . . . . . . . . . . . . . . . 54
Signal Words . . . . . . . . . . . . . . . . . . . 4
Spark Arrester . . . . . . . . . . . . . . . . 110
Spark Arrester Requirements. . . . . . 73
Spark Plug Inspection . . . . . . . 107-108
Spark Plug Recommendations. . . . 107
Spark Plugs . . . . . . . . . . . . . . . 107-108
Spring Adjustment, Shock. . . . . . . 106
Standard/Metric Display . . . . . . . . . 35
Starting the Engine . . . . . . . . . . . . . 45
Steering Assembly. . . . . . . . . . . . . . 95
Steering Lock. . . . . . . . . . . . . . . . . . 26
Storage. . . . . . . . . . . . . . . . . . . 120-125
Storage Tips. . . . . . . . . . . . . . . 123-125
Switches
4X4 Switch . . . . . . . . . . . . . . 20, 28
Engine Stop Switch. . . . . . . . . . . 21
Hazard Warning . . . . . . . . . . . . . 21
Headlight Switch. . . . . . . . . . . . . 21
Horn . . . . . . . . . . . . . . . . . . . . . . 21
Main Key Switch . . . . . . . . . . . . 21
Mode Switch. . . . . . . . . . . . . . . . 20
Momentary High Beam Switch . 20
Reverse Override Switch . . . . . . 20
Stop Switch. . . . . . . . . . . . . . . . . 21
Turn Signal . . . . . . . . . . . . . . . . . 21
Winch Switch . . . . . . . . . . . . . . . 20
T
Taillight . . . . . . . . . . . . . . . . . . . . . . 103
Throttle Body Adjustment. . . . . . . . 104
Throttle Cable Freeplay Adjustment . . .
104-105
Throttle Lever . . . . . . . . . . . . . . . . . . 22
Tire Tread Depth . . . . . . . . . . . . . . . . 96
Tires . . . . . . . . . . . . . . . . . . . . . . 96-97
Wheel Installation. . . . . . . . . . . . . 97
Wheel Nut Torque . . . . . . . . . . . . 97
Wheel Removal . . . . . . . . . . . . . . 96
Toe Alignment. . . . . . . . . . . . . . . . . . 94
Towing Loads . . . . . . . . . . . . . . . . . . 60
Training . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission Gear Selector. . . . . . . . 25
Transmission Oil . . . . . . . . . . . . . . . . 82
Transporting the Vehicle . . . . . . . . . 126
Turn Signal Lamp, Rear . . . . . . . . . 102
Turn Signal Switch . . . . . . . . . . . . . . 21
Turning Around on a Hill . . . . . . 56-57
Turning the Vehicle. . . . . . . . . . . . . . 47
V
Vehicle Identification Numbers. . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . 109
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle . . . . . . . . 120-121
Wheel Hub Tightening . . . . . . . . . . . 96
Wheel Installation . . . . . . . . . . . . . . . 97
Wheel Nut Torque Specifications . . . 97
Wheel Removal . . . . . . . . . . . . . . . . . 96
Winch Cable Care . . . . . . . . . . . . . . . 69
Winch Maintenance/Service Safety. . 72
Winch Operation . . . . . . . . . . . . . 64-68
Winch Safety Precautions . . . . . . 61-63
Winch Shock Loading . . . . . . . . . 70-71
For your nearest Polaris dealer,
visit www.polaris.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Part No. 9924662 Rev 02
Printed in USA
*9924662 *
PMS 419
Before you operate this vehicle,
read the owner’s manual
