PMS 419
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.
Owner's Manual
for Maintenance and Safety
Sportsman Touring
550 EPS
Sportsman Touring
850 EPS
A card containing important ATV safety information should be
attached to the owner's manual on the next page. If you cannot
locate this card, or if it has been removed, please call 1-800-
342-3764 for assistance.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
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® vehicles
We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the POLARIS Service Manual and should be
performed only by a factory certified Master Service Dealer® (MSD)
technician.
Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
2
POLARIS® and SPORTSMAN® are registered trademarks of POLARIS Industries Inc.
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.
2014 SPORTSMAN 550/850 Touring Owner’s Manual
P/N 9924609
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Emission Control Systems . . . . . . . . . . . . . . . 87
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 139
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 143
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 144
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 156
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A POLARIS ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.
• Never operate an ATV without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
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
WARNING
6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
The manufacturer’s label is located on the front right side of the vehicle
behind the radiator.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key
Number
550 850
Manufacturer’s Label
7
SAFETY
Safety Training
ATV safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding the ATV to
take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer
provided information about the authorized ATV RiderCourse
sm
that is
available to you and your eligible family members. This training is
included in the purchase price of your ATV. You were also provided
with printed materials that explain safe operating procedures. You
should review this information on a regular basis.
If you purchased a used POLARIS ATV in the United States, you can
enroll in the ATV RiderCourse
sm
for a fee. Call ATV Enrollment Express
at (800) 887-2887 or visit www.atvsafety.org.
If you purchased a POLARIS ATV outside the United States, please
contact your dealer or local law enforcement agencies for information
about safety training.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of this vehicle in your
area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your
vehicle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800-
638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
POLARIS at 1-800-342-3764.
8
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
9
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding a POLARIS vehicle, always wear shatterproof goggles
or use a shatterproof helmet face shield. POLARIS recommends
wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye
wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS
ATV any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your POLARIS ATV is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to)
mowers, blades, tires, sprayers, or large racks, may change the handling
characteristics of the vehicle. Use only POLARIS-approved accessories,
and familiarize yourself with their function and effect on the vehicle.
10
SAFETY
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.
Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.
Never permit a guest to operate the ATV unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age. Never allow anyone under 12 years of age to ride as a
passenger on this 2-up ATV.
Even though a child may be within the recommended age group for operating
some ATVs, he/she may not have the skills, abilities, or judgment needed to
operate or ride on this ATV safely and could be susceptible to accident or injury.
WARNING
11
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.
Always inspect the ATV before each use to make
sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
12
SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).
Carrying a Passenger
Do not carry a passenger until you have at
least two hours of driving experience with this vehicle.
Carrying More Than One
Passenger
Carrying more than one passenger greatly
reduces the operator's ability to balance and
control the ATV, which may result in an
accident or overturn.
Never carry more than one passenger on this
2-up ATV.
Using Alcohol or Drugs
Operating the ATV after consuming alcohol or
drugs could adversely affect operator
judgment, reaction time, balance and
perception.
Never consume alcohol or drugs before or
while operating an ATV.
13
SAFETY
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.
Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.
Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.
Operating at Excessive
Speeds
Operating the ATV at excessive
speeds increases the operator's risk
of losing control.
Never operate at excessive speeds.
Travel at speeds appropriate for
your skills, your passenger's skills,
and operating conditions.
14
SAFETY
Safety Warnings
Physical Control of the ATV
Removing even one hand or foot can reduce
ability to control the vehicle or could cause loss
of balance and ejection from the ATV.
If a person's feet are not firmly planted on the
footrests, they could come into contact with the
wheels or other moving parts and lead to
accident or injury.
Always keep both hands on the handlebars
and both feet on the footrests of the ATV during
operation. A passenger should always be
seated in the passenger seat with both feet on the footrests and both hands on
the passenger grab handles at all times. The passenger should never hold on to
the operator.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or
overturn.
Always follow proper procedures for
turning as described in the owner's
manual.
Practice turning at slow speeds before
attempting to turn at faster speeds.
Never turn at excessive speed.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
15
SAFETY
Safety Warnings
Improper Hill Climbing
Improper hill climbing could cause loss of control
or overturn. Always follow proper procedures for
climbing hills as described in the owner's manual.
See page 63. Always move the 4X4 switch to
ADC 4X4 before ascending or descending a hill.
Descending Hills Improperly
Improperly descending a hill could cause loss of
control or overturn.
• Always follow proper procedures for traveling
down hills as described in the owner's manual. See page 65.
• Always descend a hill with the transmission in
forward gear. Do not descend a hill with the
transmission in neutral. Always move the 4X4
switch to ADC 4X4 before ascending or
descending a hill. See page 39.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which
would cause the vehicle to lean sharply to one
side. Travel straight down the hill when
possible.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a hillside is unavoidable, always
follow proper procedures as described in the
owner's manual. See page 64.
Never attempt to turn the ATV around on any
hill until you've mastered the turning technique
(on level ground) as described in the owner's
manual. See page 66.
16
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause
an overturn.
• Always maintain a steady speed when
climbing a hill.
• Always move the 4X4 switch to ADC 4X4
before ascending or descending a hill. See
page 39.
If all forward speed is lost:
• Lean forward to keep body weight uphill. A
passenger should also lean uphill.
• Apply the single lever brakes.
• Lock the parking brake when fully stopped.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 66.
If the ATV begins rolling backwards:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards.
• Apply the single-lever brake gradually.
• When fully stopped, apply the foot brake as well, and then lock the parking
brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 66.
Operating on Steep Hills
Operating on excessively steep hills could
cause an overturn.
Never operate on hills too steep for the ATV or
for your abilities. Never operate the ATV on
hills steeper than 15 degrees.
>15°
17
SAFETY
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating
on excessively rough, slippery or loose terrain
could cause loss of traction, loss of control,
accident or overturn.
Do not operate on excessively rough, slippery
or loose terrain until you've learned and
practiced the skills necessary to control the
ATV on such terrain.
Always use extra caution on rough, slippery
or loose terrain.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating
on unfamiliar terrain could result in an
accident or overturn.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of
control or overturn.
Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions.
Operating Improperly in
Reverse
Improperly operating in reverse could result
in a collision with an obstacle or person.
Always follow proper operating procedures
as outlined in this manual. See page 70.
Before shifting into reverse gear, always
check for obstacles or people behind the ATV.
When it's safe to proceed, back slowly.
18
SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this ATV with improper tires or
with improper or uneven tire pressure could
cause loss of control or accident.
Always use the size and type of tires
specified for your ATV.
Always maintain proper tire pressure as
described in the owner's manual and on
safety labels.
Operating Over Obstacles
Improperly operating over obstacles could
cause loss of control or overturn.
Before operating in a new area, check for
obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If
unavoidable, use extreme caution and
always follow proper operating procedures
as outlined in this manual. See page 69.
Skidding or Sliding
Skidding or sliding can cause loss of control
or overturn (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose
gravel, travel slowly and use extra caution
to reduce the chance of skidding or sliding.
Do not operate on excessively slippery
surfaces.
19
SAFETY
Safety Warnings
Operating Through Deep Water
Operating the ATV through deep or fast-
flowing water could cause the tires to float,
causing loss of control or overturn.
Avoid operating the ATV through deep or
fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page
68):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving. The friction will help dry
out the pads.
Improper Cargo Loading
Overloading the ATV or carrying/towing
cargo improperly may cause changes in
handling, which could cause loss of control
or an accident.
• Never exceed the stated load capacity for
this ATV.
• Cargo should be properly distributed and
securely attached.
• Reduce speed when carrying cargo or
pulling a trailer. Allow a greater distance
for braking.
• 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 50 MPH (80 km/h) while carrying a passenger.
• 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).
• Always follow the instructions in the owner's manual for carrying cargo or
pulling a trailer. See pages 72-74.
• Always follow the instructions in the owner's manual for operating with a
passenger. See page 60.
20
SAFETY
Safety Warnings
Operating on Frozen Bodies of
Water
Operating on frozen bodies of water may
result in serious injury or death if the ATV
and/or riders fall through the ice.
Never operate the ATV on a frozen body of
water unless you have independently
verified that the ice is sufficiently thick to
support the weight and moving force of the
ATV, you and your cargo, together with any
other vehicles in your party. Variances in
snow depth and/or water currents may result
in uneven ice thickness. Always check with
local authorities and residents to confirm ice
conditions and thickness over your entire
route. ATV operators assume all risk
associated with ice conditions on frozen
bodies of water.
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.
21
SAFETY
Safety Warnings
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control. Never secure a
passenger to the vehicle or to the operator with a belt, rope or similar device.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
22
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off,
contact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
Reverse Override Warning/AWD Caution
WARNING
Improper use of override
button can lead to loss of
control resulting in severe
injury or death. Do not
activate override while throttle
is engaged. Always apply
throttle gradually while in
reverse.
CAUTION
Do not push switch to engage
4x4 (AWD) if the rear wheels
are spinning. This may cause
severe drive shaft and clutch
damage.
7175512
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases the chances of
severe injury or death to both operator and passenger.
NEVER operate this ATV if you are under age 16.
7175375
2x4
Trip 1
km
mi
RPM
FE
88
:
88
Reverse Override Warning
AWD Caution
Age 16 Warning
23
SAFETY
Safety Labels and Locations
General Warning
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR FOR DRIVER AND
PASSENGER
NEVER USE ON PUBLIC ROADS
NEVER CARRY MORE THAN 1 PASSENGER
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper ATV training or instruction
• at speeds too fast for your skills or the
conditions
• on public roads - a collision can occur with
another vehicle
• with a passenger unless passenger seat is securely in place
THE OPERATOR MUST ALWAYS:
• use proper riding techniques to avoid overturns on hills and rough terrain and
in turns
• avoid paved surfaces - pavement may seriously affect handling and control
• reduce speed and use extra caution at all times when carrying a passenger -
dismount passenger when conditions require
• make sure passenger reads and understands this label and passenger safety
label
LOCATE AND READ OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175844
General Warning
24
SAFETY
Safety Labels and Locations
Passenger Warning/Discretionary Warning
WARNING
PASSENGER SAFETY
To reduce the risk of SEVERE INJURY or
DEATH
NEVER CARRY MORE THAN ONE
PASSENGER
NEVER RIDE AFTER USING DRUGS OR
ALCOHOL
NEVER carry a passenger too small to firmly
plant feet on footrests and securely grasp
hand holds.
THE PASSENGER MUST ALWAYS:
• use an approved helmet and protective gear
• securely grasp hand holds and plant feet firmly on footrests while seated in
the passenger seat
• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require
WARNING
• Never operate this ATV on HILLS steeper than 15 degrees 15°. To
prevent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
7175845
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause
loss of control.
Loss of control can result in severe injury or
death.
• Cold tire pressure:
Front: 7.0 psi (48.3 kPa)
Rear: 7.0 psi (48.3 kPa)
• Maximum weight capacity: 575 lbs. (261kg)
• Lug nut torque values:
Steel rims 45 ft-lbs. (61 Nm)
Aluminum rims 75 ft-lbs. (102 Nm)
Passenger Warning
Discretionary Warning
Tire Pressure/Load
Warning
25
SAFETY
Safety Labels and Locations
Rack/Box Warning
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
• Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg)
7175448
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
7175488
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
7170509
Clutch Cover
Warning
(under seat)
Rack/Box
Warning
Rack/Box
Warning
Hitch
Capacity
Label
26
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 button.
WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.
The reverse override button also acts as a MODE button when held
down for approximately one half second. See the instrument cluster
information beginning on page 40.
Tip: The override button will not function as a MODE button if the transmission
is in reverse.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 39. The
vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.
2x4
Trip 1
km
mi
RPM
FE
88
:
88
Mode/Reverse
Override
Switch
Main Key
Switch
Engine
Stop Switch
Headlight
Switch
4X4
Switch
27
FEATURES AND CONTROLS
Switches
Engine Stop Switch
Move the stop switch either
left or right to the OFF position
to stop the engine quickly.
Move the stop switch to the
RUN position before
attempting to start the engine.
The engine will not start or run
when the switch is off.
Both the main switch and the engine stop switch will shut off all
electrical power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 57.
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
and the engine stop switch must be in the RUN position.
OFF OFFRUN
28
FEATURES AND CONTROLS
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Always check the lever
for free movement and return before starting the engine. Also check
occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.
Engine speed and vehicle movement are controlled by pressing the
throttle lever. The throttle lever is spring loaded. Engine speed returns to
idle when the lever is released.
This ATV is equipped with a
throttle release switch, which is
designed to reduce the risk of a
frozen or stuck throttle.
If the throttle cable should stick
in an open position when the
operator releases the throttle
lever, engine speed will be
limited, and power to the rear
wheels will be reduced.
WARNING
29
FEATURES AND CONTROLS
Brake Lever
Operating the ATV with a spongy brake lever can result in loss of braking, which
could cause an accident. Never operate the ATV with a spongy-feeling brake
lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These brakes are
hydraulically activated disc type
brakes that are activated by only
one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever
should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
WARNING
30
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master
cylinder before each ride.
1. Position the ATV on a level
surface.
2. Position the handlebars so the
master cylinder is level.
3. View the brake fluid level
through the indicator window
on the top of the master
cylinder. The eye will appear
dark when the fluid level is
full. When fluid is low, the
eye will be clear.
4. If the fluid level is low, remove the cover screws and add fluid to the
fill line. Do not overfill. Use DOT 4 brake fluid only.
5. Reinstall the cover. Torque screws to 7 in. lbs. (.8 Nm).
WARNING
Master Cylinder
Indicator
Window
31
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
PARK.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
WARNING! Operating the ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.
32
FEATURES AND CONTROLS
Auxiliary Foot Brake
Never back down a hill. Applying the auxiliary brake when backing down a hill
may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the
auxiliary brake when going forward. The rear wheels may skid and slide
sideways, causing loss of control and serious injury or death.
The auxiliary brake system is
intended to be used as a backup for
the main brake system. Should the
main system fail, use the auxiliary
foot brake.
The auxiliary foot brake is located
on the inside of the right footrest.
Operate this brake with your right
foot.
If the rear wheels slide while using
the auxiliary brake, reduce brake
pedal pressure to brake the rear
wheels without skidding.
Brake Fluid Level
Check the brake fluid level
frequently for the auxiliary brake
system. The reservoir is located
under the front storage box. See
page 36.
Maintain the fluid level between
the maximum and minimum marks.
Use DOT 4 brake fluid only.
NOTICE: Do not use ADC fluid in the
brake fluid reservoir. ADC
fluid will damage the rubber
components of the brake
system.
WARNING
Auxiliary
Foot Brake
Brake Fluid
Reservoir
33
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear
selector is located on the
right side of the vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
To shift gears, brake to a
complete stop. When the
engine is idling, move
the lever to the desired
gear.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
moving could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in
PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.
Gear
Selector
34
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 41 for EPS Warning Indicator information.
Passenger Seat
Always make sure the passenger seat is installed and securely latched
before operating with a passenger. Test the seat latch by attempting to
pull the seat upward. If the lock-out is not working properly, do not
allow a passenger to ride the vehicle. See your POLARIS dealer for
service.
See pages 107-108 for passenger seat adjustment procedures.
See page 107 for passenger seat removal and installation procedures.
Beverage Holders
This vehicle is equipped with
beverage holders on each side
of the passenger seat. To
secure a beverage or other
container, remove the rubber
retainer strap from one side of
the holder. Place the container
into the recess and reinstall the
strap over the top of the
container. Place one of the
rubber cylinders through one
of the holes to secure a strap.
When trailering the vehicle,
and whenever a holder is not
in use, always secure the
rubber straps in one of the
tighter positions to prevent
loss of the retainer.
Tight Position
Less Tight Position
35
FEATURES AND CONTROLS
Fuel Tank
Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level
surface.
Remove the fuel tank cap and add
fuel. Use either leaded or unleaded
gasoline with a minimum pump
octane number of 87=(R+ M/2)
octane. Do not use fuel with ethanol
content greater than 10%, such as
E-85 fuel.
The fuel tank is designed to allow
for the normal expansion of fuel. Do
not overfill. Do not fill the tank
neck.
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 129.
2. To install the 30 AH battery, remove the 18 AH battery. See page
127.
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 128.
Fuel Tank
Cap
36
FEATURES AND CONTROLS
Front Storage Box
Open the front storage box to access the under-compartment area.
1. Release the front
box cover latches
and lift the cover.
2. Release the plunger
latches that secure
the box to the
frame.
3. Close the cover and
lift the unlatched
edge of the box to
disengage the plungers. Pivot the box forward.
4. To remove the box completely, disengage the plungers and slide the
box rearward and upward.
5. Always secure the plunger latches and the cover latches before
operating the vehicle.
Access the following components under the front box:
• Radiator cap • Coolant recovery bottle cap
• Brake fluid reservoir • Electrical/fuse/relay components
• ADC fluid reservoir • Battery
Cover Latches Plunger Latches
ADC Fluid
Reservoir
Brake Fluid
Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
Battery
37
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 39.
4X4 Mode
When the switch is on 4X4, the
ATV is in 4X4, and the 4X4
indicator icon in the instrument
cluster display will be visible.
When in 4X4, the demand drive
unit will automatically engage
any time the rear wheels lose
traction. When the rear wheels
regain traction, the demand drive
unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in 4X4.
The vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.
2X4 Mode
When the switch is on 2X4, the ATV is in two-wheel drive at all times.
4X4
Switch
ADC 4X4
38
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.
39
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the
vehicle descends a hill or incline. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the
following conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 mph (24 km/h) or less
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the
following conditions occur:
• The 4X4 switch is moved out of the ADC 4X4 position
• Vehicle speed exceeds 15 mph (24 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
40
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage ATV components. Wash the ATV
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.
Digital/Analog Gauge
Speedometer
The speedometer displays vehicle speed in either miles per hour (MPH)
or kilometers per hour (km/h).
Trip 1
km
mi
RPM
FE
88
:
88
Rider
Information
Center
Speedometer
Indicator Lamps
41
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Indicator Lamps
Lamp Indicates Condition
Vehicle
Speed
When standard mode is selected, speed displays in
miles per hour.
When metric mode is selected, speed displays in
kilometers per hour.
Over
Temperature
This lamp 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.
EPS Warning 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.
Neutral This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam This lamp illuminates when the headlamp switch is
set to high beam.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the ATV if this warning appears.
Serious engine damage could result. See your dealer.
42
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The rider information center is located in the instrument cluster. All
segments will light up for one second at start-up. If the instrument
cluster fails to illuminate, a battery over-voltage may have occurred and
the instrument cluster may have shut off to protect the electronic
speedometer. If this occurs, take the ATV to your POLARIS dealer for
proper diagnosis.
The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 45.
Trip 1
km
mi
RPM
EF
88
:
88
1
2
6
5
7
3
4
43
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
1. Gear Display - This area 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. Fuel Gauge Display - 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.
3. Information Display - This area displays odometer, trip meter,
engine hour meter, engine speed and programmable service hour
interval.
4. Active Descent Control Display - This icon displays when ADC is
active. See page 39.
5. Clock Display - 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 45 for resetting
instructions.
6. Service Reminder Display - 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 45 for resetting instructions.
7. 4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either ADC 4X4 or 4X4).
44
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The reverse override button acts as the MODE button when pressed and
released quickly. The transmission cannot be in reverse when using the
override button as a MODE button. This feature does not contain a
vehicle speed lockout function and can be used at any operating speed.
Display Units (Standard/Metric)
The display can be changed to display either standard or metric units of
measurement.
Tip: To exit the set-up mode at any time, wait 10 seconds.The display
automatically exits and returns to the odometer display.
1. Turn the key to the OFF position.
2. Place the transmission in neutral.
3. Press and hold the MODE button while turning the key to the ON
position.
4. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting.
5. Press and hold the MODE button to save the setting and advance to
the next display option.
6. Repeat the procedure to change remaining display settings.
Standard Display Metric Display
Distance Miles Kilometers
Time 12-Hour Clock 24-Hour Clock
45
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or
discharged.
1. Turn the key to the ON position. Use the MODE button to toggle to
the odometer display.
2. Press and hold the MODE button until the hour segment flashes.
Release the button.
3. With the segment flashing, tap the MODE button to advance to the
desired setting.
4. Press and hold the MODE button until the next segment flashes.
Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.
6. Turn the key to the OFF position.
Odometer Mode
The odometer records and displays the distance traveled by the ATV.
Trip Meter Mode
The trip meter records the distance traveled by the ATV if reset before
each trip. To reset, select the trip meter mode. Press and hold the MODE
button until the meter resets to zero. 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.
46
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
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 MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.
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.
47
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Engine Error Codes
The error screen displays
only when the CHECK
ENGINE light is on or when
it goes on and off during one
ignition cycle. Error codes
are not stored in the gauge
when the key is turned off.
The code and message is
lost, but will reappear if the
fault reoccurs after
restarting the engine.
If the CHECK ENGINE
light illuminates, retrieve
the error codes from the
display. Please see your
Polaris dealer for all major repairs.
1. If the error codes are not displayed, use the MODE button to toggle
until “Ck ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code
menu.
3. Record the numbers displayed in the gear position (if any), clock
and odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. See pages 48-51 for code definitions and failure descriptions. Please
see your Polaris dealer for all major repairs.
Suspect Parameter
Number (SPN)
Error Code
Number (0-9)
Failure Mode Indicator (FMI)
48
FEATURES AND CONTROLS
Instrument Cluster
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 550 Touring 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
49
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
*Assumes unipolar configuration of stepper motor
SPORTSMAN 550 Touring Diagnostic Codes
Component Condition SPN FMI
Idle Air Control Driver Circuit Grounded 520193 5
Shorted Load* 520193 11
Starter Enable Circuit Driver Circuit Short to B+ 1321 3
All Wheel Drive Control Driver Circuit Short to B+ 520207 3
System Power Voltage Too High 168 3
Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3
Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7
Active Descent Control System Driver Circuit Short to B+ 520203 3
EPS Models Only
Steering Over Current Shut Down Current Above Normal or
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
50
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
SPORTSMAN 850 Touring 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
51
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
SPORTSMAN 850 Touring Diagnostic Codes
Component Condition SPN FMI
Chassis Relay Driver Circuit Open/Grounded 520208 5
Driver Circuit Short to B+ 520208 3
Driver Circuit Grounded 520208 4
All Wheel Drive Control Driver Circuit Open/Grounded 520207 5
Driver Circuit Short to B+ 520207 3
Driver Circuit Grounded 520207 4
System Power Voltage Too High 168 3
Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3
Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7
Active Descent Control System Driver Circuit Open/Grounded 520203 5
Driver Circuit Short to B+ 520203 3
Driver Circuit Grounded 520203 4
Idle Speed Speed Too High 520211 3
Speed Too Low 520211 4
EPS Models Only
Steering Over Current Shutdown Current Above Normal/Grounded 520221 6
Steering Excessive Current Error Current Above Normal/Grounded 520222 6
Steering Torque Sensor T1
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 Short to Ground & T2 Short to Bus 520225 16
T2 Short to Ground & T1 Short to Bus 520225 17
T1 and T2 are Shorted 520225 2
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 Err No RX Message for 2 Seconds 520230 9
EPAS CAN Comm. Transmit Err No TX Message for 2 Seconds 520231 9
IC CAN Comm. w/EPAS EPAS Offline 520230 31
52
OPERATION
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new POLARIS ATV is the first 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.
WARNING
53
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 35. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 93. 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 54.
6. Pull only light loads.
7. Check fluid levels of transmission and all gearcases after the first 25
hours of operation and every 100 hours thereafter.
8. Change both the oil and the filter at 25 hours.
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.
54
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.
Item Remarks Page
Passenger seat latch Ensure latch is secure 34
Brake system/lever travel Ensure proper operation 29
105
Brake fluid Ensure proper level 30
Auxiliary brake Ensure proper operation 32
Front suspension Inspect, lubricate if necessary 92
Rear suspension Inspect, lubricate if necessary 92
Steering Ensure free operation -
Tires Inspect condition and pressure 110
Wheels/fasteners Inspect, ensure fastener tightness 112
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 35
93
Coolant level Ensure proper level 103
104
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 28
132
Indicator lights/switches Ensure operation 26
Engine stop switch Ensure proper operation 27
Air filter, pre-filter Inspect, clean 113
Headlamp Check operation 27
115
Brake light/taillight Check operation 119
Riding gear Wear approved helmet, goggles, and
protective clothing
8
ADC Fluid Ensure proper level 99
Winch (if equipped) Inspect cable and switch 75-86
55
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle. See page 7.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to
operate this vehicle.
3. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
4. Before operating, learn how to use the auxiliary brake for
emergency situations (if service brakes become inoperable).
5. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
6. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights
frequently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills, your passenger’s
skills and operating conditions. Never operate at excessive speeds.
Never attempt wheelies, jumps, or other stunts. Never remove your
hands from the handlebars while operating, and always keep both
feet on the footrests.
8. Never consume alcohol or drugs before or while operating an ATV.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged ATV. After any overturn or accident, have
a qualified service dealer inspect the entire machine for possible
damage.
11. Never operate the ATV on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the
weight and moving force of the ATV, you and your cargo, together
with any other vehicles in your party.
12. Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
56
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the
operation of this off-road vehicle in your area. Respect the environment
in which you ride. Find out where the designated riding areas are by
contacting your POLARIS dealer, a local riding club or local officials.
Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of
vehicles in your group. When stopping, move your vehicle to the edge
of the trail as far as possible to allow others to pass safely.
57
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-
ventilated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
Tip: The starter interlock will prevent the engine from starting if the transmission
is in gear and the brake is not engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
Tip: Do not press the throttle while starting the engine.
5. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.
6. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising oil
level could indicate the accumulation of contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water
accumulation increases as outside temperature decreases.
If a belt fails, always clean away all debris when replacing the belt.
58
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 8.
2. Perform the pre-ride inspection. See page 54.
3. Place the transmission in PARK.
4. Lock the parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the
handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
59
OPERATION
Turning the Vehicle
Both rear wheels drive
equally at all times. This
means that the outside wheel
must travel a greater distance
than the inside wheel when
turning, and the inside tire
must slip traction slightly.
1. Slow down.
2. Never turn quickly when
carrying a passenger or
cargo.
3. Steer in the direction of
the turn.
4. Keep both feet on the
footrests.
5. Lean your upper body to the inside of the turn while supporting your
weight on the outer footrest. This technique alters the balance of
traction between the rear wheels, allowing the turn to be made
smoothly. The same leaning technique should be used for turning in
reverse.
6. Practice making turns at slow speeds before attempting to turn at
faster speeds.
WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.
60
OPERATION
Driving with a Passenger
1. Never allow anyone under 12 years of age to ride as a passenger on
this 2-up ATV. Make sure any passenger is tall enough to
comfortably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear,
including an approved helmet with a rigid chin guard. See page 8.
4. Perform the pre-ride
inspection. See page 54.
5. Always make sure the
passenger seat is installed
and securely latched
before operating with a
passenger.
6. Lock the parking brake.
7. Mount the vehicle from
the left side. After the
operator is seated, the
passenger should mount
the vehicle from the left
side. Always make sure
the brake is engaged to
ensure the vehicle
remains motionless whenever a passenger mounts or dismounts.
8. Allow a passenger to ride only in the approved passenger seat.
9. Do not carry more than one passenger.
10. Slow down. Control may be more difficult with a passenger on
board. Allow more time and distance for braking.
61
OPERATION
Driving with a Passenger
11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected or aggressive maneuvers that could cause a
passenger to fall from the vehicle.
12. Do not cross a hillside with a passenger on board. See page 64.
13. A passenger should always be seated in the passenger seat with both
feet on the footrests and both hands on the passenger grab handles
at all times. The passenger should never hold on to the operator.
Never secure a passenger to the vehicle or to the operator with a
belt, rope or similar device.
14. Make sure the passenger understands the importance of "active
riding." When hill-climbing or performing maneuvers, a passenger
should shift body weight in the same manner in which the driver
shifts body weight. For example, the passenger should lean to the
inside of a turn along with the operator and should always lean
uphill when climbing and descending hills.
62
OPERATION
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Engage 4X4 before wheels begin to lose traction.
NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while
the wheels are spinning. Allow the rear wheels to stop spinning
before engaging 4X4, or engage 4X4 before wheels begin to lose
traction.
4. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
5. 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.
Sideways
skid
Turn in
direction of
skid
63
OPERATION
Driving Uphill
Braking and handling are greatly affected when operating in hilly
terrain. Improper procedure could cause loss of control or overturn.
Whenever traveling uphill, follow these precautions:
1. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 39.
2. Drive straight uphill.
3. Avoid steep hills (15° maximum).
4. Always check the terrain carefully before ascending any hill.
5. Never climb hills with excessively slippery or loose surfaces.
6. Keep both feet on the footrests.
7. Shift body weight uphill. A passenger should also shift body weight
uphill.
8. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.
9. Never go over the top of any hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.
10. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
15° Maximum
64
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Do not cross a hillside with a passenger on board. Ask the passenger
to dismount and walk across the hillside before remounting the
vehicle.
4. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.
5. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
65
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 39.
3. Always descend a hill with the transmission in forward gear. Do not
descend a hill with the transmission in neutral.
4. Slow down. Never travel down a hill at high speed.
5. Drive straight downhill. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.
6. Shift body weight uphill. A passenger should also shift body weight
uphill.
7. Apply the brakes slightly to aid in slowing. Applying the brakes too
firmly may cause the rear wheels to lock, which could result in loss
of control.
15° Maximum
66
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.
8 ft. (2.4 m)
67
OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 39.
3. Leave the transmission in forward and shut off the engine.
4. If a passenger is on board, ask the passenger to dismount first, then
the operator may dismount. Dismount on the uphill side of the
vehicle, or on the left if the vehicle is pointing straight uphill. A
passenger should not remount until the vehicle returns to firm, level
ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's
pointing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill. A passenger should not remount until
the vehicle returns to firm, level ground.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
68
OPERATION
Driving Through Water
Your ATV can operate
through water with a
maximum recommended
depth equal to the bottom
of the footrests. Follow
these procedures when
operating through water:
1. Determine water
depths and current
before entering water.
2. Choose a crossing
where both banks have
gradual inclines.
3. Avoid operating
through deep or fast-flowing water.
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 88. The following areas need
special attention: engine oil, transmission oil, demand drive fluid and
all grease fittings
.
If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 122,
then see your dealer for service at the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops.
Do not make sudden throttle changes.
Maximum Depth
69
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for
hazards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.
5. Always have a passenger dismount before operating over an
obstacle that could cause a fall from the vehicle or vehicle tipover.
70
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle. Be aware
that a passenger can obstruct your view.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch unless additional wheel speed is
required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.
NOTICE: Excessive throttle operation while in the speed limit mode may cause
fuel to build in the exhaust, resulting in engine popping and/or engine
damage.
71
OPERATION
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
72
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, which can result in
serious injury or death. Always follow these precautions when hauling cargo:
Never carry cargo on the rear rack when operating the ATV in the 2-up mode
with a passenger.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, passenger, accessories, loads in the rack or box and the load on the
trailer tongue. The combined weight of these items must not exceed the
maximum weight capacity.
CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high
on the racks raises the center of gravity of the vehicle and creates a less stable
operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
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 50 MPH
(80 km/h) while carrying a passenger. 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).
The vehicle should never exceed 10 mph (16 kph) while towing a load on a level
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
WARNING
73
OPERATION
Hauling Cargo
1. Never exceed the weight
capacities specified for your
ATV 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 50 MPH (80 km/h) while carrying a passenger.
6. 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).
7. Do not obstruct the headlight beam with cargo.
8. Slow down.
9. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
10. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.
2/3
1/3
74
OPERATION
Hauling Cargo
Towing Loads
Always attach a towed load to the hitch point. Remove the hitch from
the ATV when not towing a trailer. If towing a load, reduce rear rack
cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must
not exceed the rear rack capacity.
• The total load (operator, passenger, accessories, cargo and weight on
hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding
the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your ATV
warranty. Never install a hitch longer
than 4" (10 cm). Never install
automotive accessories on your
POLARIS ATV. Always install
POLARIS-approved (or equivalent)
accessories designed for ATV use.
Maximum Towing Capacities
Do not exceed maximum towing capacities. Avoid towing on inclines.
550 850
Maximum Towed Load (Level Ground) 1500 lbs. (680 kg) 1500 lbs. (680 kg)
Maximum Vertical Hitch Weight 150 lbs. (68 kg) 150 lbs. (68 kg)
Maximum
4" (10 cm)
75
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 84.
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
76
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 82 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.
77
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.
78
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
79
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 84.
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
80
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.
81
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 84. 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.
82
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.
83
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
84
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.
85
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.
86
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.
87
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and qualified
to be in accordance with the USFS standard 5100-1c. Federal law
requires that this spark arrester be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled
by engine design. An electronic
fuel injection (EFI) system controls
fuel delivery. The engine and EFI
components are set at the factory
for optimal performance and are
not adjustable.
The emissions label is located on
the right rear frame tubing of the
vehicle.
Electromagnetic Interference
This spark ignition system complies with Canadian standard ICES-002.
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.
Emissions Label
88
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in safe,
reliable condition. 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
156.
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.
89
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
WARNING! 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 (failure to conduct this maintenance will not void
the emissions warranty but may affect emissions)
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
Make adjustments as
needed. See Pre-Ride
Checklist on page 54.
Front suspension - -
Rear suspension - -
Tires - -
Brake fluid level - -
Brake lever travel - -
Brake system - -
Passenger seat
latch
--
Wheels/fasteners - -
Frame fasteners - -
Engine oil level - -
Winch (if
equipped)
- - See pages 75-86
90
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)
►
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, add as needed
► Power steering unit - Daily - Inspect daily; clean often
Headlight/taillight - Daily - Check operation
►
E
Air filter,
main element
- Weekly - Inspect; replace as needed
►
D
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 52)
► 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 98.
► 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
sealing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; 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
91
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
► Oil lines and
fasteners
100 H 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
92
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 88. Items not listed in
the chart should be lubricated at the General Lubrication interval.
The a-arms and upper control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
Item Recommended
Lubricant
Capacity
at Fluid
Change
Fill Plug
Torque
Drain Plug
Torque
See Page
550 Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt.
(1.9 l)
--- 15-17 ft. lbs.
(20-23 Nm)
93
850 Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt.
(1.9 l)
--- 12 ft. lbs.
(16 Nm)
93
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)
96
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)
98
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)
101
Brake Fluid DOT 4 Brake
Fluid
--- --- --- 30
ADC Fluid Demand Drive
Fluid
--- --- --- 99
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
93
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 143 for the part numbers of POLARIS
products.
See the table on page 92 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.
1. Position the vehicle on a
level surface.
2. Access the oil dipstick and
fill tube from the left side of
the ATV. 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
94
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 92 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 88. Always change the
oil filter whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three
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.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque to specification.
550 Drain
Plug
to front
850 Drain
Plug
Filter Access
95
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 counter-clockwise
to remove it.
10. Using a clean dry cloth, clean
the filter sealing surface on
the crankcase.
11. Lubricate the o-ring on the
new filter with a film of fresh
engine oil. Check to make
sure the o-ring is in good
condition.
12. Insta
ll 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. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
21. Dispose of used filter and oil properly.
Oil Filter
850550
96
MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 88. See the table
on page 92 for fluid recommendations, capacities and plug torques. See
page 143 for the part numbers of POLARIS products.
Maintain the oil level at the
bottom of the fill plug hole. The
fill plug is located on the right side
of the ATV behind the footwell.
The drain plug is located on the
bottom rear side of the gearcase.
Oil Check
1. Remove the footwell (see
page 109).
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.
Drain Plug
Fill Plug
Fill
Level
97
MAINTENANCE
Transmission Oil
Oil Change
1. Remove the footwell.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow
the oil to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Remove the fill plug. Add the proper amount of the recommended
oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the footwell.
8. Dispose of used oil properly.
98
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Always check and change the demand drive fluid at the intervals
outlined in the Periodic Maintenance Chart beginning on page 88. See
the table on page 92 for fluid recommendations, capacities and plug
torques. See page 143 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. 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
99
MAINTENANCE
Active Descent Control (ADC) Fluid
Check and change the ADC fluid at the intervals outlined in the Periodic
Maintenance Chart beginning on page 88.
We recommend the use of POLARIS Demand Drive Fluid for the ADC
unit. Maintain the fluid level between the minimum and maximum
marks on the reservoir. See page 143 for the part numbers of POLARIS
products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
Fluid Check
1. Access the reservoir under
the front box. See page 36.
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. Close and secure the front
box and cover.
ADC Fluid Reservoir
100
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 fluid.
5. Remove the protective caps from the bleeder valves.
6. Slowly loosen one of the bleeder valve 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 valve screws 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 bleeder valve screws to 80 in. lbs. (9 Nm). Reinstall the
bleeder valve caps.
8. Add fresh ADC 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
101
MAINTENANCE
Rear Gearcase Oil
Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 88. See the table
on page 92 for fluid recommendations, capacities and plug torques. See
page 143 for the part numbers of POLARIS products.
The fill plug is located on the
rear of the gearcase. The drain
plug is located on the bottom
of the gearcase.
Maintain the fluid level at the
bottom of the fill hole threads.
Do not overfill.
Oil Check
1. Position the vehicle on a
level surface.
2. Remove the fill plug.
Check the oil level.
3. Add the recommended oil
as needed to bring the
level to the bottom of the
fill hole threads. Do not overfill.
4. Reinstall the fill plug. Torque to specification.
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. Torque
to specification.
5. Remove the fill plug. Add the proper amount of the recommended
oil. Do not overfill.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
Drain Plug
Fill Plug
Fill
Level
102
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.
Steering Assembly
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your
POLARIS dealer for service before operating the vehicle.
Cooling System
The engine coolant level is controlled, or maintained, by the recovery
system. The recovery system components are the recovery bottle, the
radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the bottle, past the
pressure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS 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 143 for the part
numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Clean
Often
103
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 box. See page
36.
1. View the fluid level in the bottle.
2. If the level is low, remove the bottle cap and add coolant as needed.
Maintain the coolant level between the minimum and maximum
marks on the bottle (when the fluid is cool).
3. Reinstall the cap.
4. Close and secure the front box and cover.
Maximum
Mark
Minimum
Mark
Recovery
Bottle Cap
104
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.
CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.
1. Access the pressure cap under the
front box. See page 36.
2. Remove the pressure cap.
3. Using a funnel, slowly add
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. Close and secure the front box and cover.
Radiator
Cap
105
MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self-
adjusting.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
WARNING! An over-full master cylinder may cause brake drag or brake lock-
up, which could result in serious injury or death. Maintain brake fluid at the
recommended level. Do not overfill.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an adequate
level. See page 30.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).
5. Check the security and surface condition
of the disc. 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.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 32.
3/64" (1 mm)
106
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).
WARNING! Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized POLARIS dealer.
1. Position the vehicle on a
level surface.
2. Place the handlebars in a
straight-ahead position.
3. Tie a length of string
between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long 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 1/8-1/4 inch (3-6 mm) more than the front measurement
on each side of the vehicle to obtain the recommended 1/4-1/2 inch
(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
107
MAINTENANCE
Seats
Passenger Seat Removal
1. Pull the latch at the rear of the seat.
2. Pivot the rear of the seat upward and
remove the front legs of the seat base
from the frame.
3. To reinstall the seat, position the
front legs of the seat base under the
frame. Pivot the rear of the seat
downward onto the latch. Press
down firmly on the seat pad until the
latch clicks. Test the seat latch by attempting to pull the seat
upward.
Passenger Seat Backrest Adjustments
The passenger backrest can be adjusted horizontally and vertically.
1. Unzip the two zippers at the
bottom of the backrest pad. Lift
the pad upward to remove it from
the backrest frame.
2. To adjust the backrest forward or
rearward, loosen the top adjuster
bolt. Pivot the adjuster forward or
rearward to one of the three
adjustment positions and tighten
the bolt.
3. To adjust the backrest upward or
downward, loosen the four
vertical adjustment screws on the
front side of the backrest frame.
Slide the backrest upward or
downward to the desired position
and tighten the screws.
4. Reinstall the backrest pad.
108
MAINTENANCE
Seats
Passenger Seat Suspension
1. Remove the passenger seat.
2. Remove the fastener retaining the
passenger seat shock to the passenger
seat support.
3. Pivot the seat support upward to
access the lower shock fastener.
Remove the lower shock fastener.
4. Remove the shock from the vehicle.
If adjustment is necessary, use a
suitable pliers or spanner wrench.
Adjust the shock to the desired
spring preload. Rotate the adjustment
cam to the left to increase preload.
5. Reinstall the shock.
6. Torque the upper and lower shock
fasteners to 38 ft. lbs. (51 Nm).
7. Reinstall the passenger seat.
Operator Seat Removal
1. Remove the passenger
seat. See page 107.
2. Grasp one side of the
operator’s seat near the
rear edge.
3. Pull upward abruptly to
disengage the under-seat
fasteners.
4. Remove the seat.
109
MAINTENANCE
Side Panel/Footwell Removal
1. Remove the seat before removing a side panel.
2. To remove a side panel or footwell, remove the fasteners securing it
to the frame. Lift the right side panel upward while removing it to
clear the shifter knob
Plastic Rivet
Hex Head Screw
Plastic Rivet
110
MAINTENANCE
Tires
Operating your ATV 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 144 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.
WARNING
1/8" (3 mm)
111
MAINTENANCE
Tires
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. Lock the parking brake.
4. Loosen the wheel nuts slightly.
WARNING! Do not service axle nuts that have a cotter pin installed. See your
POLARIS dealer.
5. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
112
MAINTENANCE
Tires
Wheel Installation
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation.
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
WARNING! 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 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)
113
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
114
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. Access the fuses under the front box. See page 36.
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. Close and secure the front box and cover.
550 850
Fuse Box
115
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean
headlights frequently and replace burned out headlamps promptly.
Always make sure lights are adjusted properly for best visibility.
Headlight Lamp Replacement
When servicing a halogen lamp, avoid touching the lamp with bare
fingers. Oil from your skin leaves a residue, causing a hot spot that will
shorten the life of the lamp. If fingers do touch a lamp, clean it with
denatured alcohol.
1. Remove the five (5)
headlight pod screws.
2. Lift the pod cover and
disconnect the
speedometer harnesses
from the speedometer.
CAUTION! Hot components
can cause burns to skin. Allow
lamps to cool before servicing.
3. Unplug the headlamp
from the wiring harness.
Be sure to pull on the
connector, not on the
wiring.
4. Turn the lamp counter-clockwise to remove it.
5. Install the new lamp. Make sure the tab on the lamp locates properly
in the housing.
6. Reassemble the pod.
116
MAINTENANCE
Lights
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall. Place the transmission in
PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Start the engine.Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.
5. The adjustment knob is
located on the right side of
the headlight pod. Adjust
the beam to the desired
position by turning the
knob either clockwise or
counter-clockwise.
2" (5 cm)
Lamp Center Height
25 ft. (7.6 m)
Adjustment
Screw
117
MAINTENANCE
Lights
Low Beam Adjustment
The low beam can be adjusted
slightly upward or downward.
1. Loosen the phillips screw
located at the rear of the
headlamp.
2. Tilt the headlamp upward
or downward.
3. Tighten the screw.
Phillips Screw
118
MAINTENANCE
Lights
Headlight Housing Replacement
1. Remove the five (5)
headlight pod screws.
2. Lift the pod cover and
disconnect the
speedometer harnesses
from the speedometer.
3. Unplug the headlamp
from the wiring harness.
4. Use a small screwdriver
to remove the o-rings
from the headlight
mounting tabs.
5. Pull the headlight housing up to release it from the locking tabs.
6. Carefully pull the assembly up and out of the pod.
7. Reverse the steps to install the new housing and reassemble the pod.
119
MAINTENANCE
Lights
Lower Headlamp Replacement
1. Turn the back of the headlight
harness counter-clockwise and
pull the harness assembly away
from the headlight assembly.
2. Remove the headlamp and install
the new headlamp.
3. Reinstall the harness assembly
into the headlight assembly.
4. Turn the headlight harness
clockwise to secure the
headlamp.
Taillight/Brakelight Lamp Replacement
1. Remove the harness connector
from the back of the light
assembly.
2. Turn the lamp counter-clockwise
to remove it.
3. Install the new lamp.
4. Reinstall the harness connector.
5. Test the light for proper operation.
Harness
Lamp
Connector
120
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 144 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
plug for correct color. See page 121.
CAUTION! 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 counter-clockwise 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)
121
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.
122
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 ATV to a dealer
before starting it, follow the steps outlined below.
1. Move the ATV 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. Reinstall the
drain plug. 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.
NOTICE: Serious damage can occur after immersion if fluids are not changed
promptly. See your dealer as recommended
.
7. Take the ATV 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 126 for drying out the PVT.
Drain Plug (850)
123
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. Repeat steps 4 to 6 until no more particles are expelled.
9. Stop the engine. Allow the arrester to cool.
10. Reinstall the arrester plug and remove the exhaust outlet cover or
plug.
WARNING
Clean-Out Plug
124
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.
WARNING
125
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.
On POLARIS ATVs, 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.).
126
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 5 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the
transmission to low 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
127
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.
Your ATV is equipped with a sealed battery, which requires little
maintenance. POLARIS does not recommend using a conventional
battery in this vehicle. The orientation of the battery could result in
electrolyte leakage, which would shorten the life of the battery
considerably.
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.
Battery Removal
1. Access the battery under the front box. See page 36.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Disconnect the battery hold-down strap.
5. Lift the battery out of the ATV.
WARNING
128
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 129
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. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
8. Close and secure the front box and cover.
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 143 for the
part numbers of POLARIS products.
129
MAINTENANCE
Battery
Battery Charging
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.
WARNING! 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.
130
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
131
MAINTENANCE
Camber and Caster
The camber and caster are non-
adjustable.
Rear Spring
The rear shock absorber spring is
adjusted by rotating the adjuster either
clockwise or counter-clockwise to
increase or decrease spring tension.
Accessory springs are available through
your POLARIS dealer.
Handlebars
The handlebars can be adjusted for rider preference.
WARNING! 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.
Adjuster
Handlebar
Bolts
132
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 four 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 lock nut.
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
133
MAINTENANCE
Throttle Cable Freeplay
4. Place the transmission in PARK. Lock the parking brake.
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.
134
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.
135
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 decals. 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
136
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 clean the vehicle as recommended. See
page 134.
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 94.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
113.
2. Clean the air box.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 88.
• 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/fill)
137
MAINTENANCE
Cleaning and Storage
Storage Tips
Fog the Engine
1. After stabilizing the fuel, remove the spark plug and add 2-3
tablespoons of engine oil. To access the plug hole, use a section of
clear 1/4" hose and a small plastic squeeze bottle filled with the pre-
measured amount of oil.
2. Reinstall the spark plug. Torque to specification.
3. Apply dielectric grease to the inside of each spark plug cap and
reinstall the caps onto the plugs.
4. 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.
5. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and injectors should be completely drained of gasoline.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 88.
Battery Storage
See pages 128-129 for storage and charging procedures. Store the
battery in a cool, dry place.
Storage Area/Covers
Set the tire pressure and safely support the ATV 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.
138
MAINTENANCE
Cleaning and Storage
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 ATV.
Always install accessories that are approved for ATV use. Please see
your POLARIS dealer.
Transporting the ATV
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap and seats.
5. Always tie the frame of the ATV 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.
6. Remove the key to prevent loss during transporting.
139
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
66).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 126.
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 126. 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 53.
140
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
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 plug(s) 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
plug(s)
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
Leaking exhaust components See your dealer
141
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 plug(s) 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
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
142
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 plug(s) 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 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. NOTICE: High
pressure washers can deform the radiator
fins and reduce cooling efficiency.
143
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)
2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919 PS-4 Extreme Duty Synthetic 10W-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 Plus Fluid (qt./.95 l)
2877923 Demand Drive Plus Fluid (gal./3.8 l)
2870465 Pump for Gallon (3.8 l) Jug
Coolant
2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l)
2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
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
144
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN 550 Touring
Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, passenger,
cargo, accessories)
Dry Weight 765 lbs. (347 kg)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Rack Capacity 240 lbs. (109 kg)
Hitch Tongue Weight 150 lbs. (68 kg) (Rear rack capacity and tongue
weight not to exceed 240 lbs./109 kg)
Hitch Towing Rating 1500 lbs. (680 kg) on level ground
Unbraked Trailer Towing
Capacity*
1995 lbs. (905 kg)
Overall Length 86.5 in. (219.7 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 58.25 in. (148 cm)
Wheelbase 57 in. (145 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 96 in. (244 cm) unloaded
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Transmission Fluid Capacity 37 oz. (1100 ml)
Rear Gearcase Fluid Capacity 7.1 oz. (210 ml)
Fuel System Visteon Electronic Fuel Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Engine ES550PLE011
Displacement 549 cc
Bore x Stroke 96.6 x 75 mm
Alternator Output 490w @ 1350 RPM/Peak 630w
Compression Ratio 9.6:1
Starting System Electric
Ignition System Visteon EFI (ECU Controlled)
Ignition Timing 13° +/- 3° BTDC @ 1650 RPM
Idle RPM 1425 +/- 50
Throttle Body/Size Mikuni/42 mm
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
145
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN 550 Touring
Lubrication System Pressurized Wet Sump
Transmission Type Automatic PVT (POLARIS Variable Transmission)
In-Line H-L-N-R-P
Front Suspension Dual a-arm, 9" (22.9 cm) travel
Rear Suspension Dual a-arm with Rolled IRS, 10" (25.4 cm) travel
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
Tire Type/Pressure, Front Maxxis AT 26 x 8 - 14 / 7 psi (48.3 kPa)
Tire Type/Pressure, Rear Maxxis AT 26 x 10 - 14 / 7 psi (48.3 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc, All-Wheel
Brake, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillight 12v/7 watts
Brake Light 12v/27 watts
Instrumentation Digital/Analog
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
146
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN 850 Touring
Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, passenger,
cargo, accessories)
Dry Weight 798 lbs. (362 kg)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Rack Capacity 240 lbs. (109 kg)
Hitch Tongue Weight 150 lbs. (55 kg) (Rear rack capacity and tongue
weight not to exceed 240 lbs./55 kg)
Hitch Towing Rating 1500 lbs. (680 kg) on level ground
Unbraked Trailer Towing
Capacity*
1995 lbs. (905 kg)
Overall Length 86.5 in. (219.7 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 58.25 in. (148 cm)
Wheelbase 57 in. (145 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 96 in. (244 cm) unloaded
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Transmission Fluid Capacity 37 oz. (1100 ml)
Rear Gearcase Fluid Capacity 7.1 oz. (210 ml)
Fuel System Bosch Multi-Port Sequential Electronic Fuel
Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Engine EH085OLE013
Displacement 850 cc
Bore x Stroke 87 x 71.5 mm
Alternator Output 475w @ 1200 RPM/Peak 630w
Compression Ratio 11.0:1
Starting System Electric
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 6° +/- 5° BTDC @ 1200 RPM
Idle RPM 1200 +/- 50
Throttle Body/Size Mikuni Dual Bore/42 mm
Spark Plug / Gap REA6MCX / .035 in. (0.9 mm)
147
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN 850 Touring
Lubrication System Pressurized Wet Sump
Transmission Type Automatic PVT (POLARIS Variable Transmission)
In-Line H-L-N-R-P
Front Suspension Dual a-arm, 9" (22.9 cm) travel
Rear Suspension Dual a-arm with Rolled IRS, 10" (25.4 cm) travel
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
Tire Type/Pressure, Front Maxxis AT 26 x 8 - 14 / 7 psi (48.3 kPa)
Tire Type/Pressure, Rear Maxxis AT 26 x 10 - 14 / 7 psi (48.3 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc, All-Wheel
Brake, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillight 12v/7 watts
Brake Light 12v/27 watts
Instrumentation Digital/Analog
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
148
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.
149
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.
• 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
150
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
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.
151
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.
152
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.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
153
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first
purchased, this emissions-certified vehicle is designed, built and equipped so it
conforms with applicable U.S. Environmental Protection Agency emission regulations.
POLARIS warrants that the vehicle is free from defects in materials and workmanship
that would cause it to fail to meet these regulations.
The warranty period for off-road vehicles 100cc or greater emissions-certified vehicles
starts on the date of purchase by original retail purchaser and continues for a period of
500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30
calendar months from the date of purchase, whichever comes first. The warranty period
for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by
original retail purchaser and continues for a period of 250 hours of engine operation,
2500 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of
purchase, whichever comes first. This EPA emissions warranty period is extended for at
least as long as the standard factory warranty that Polaris provides on the vehicle as a
whole. The EPA emissions warranty period does not further extend if you purchase
additional warranty coverage in the form of a service contract or other paid warranty
extension, but emission-related parts may be covered subject to the terms of any such
paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the
vehicle’s regulated emissions, and it covers components of systems whose only purpose
is to control emissions. Repairing or replacing other components not covered by this
warranty is the responsibility of the vehicle owner. This emissions limited warranty does
not cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
The following parts are also considered emission-related components for exhaust
emissions:
• Air-induction system • Ignition system
• Fuel system • Exhaust gas recirculation systems
• Aftertreatment devices • Sensors
• Crankcase ventilation valves • Electronic control units
154
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The following parts are considered emission-related components for evaporative
emissions:
*As related to the evaporative emission control system.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of POLARIS, repair or replacement of any defective materials, components or
products. THE REMEDIES SET FORTH IN THIS LIMITED 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 CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL
PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply
if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover damage due to accidents, abuse or
improper handling, maintenance or use. This limited warranty also does not cover any
engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or
defects caused by fire, explosions or other similar causes beyond the control of
POLARIS.
• Fuel Tank • Vacuum Control Diaphragms*
• Fuel Cap • Control Cables*
• Fuel Line • Control Linkages*
• Fuel Line Fittings • Purge Valves
• Clamps* • Vapor Hoses
• Pressure Relief Valves* • Liquid/Vapor Separator
• Control Valves* • Carbon Canister
• Control Solenoids* • Canister Mounting Brackets
• Electronic Controls* • Carburetor Purge Port Connector
155
WARRANTY
U.S.A. EPA Emissions Limited Warranty
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. POLARIS may deny warranty claims for failures that have been caused
by the owner’s or operator’s improper maintenance or use, by accidents for which
POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission
control devices or systems on your vehicle. POLARIS recommends that you contact an
authorized POLARIS dealer to perform any service that may be necessary for your
vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a
potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering
with emission controls is prohibited by federal law.
California Residents
Certain POLARIS off-road vehicles are available in 49-state and 50-state versions. Only
the 50-state models are certified for sale in California. The 50-state models available for
sale in California are identified by the letter “C” in the model name (e.g.,
R13UH88A_C). The POLARIS 50-state models are designed and built with features
such as a reduced cargo box capacity. Any modifications to these features may be a
violation of the applicable California regulations and may void this limited emissions
warranty offered by the manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please
contact POLARIS Customer Assistance.
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
156
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
157
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
158
INDEX
0-9
4X4 Switch . . . . . . . . . . . . . . . . 26, 37
A
Accessories . . . . . . . . . . . . . . . . . . 138
Active Descent Control Fluid . . 99-100
Active Descent Control System. . . . 39
Air Filter . . . . . . . . . . . . . . . . . . . . 113
All Wheel Drive System . . . . . . . 37-38
Auxiliary Foot Brake. . . . . . . . . . . 105
B
Battery
Charging . . . . . . . . . . . . . . . . . . 129
Charging (Sealed Battery) . . . . 130
Extreme Use 30 AH . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . 128
Removal . . . . . . . . . . . . . . . . . . 127
Storage . . . . . . . . . . . . . . . . . . . 128
Belt Life. . . . . . . . . . . . . . . . . . . . . . 33
Brake Fluid, Auxiliary Foot Brake . 32
Brake Fluid, Main Brake System. . . 30
Brake Lever . . . . . . . . . . . . . . . . . . . 29
Brake, Foot . . . . . . . . . . . . . . . 32, 105
Brake, Hand Lever. . . . . . . . . . . . . 105
Brake, Parking . . . . . . . . . . . . . . . . . 31
Brakelight Lamp Replacement . . . 119
Brakes . . . . . . . . . . . . . . . . . . . . . . 105
Break-In Period . . . . . . . . . . . . . . 52-53
C
Camber Adjustment. . . . . . . . . . . . 131
Cargo . . . . . . . . . . . . . . . . . . . . . . 73-74
Cargo Loading . . . . . . . . . . . . . . . . . 72
Caster Adjustment . . . . . . . . . . . . . 131
Check Engine Indicator . . . . . . . . . . 47
Cleaning and Storage. . . . . . . . 134-138
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching (550) . . . . . . . . . . . . . . . 145
Clutching (850) . . . . . . . . . . . . . . . 147
Cold Weather Operation . . . . . . . . . 57
Consumer Product Safety . . . . . . . . . 7
Coolant Bottle . . . . . . . . . . . . . . . . 103
Coolant, Radiator. . . . . . . . . . . . . . 104
Cooling System . . . . . . . . . . . . 102-104
Crankcase Emission Control System 87
D
Demand Drive Fluid . . . . . . . . . . . . . 98
Diagnostic Codes, 550 XP EPS. . 48-49
Diagnostic Codes, 850 XP EPS. . 50-51
Disengaging Active Descent Control 39
Display Units, Standard/Metric. . . . . 44
Drive Belt Wear/Burn . . . . . . . . . . . 139
Drivetrain Break-In . . . . . . . . . . . . . . 53
Driving Downhill. . . . . . . . . . . . . . . . 65
Driving in Reverse. . . . . . . . . . . . . . . 70
Driving on a Sidehill . . . . . . . . . . . . . 64
Driving on Slippery Surfaces . . . . . . 62
Driving Over Obstacles . . . . . . . . . . . 69
Driving Procedures . . . . . . . . . . . . . . 58
Driving Through Water . . . . . . . . . . . 68
Driving Uphill . . . . . . . . . . . . . . . . . . 63
Driving With a Passenger . . . . . . 60-61
E
Electromagnetic Interference. . . . . . . 87
Electronic Power Steering . . . . . . . . . 34
Emissions Limited Warranty. . 153-155
Engaging 4X4 . . . . . . . . . . . . . . . . . . 38
Engaging Active Descent Control. . . 39
Engine Break-In. . . . . . . . . . . . . . . . . 53
Engine Fogging . . . . . . . . . . . . . . . . 137
Engine Oil . . . . . . . . . . . . . . . . . . 93-95
Engine Stop Switch . . . . . . . . . . . . . . 27
EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E
Equipment Modifications . . . . . . . . . . 9
Error Codes, Engine . . . . . . . . . . . . . 47
Etiquette, Trail Riding. . . . . . . . . . . . 56
Exhaust Emission Control System . . 87
Extreme Use 30 AH Battery . . . . . . . 35
Eye Protection . . . . . . . . . . . . . . . . . . . 9
F
Fluid
Active Descent Control. . . . . . . . . 99
ADC . . . . . . . . . . . . . . . . . . . 99-100
Brake. . . . . . . . . . . . . . . . . . . . . . . 30
Demand Drive. . . . . . . . . . . . . . . . 98
Engine Oil. . . . . . . . . . . . . . . . 93-95
Front Gearcase . . . . . . . . . . . . . . . 98
Rear Gearcase Oil. . . . . . . . . . . . 101
Transmission. . . . . . . . . . . . . . 96-97
159
INDEX
F
Fluid Change
ADC . . . . . . . . . . . . . . . . . . . . . . 100
Demand Drive . . . . . . . . . . . . . . . 98
Engine Oil . . . . . . . . . . . . . . . 94-95
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission . . . . . . . . . . . . . . . . 97
Fluid Level
ADC . . . . . . . . . . . . . . . . . . . . . . . 99
Brake . . . . . . . . . . . . . . . . . . . . . . 30
Brake (Auxiliary). . . . . . . . . . . . . 32
Brake Fluid. . . . . . . . . . . . . . . . . . 30
Coolant (Bottle) . . . . . . . . . . . . . 103
Coolant (Radiator) . . . . . . . . . . . 104
Demand Drive . . . . . . . . . . . . . . . 98
Engine Oil . . . . . . . . . . . . . . . . . . 93
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission . . . . . . . . . . . . . . . . 96
Foot Brake, Auxiliary . . . . . . . . . . . . 32
Footwell Removal. . . . . . . . . . . . . . 109
Front Gearcase Fluid. . . . . . . . . . . . . 98
Fuel Recommendations. . . . . . . . . . . 35
Fuel Safety . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 35
Fuse Replacement. . . . . . . . . . . . . . 114
G
Gasoline Handling . . . . . . . . . . . . . . 11
Gauge, Code Definitions. . . . . . . 48-51
Gauge, Digital/Analog . . . . . . . . 40-47
Gear Selector. . . . . . . . . . . . . . . . . . . 33
Gearcase Oil, Front. . . . . . . . . . . . . . 98
Gearcase Oil, Rear . . . . . . . . . . . . . 101
H
Hand Brake . . . . . . . . . . . . . . . . . . . 105
Handlebar Adjustment . . . . . . . . . . 131
Hauling Cargo. . . . . . . . . . . . . . . 72-74
Headlight Housing Replacement . . 118
Headlight Lamp Replacement . . . . 115
Headlight Switch. . . . . . . . . . . . . . . . 27
Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8
High Beam Adjustment . . . . . . . . . 116
High Range Use . . . . . . . . . . . . . . . 126
Hub Tightening. . . . . . . . . . . . . . . . 111
I
Idle RPM Adjustment. . . . . . . . . . . 132
Immersion Maintenance . . . . . . . . . 122
Indicator Lamps . . . . . . . . . . . . . . . . 41
Instrument Cluster . . . . . . . . . . . 40-51
K
Key Switch . . . . . . . . . . . . . . . . . . . . 27
K-Turn . . . . . . . . . . . . . . . . . . . . 66-67
L
Lights
Headlight Housing Replacement 118
Headlight Lamp . . . . . . . . . . . . . 115
High Beam Adjustment . . . . . . . 116
Low Beam Adjustment . . . . . . . 117
Lower Headlamp Replacement . 119
Taillight/Brakelight/Worklight . 119
Low Beam Adjustment. . . . . . . . . . 117
Low Range Use. . . . . . . . . . . . . . . . 126
Lower Headlamp Replacement. . . . 119
Lubrication Guide. . . . . . . . . . . . . . . 92
M
Maintenance Chart . . . . . . . . . . . 88-91
Master Cylinder . . . . . . . . . . . . . . . . 30
Metric Display . . . . . . . . . . . . . . . . . 44
Mode Switch. . . . . . . . . . . . . . . . . . . 26
N
Noise Emission Control System . . . . 87
O
Oil
Engine . . . . . . . . . . . . . . . . . . 93-95
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission . . . . . . . . . . . . . 96-97
Oil and Filter Change . . . . . . . . . 94-95
Oil Change
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission . . . . . . . . . . . . . . . . 97
Oil Level
Engine . . . . . . . . . . . . . . . . . . . . . 93
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission . . . . . . . . . . . . . . . . 96
Oil Recommendations . . . . . . . . . . . 93
Operation on Public Lands . . . . . . . . 87
Override Switch . . . . . . . . . . . . . . . . 26
160
INDEX
P
Parking Brake . . . . . . . . . . . . . . . . . 31
Parking on an Incline. . . . . . . . . . . . 71
Passenger Seat . . . . . . . . . . . . . . . . . 34
Periodic Maintenance Chart . . . . 88-91
Polaris Product List . . . . . . . . . . . . 143
Polishing the Vehicle. . . . . . . . . . . 135
Power Steering. . . . . . . . . . . . . . . . . 34
Power Steering Unit (Cleaning). . . 102
Pre-Ride Checklist. . . . . . . . . . . . . . 54
PVT Break-In. . . . . . . . . . . . . . . . . . 53
PVT Drying . . . . . . . . . . . . . . . . . . 126
PVT System. . . . . . . . . . . . . . . 124-126
R
Rear Gearcase Oil . . . . . . . . . . . . . 101
Reverse Operation . . . . . . . . . . . . . . 70
Reverse Override Switch . . . . . . . . . 26
Rider Information Center. . . . . . . 42-47
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9
S
Safe Operation Practices . . . . . . . . . 55
Safety Labels . . . . . . . . . . . . . . . . 22-25
Safety Training . . . . . . . . . . . . . . . . . 7
Safety Warnings. . . . . . . . . . . . . . 10-21
Safety, Winch Maintenance. . . . . . . 86
Seat Backrest Adjustments . . . . . . 107
Seat Removal, Operator. . . . . . . . . 108
Seat Removal, Passenger. . . . . . . . 107
Seat Suspension, Passenger . . . . . . 108
Seats. . . . . . . . . . . . . . . . . . . . . 107-108
Severe Use . . . . . . . . . . . . . . . . . . . . 88
Shock Loading the Winch . . . . . . 84-85
Side Panel Removal. . . . . . . . . . . . 109
Sidehilling . . . . . . . . . . . . . . . . . . . . 64
Spark Arrester . . . . . . . . . . . . . . . . 123
Spark Plugs . . . . . . . . . . . . . . . 120-121
Specifications. . . . . . . . . . . . . . 144-147
Speedometer . . . . . . . . . . . . . . . . . . 40
Spring Adjustment, Rear Shock . . 131
Starting the Engine . . . . . . . . . . . . . 57
Steering Assembly. . . . . . . . . . . . . 102
Storage. . . . . . . . . . . . . . . . . . . 134-138
Storage Box, Front. . . . . . . . . . . . . . 36
Storage Tips. . . . . . . . . . . . . . . 136-137
Suspension, Passenger Seat . . . . . . 108
S
Switches
4X4 Switch . . . . . . . . . . . . . . . 26, 37
Engine Stop Switch. . . . . . . . . . . . 27
Headlight Switch . . . . . . . . . . . . . 27
Main Key Switch . . . . . . . . . . . . . 27
Mode/Reverse Override Switch . . 26
T
Taillight Lamp Replacement . . . . . . 119
Throttle Body Adjustment. . . . . . . . 132
Throttle Cable Freeplay. . . . . . 132-133
Throttle Lever . . . . . . . . . . . . . . . . . . 28
Tire Tread Depth . . . . . . . . . . . . . . . 110
Tires
Wheel Installation. . . . . . . . . . . . 112
Wheel Nut Torque . . . . . . . . . . . 112
Wheel Removal . . . . . . . . . . . . . 111
Toe Alignment. . . . . . . . . . . . . . . . . 106
Towing Capacities . . . . . . . . . . . . . . . 74
Towing Loads . . . . . . . . . . . . . . . . . . 74
Trail Etiquette . . . . . . . . . . . . . . . . . . 56
Training . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission . . . . . . . . . . . . . . . . . . . 33
Transmission Oil . . . . . . . . . . . . . 96-97
Transporting the ATV . . . . . . . . . . . 138
Tread Lightly. . . . . . . . . . . . . . . . . . . 56
Turning Around on a Hill . . . . . . 66-67
Turning the Vehicle. . . . . . . . . . . . . . 59
V
Vehicle Identification Numbers. . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . 122
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
W
Washing the Vehicle . . . . . . . . 134-135
Wheel Installation . . . . . . . . . . . . . . 112
Wheel Nut Torque Specifications . . 112
Wheel Removal . . . . . . . . . . . . . . . . 111
Winch Cable Care . . . . . . . . . . . . . . . 83
Winch Maintenance/Service Safety. . 86
Winch Operation . . . . . . . . . . . . . 78-82
Winch Safety Precautions . . . . . . 75-77
Winch Shock Loading . . . . . . . . . 84-85
Improper vehicle use can result in SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
FOR DRIVER
AND PASSENGER
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
MORE THAN
1 PASSENGER
NEVER USE
WITH DRUGS
OR ALCOHOL
without proper ATV training or instruction
at speeds too fast for your skills or the conditions
on public roads - a collision can occur with another vehicle
with a passenger unless passenger seat is securely in place
THE OPERATOR MUST ALWAYS:
use proper riding techniques to avoid vehicle overturns on hills
and rough terrain and in turns
avoid paved surfaces - pavement may seriously affect handling
and control
reduce speed and use extra caution at all times when carrying a
passenger - dismount passenger when conditions require
make sure passenger reads and understands this label and
passenger safety label
NEVER operate:
PMS 419
*
WARNING
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polaris.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9924609 Rev 02
Printed in USA
*9924609
