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 550 X2
Sportsman 850 X2
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.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone 1-888-704-5290
Part No. 9922731 Rev 01
Printed in USA
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
*9922731 *
WARNING
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit-
ing line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
®
utility vehicles
• Victory Motorcycles
®
• Low emission vehicles (LEVs)
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 pro-
duced.
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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
2
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS
Industries Inc.
Copyright 2010 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 discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. 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.
2011 Sportsman 550/850 X2 Owner’s Manual
P/N 9922731
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emission Control Systems . . . . . . . . . . . . . . . 80
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 133
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 137
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 138
Declaration of Conformity. . . . . . . . . . . . . . . 142
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 151
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
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.
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.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key
Number
550 850
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 estab-
lished safety standards. A passenger (on approved models) should wear
a helmet that includes a rigid chin guard.
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. When-
ever 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) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics 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
Carrying a Passenger in the
Cargo Box
A passenger riding in the cargo box could fall
from the vehicle unexpectedly or may contact
moving components, both of which can result in
severe injury or death. Never allow a passenger
to ride in the cargo box.
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 67.
Never operate in TURF mode while operating on
a hill or other irregular terrain. Always move the
4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 40.
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 69.
Always descend a hill with the transmission in
forward gear. Do not descend a hill with the
transmission in neutral.
Never operate in TURF mode while operating on
a hill or other irregular terrain. Always move the
4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 40.
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 68.
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 70.
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.
• Never operate in TURF mode while
operating on a hill or other irregular terrain.
Always move the 4X4 switch to ADC 4X4
before ascending or descending a hill. See
page 40.
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 70.
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 70.
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 74.
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 73.
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
72):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving. The friction will help dry
out the pads.
Improper Cargo Loading
Overloading the ATV or carrying/towing
cargo improperly may cause changes in
handling, which could cause loss of control
or an accident.
• Never exceed the stated load capacity for
this ATV.
• Cargo should be properly distributed and
securely attached.
• Reduce speed when carrying cargo or
pulling a trailer. Allow a greater distance
for braking.
• Always follow the instructions in the owner's manual for carrying cargo or
pulling a trailer. See pages 76-78.
• Always follow the instructions in the owner's manual for operating with a
passenger. See page 64.
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, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
General Warning
WARNING
Improper use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR
DRIVER AND PASSENGER
NEVER USE ON PUBLIC ROADS
NEVER CARRY MORE THAN 1 PASSENGER
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper ATV training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger unless passenger seat is securely in place
THE OPERATOR MUST ALWAYS:
• use proper riding techniques to avoid overturns on hills and rough terrain and
in turns
• avoid paved surfaces - pavement may seriously affect handling and control
• reduce speed and use extra caution at all times when carrying a passenger -
dismount passenger when conditions require
• make sure passenger reads and understands this label and passenger safety
label
LOCATE AND READ OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175844
23
SAFETY
Safety Labels and Locations
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 vehicle if you are under age 16.
7175375
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
Passenger Safety/Discretionary
Warning
General Warning
Reverse Override Warning
4X4 Caution
Age 16 Warning
24
SAFETY
Safety Labels and Locations
Passenger Safety//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
25
SAFETY
Safety Labels and Locations
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading
can cause loss of control.
Loss of control can result in severe injury
or death.
• Cold tire pressure:
Front: 7.0 psi (48.3 kPa)
Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 735 lbs.
(333 kg)
• Lug nut torque values:
Steel rims 45 ft-lbs. (61 Nm)
Aluminum rims 75 ft-lbs. (102 Nm)
7175846
H
Tire Pressure/Load
Warning
26
SAFETY
Safety Labels and Locations
Rack Warning, Front
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 combined Front Rack and Container Load: 120 lbs. (54 kg)
7175847
Clutch Cover Warning
WARNING
NO STEP
• 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.
7172563
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
H
Clutch Cover
Warning
(under seat)
H
H
Rack
Warning
Box
Warning
Hitch
Capacity
Label
27
SAFETY
Safety Labels and Locations
Box Warning
WARNING
Remove flammable material
containers from box before filling.
WARNING
Passengers can be thrown off. This
can cause serious injury or death.
Never carry passengers in cargo box.
Maximum Box Load - 400 lbs. (181 kg)
7173890
28
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, depress the override switch.
WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.
The reverse override button also acts as a MODE button when held
down for approximately one half second. See the instrument cluster
information beginning on page 44.
Tip: The override button will not function as a MODE button if the transmission
is in reverse.
Engine Stop Switch
Move the stop switch either left or right to
the OFF position to stop the engine quickly.
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 electri-
cal power to the vehicle, including lights.
2x4
Trip 1
km
mi
RPM
FE
88
:
88
Mode/Reverse
Override
Button
Main Key
Switch
Engine
Stop Switch
Headlight
Switch
4X4 Switch
OFF OFFRUN
29
FEATURES AND CONTROLS
Switches
Main Key Switch
Use the main key switch to start the engine. See page 61.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4, 4X4, 2X4 or TURF mode. See
pages 38-39. The vehicle automatically engages 4X4 when operating in
reverse if the switch is set to either 4X4 position.
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
and the engine stop switch must be in the RUN position to operate the
headlights.
30
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 properly installed to the throttle control.
Engine speed and vehicle
movement are controlled by
pressing the throttle lever.
The throttle lever is spring
loaded. Engine speed
returns to idle when the
lever is released.
This ATV is equipped with
POLARIS Electronic Throt-
tle Control (ETC), which is
designed to reduce the risk of a frozen or stuck throttle. If the throttle
cable should stick in an open position when the operator releases the
throttle lever, the engine will stop, and power to the rear wheels will
cease.
WARNING
31
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
32
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 cylin-
der. 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 add DOT 4 brake fluid only. Do not overfill.
WARNING
Master Cylinder
Indicator
Window
33
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.
34
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 aux-
iliary foot brake. Since this is a
rear brake only, it will not be as
effective as the all-wheel single
lever system.
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.
WARNING
Auxiliary
Foot Brake
35
FEATURES AND CONTROLS
Auxiliary Foot Brake
Brake Fluid Level
Check the brake fluid level fre-
quently for the auxiliary brake
system. The reservoir is located
under the front storage box. See
page 43.
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.
Brake Fluid
Reservoir
36
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is
located on the right side of the vehi-
cle.
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
37
FEATURES AND CONTROLS
Fuel Tank Cap
Remove the fuel tank cap to add fuel
to the fuel tank. Use either leaded or
unleaded gasoline with a minimum
pump octane number of 87=(R+ M/2)
octane. Do not use fuel with ethanol
content greater than 10 percent, such
as E-85 fuel.
Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level sur-
face.
The fuel tank is designed to allow for
the normal expansion of fuel. Do not
overfill. Do not fill the tank neck.
Fuel Tank
Cap
38
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 40.
4X4 Mode
When the switch is on 4X4, the
ATV is in 4X4, and the 4X4 indica-
tor light in the instrument cluster
will be on.
When in 4X4, the demand drive
unit will automatically engage any
time the rear wheels lose traction.
When the rear wheels regain trac-
tion, the demand drive unit will
automatically disengage. There is
no limit to the length of time the
vehicle may remain in 4X4.
Tip: The override switch allows activation of 4X4 in reverse if the 4X4 switch is
on. See page 28.
4X4 Switch
ADC 4X4
39
FEATURES AND CONTROLS
All Wheel Drive System
2X4 Mode
When the switch is on 2X4, the ATV is in two-wheel drive at all times.
TURF Mode
When operating in TURF mode, the inside rear wheel will rotate inde-
pendently from the outside wheel during turns. Operate in TURF mode
only as needed to protect smooth, level surfaces from tire damage. DO
NOT operate in TURF mode when climbing or descending hills, when
sidehilling, or when operating on uneven, loose, or slippery terrain such
as sand, gravel, ice, snow, obstacles, and water crossings. Always oper-
ate in ADC 4X4 or 4X4 on these types of terrain.
WARNING! Operating in TURF mode when on sloped, uneven, or loose terrain
could cause loss of control and result in serious injury or death. One rear wheel
may slip and lose traction or may lift up and grab when it touches the ground
again.
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.
40
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 follow-
ing 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 fol-
lowing 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
41
FEATURES AND CONTROLS
Passenger Seat
Always make sure the passenger seat lock-out is functioning properly
before operating with a passenger.
Do not operate the vehicle with the seat in the 2-up position when oper-
ating without a passenger. Always return the seat to the 1-up position for
single-rider operation.
Never carry cargo in the rear box when operating the ATV in the 2-up
mode with a passenger.
Seat Conversion
1. Make sure the cargo box dump latch is securely latched. See page
79.
2. Slide the seat latch levers inward to release the locks.
3. Tilt the backrest slightly forward.
4. Pull the passenger backrest upward from the bed of the cargo box.
Passenger
Backrest
Release Locks
Operator Backrest
Latches
42
FEATURES AND CONTROLS
Passenger Seat
Seat Conversion
5. Lift the adjustment latch at the top of the passenger backrest. Raise
the backrest to the desired position. Release the latch, making sure
it locks into one of the three operating positions.
Tip: The backrest must be moved out of the lowest position before it can be
secured in the upright position. The lowest position is for seat storage only.
Do not leave the backrest in the lowest position. Always adjust the backrest
to one of the three operating positions.
6. Lower the operator
backrest to create the
passenger seat. Two
retaining pins under the
seat should fit into the two
grommets on the seat base.
7. Test the passenger seat
lock-out by attempting to
release the cargo box dump
latch. See page 79. If the
dump latch releases, the
seat is not secure. Repeat
the set-up procedure. If the
lock-out is not working
properly, do not allow a
passenger to ride the vehicle. See your POLARIS dealer for ser-
vice.
8. To return the vehicle to single-rider
operation, reverse all steps. Always
lower the passenger backrest to the
lowest position before folding it
down into the cargo box. Slide the
seat latch levers outward to secure the
locks.
Passenger
Backrest
Adjustment
Latch
Locked
43
FEATURES AND CONTROLS
Front Box/Compartment
Release the front box anchor latches
and remove the box assembly to gain
access to the front compartment. To
reinstall the box, hold the box as
shown in the rack illustration. Posi-
tion the front edge in the tabs, then
push the box downward and secure
the latches.
Access the following components in
the front compartment:
• Radiator cap
• Brake fluid reservoir
• ADC fluid reservoir
• Battery
• Coolant recovery bottle cap
• Electrical/fuse/relay components
Latches
ADC Fluid
Reservoir
Brake Fluid
Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
Battery
44
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
45
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.
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.
46
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The rider information center is located in the instrument cluster. All seg-
ments 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 speedome-
ter. 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 49.
Trip 1
km
mi
RPM
FE
88
:
88
1
2
6
5
7
3
4
8
47
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 40.
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 49 for resetting instruc-
tions.
6. Service Reminder Display - A flashing wrench symbol alerts the
operator that the preset service interval has been reached. The vehi-
cle should be brought to your dealer for scheduled maintenance. See
page 49 for resetting instructions.
7. 4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either ADC 4X4 or 4X4).
8. Turf Mode Indicator - This icon displays when Turf Mode is
engaged.
48
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 vehi-
cle 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 automati-
cally 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
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock
49
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 dis-
charged.
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.
50
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 pro-
grammed 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 deter-
mination of persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
51
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 restart-
ing the engine.
If the CHECK ENGINE
light illuminates, retrieve
the error codes from the dis-
play. 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 52-55 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)
52
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.
53
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
*Assumes unipolar configuration of stepper motor
Sportsman 550 X2 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
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
54
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Sportsman 850 X2 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
55
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Sportsman 850 X2 Diagnostic Codes
Component Condition SPN FM
I
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
56
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 ten hours
of operation, or the time it takes to use the first two full tanks of gaso-
line. No single action on your part is as important as following the pro-
cedures 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
57
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 37. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 86. Add oil if
necessary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 58.
6. Pull only light loads.
7. Change both the oil and the filter at 20 hours, one month or 500
miles (800 km), whichever comes first.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur-
ing the break-in period.
58
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 lock-out Ensure proper operation 41
Brake system/lever travel Ensure proper operation 31
101
Brake fluid Ensure proper level 32
Auxiliary brake Ensure proper operation 34
Front suspension Inspect, lubricate if necessary 85
Rear suspension Inspect, lubricate if necessary 85
Steering Ensure free operation -
Tires Inspect condition and pressure 104
Wheels/fasteners Inspect, ensure fastener tightness 104
105
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 37
86
Coolant level Ensure proper level 99
100
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 30
124
Indicator lights/switches Ensure operation 28
Engine stop switch Ensure proper operation 28
Air filter, pre-filter Inspect, clean 106
Headlamp Check operation, apply POLARIS
dielectric grease when lamp is
replaced
29
108
Brake light/taillight Check operation, apply POLARIS
dielectric grease when lamp is
replaced
111
Riding gear Wear approved helmet, goggles, and
protective clothing
8
ADC Fluid Ensure proper level 94
59
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 oper-
ate this vehicle.
3. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
4. Before operating, learn how to use the auxiliary brake for emer-
gency situations (if service brakes become inoperable).
5. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
6. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights fre-
quently 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 com-
bustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
60
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the opera-
tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con-
tacting 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 vehi-
cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.
61
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-venti-
lated 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 accu-
mulation increases as outside temperature decreases.
62
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 8.
2. Perform the pre-ride inspection. See page 58.
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.
63
OPERATION
Turning the Vehicle
Both rear wheels drive
equally at all times (except
when operating in TURF
mode). 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 pas-
senger 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.
64
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 comfort-
ably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear, includ-
ing an approved helmet with a rigid chin guard. See page 8.
4. Perform the pre-ride inspection. See page 58.
5. Convert the seat for 2-up riding. See page 41. Always make sure the
passenger seat lock-out is functioning properly before carrying 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. Never 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.
11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected or aggressive maneuvers that could cause a pas-
senger to fall from the vehicle.
65
OPERATION
Driving with a Passenger
12. Do not cross a hillside
with a passenger on
board. See page 68.
13. A passenger should
always be seated in
the passenger seat
with both feet on the
footrests and both
hands on the passen-
ger 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.
66
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
67
OPERATION
Driving Uphill
Braking and handling are greatly affected when operating in hilly ter-
rain. Improper procedure could cause loss of control or overturn. When-
ever traveling uphill, follow these precautions:
1. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 40.
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
68
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!
69
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 40.
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
70
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)
71
OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 40.
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 vehi-
cle, or on the left if the vehicle is pointing straight uphill. A passen-
ger should not remount until the vehicle returns to firm, level
ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's point-
ing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
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.
72
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 81. 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 114,
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
73
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 haz-
ards 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 obsta-
cle that could cause a fall from the vehicle or vehicle tipover.
74
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.
75
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.
76
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:
Never carry cargo in the rear box 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.
REDUCE SPEED AND CARGO to maintain stable driving conditions when
operating over rough or hilly terrain.
WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as low
as possible. Carrying a high load raises the center of gravity and creates a less
stable operating condition. Reduce load weight when cargo is high. When
handling off-centered loads that cannot be centered, secure the load and
operate with extra caution.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift and
create unstable operating conditions, which could result in loss of control of the
vehicle. Always be sure that the cargo bed is lowered and latched before
moving the vehicle.
USE EXTREME CAUTION when operating with loads extending beyond the
rack or cargo bed. Stability and maneuverability may be adversely affected,
causing the machine to overturn.
BALANCE LOADS proportionally between the front rack and cargo bed, but do
not exceed the stated load capacity. Carrying a load on only the front rack or
cargo bed may cause an imbalanced condition and increases the possibility of
vehicle overturn.
USE EXTREME CAUTION when applying brakes with a loaded vehicle. Avoid
terrain or situations that may require backing downhill.
Always attach the tow load to the hitch point.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The
vehicle should never exceed 10 mph (16 kph) while towing a load on a level
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.
WARNING
77
OPERATION
Hauling Cargo
Never exceed the weight
capacities specified for your
ATV on warning labels and
in the specifications section
of this manual.
Cargo weight should be
mounted as low as possible.
When operating over rough
or hilly terrain, reduce speed
and cargo weight to main-
tain stable driving condi-
tions.
1. Always load the cargo
box with the load as far
forward as possible.
2. Do not obstruct the headlight beam with cargo.
3. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
4. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.
5. Slow down.
6. Make sure the cargo box dump latch is securely latched before load-
ing and operating. Unintentional dumping will result if weight is
placed in the rear of the box and the latch is not secured.
78
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 box
cargo weight by the amount of tongue weight.
• The combination of rear box cargo weight and tongue weight must
not exceed the rear box 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 the following maximum capacities when towing. 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)
79
OPERATION
Hauling Cargo
Dumping Cargo
1. Select a level site to dump the cargo box. Do not attempt to dump or
unload the vehicle while parked on an incline.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Dismount the vehicle.
5. Lower the tailgate.
WARNING! If cargo weight is placed toward the rear of the cargo box, the load
may dump unexpectedly and cause serious injury. When loading cargo, always
position the weight as far forward and as low as possible.
6. Pull the cargo box release strap
upward.
7. Lift the front of the cargo box
and dump the cargo.
8. Lower the cargo box and make
sure the release latch is
secured.
9. Secure the tailgate.
WARNING! Operating with the cargo
box in the raised position can cause
serious injury and damage to the
vehicle. The cargo box could close
unexpectedly and injure the driver. The
rear tires will also catch the rear of the
bed, damaging the vehicle and creating
hazardous driving conditions. Never
operate this vehicle with the cargo box
in the raised position.
Cargo Box
Release Strap
80
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrestor that was tested and quali-
fied to be in accordance with the USFS standard 5100-1c. Federal law
requires that this spark arrestor be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI com-
ponents are set at the factory for optimal performance and are not
adjustable.
The vehicle compliance labels can be found on the frame tubing of the
vehicle.
Electromagnetic Interference
This spark ignition system complies with Canadian standard ICES-002.
This vehicle complies with the EMC requirements of European direc-
tives 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 lim-
itations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.
81
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in safe, reli-
able condition. Inspect, clean, lubricate, adjust and replace parts as nec-
essary. 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
151.
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 crank-
case. 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.
82
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a n could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized POLARIS dealer perform these services.
Maintenance Chart Key
X Perform these operations more often for vehicles subjected to severe use.
E Emission-related service
(Failure to conduct this maintenance will not void the emissions warranty
but may affect emissions.)
n Have an authorized POLARIS dealer perform these services.
Perform all services at whichever maintenance interval is reached first.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering - Pre-Ride - Make adjustments as
needed. See Pre-Ride
Checklist on page 58.
Front suspension - Pre-Ride -
Rear suspension - Pre-Ride -
Tires - Pre-Ride -
Brake fluid level - Pre-Ride -
Brake lever travel - Pre-Ride -
Brake system - Pre-Ride -
Passenger seat
lock-out
-Pre-Ride -
Wheels/fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
Engine oil level - Pre-Ride -
X
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Coolant - Daily - Check level daily, change
coolant every 2 years
X ADC fluid - Daily - Check level daily, add as
needed
Headlight/taillight - Daily - Check operation; apply
dielectric grease if replacing
lamps
WARNING
83
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
X
E
Air filter,
main element
- Weekly - Inspect; replace as needed
X Engine oil change 20 H 1 Month 500 (800) Perform a break-in oil and
filter change (see page 88)
X
n
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
X Rear gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly
X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
X Demand drive fluid 25 H Monthly 250 (400) Inspect level
X 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 92.
X General
lubrication
50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Shift linkage 50 H 6 M 500 (800) Inspect, lubricate
n
Steering 50 H 6 M 500 (800) Lubricate
X Front suspension 50 H 6 M 500 (800) Lubricate
X Rear suspension 50 H 6 M 500 (800) Lubricate
nE Throttle Cable/
ETC Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 H 6 M 500 (800) Inspect duct for proper seal-
ing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
X Radiator 50 H 6 M 1000 (1600) Inspect; clean external
surfaces
X Cooling hoses 50 H 6 M 1000 (1600) Inspect for leaks
X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change
at one month
X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change
X Demand drive fluid
(normal use)
100 H 12 M 1000 (1600) Change fluid
X Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid
X Transmission oil 100 H 12 M 1000 (1600) Change fluid
84
MAINTENANCE
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
n Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
X Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
nE Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
n
Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
n
Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
n
Brake fluid 200 H 24 M 2000 (3200) Change every two years
X
n
ADC fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrestor 300 H 36 M 3000 (4800) Clean out
nE Valve clearance 1000 H - 10000
(16000)
Inspect; adjust
n
Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
85
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 81. 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
Inspection
Procedure
550 Engine Oil PS-4 PLUS
Performance
Synthetic 2W-50
2 qt.
(1.9 l)
--- 15-17 ft. lbs.
(20-23 Nm)
Page 86.
850 Engine Oil PS-4 PLUS
Performance
Synthetic 2W-50
2 qt.
(1.9 l)
--- 12 ft. lbs.
(16 Nm)
Page 86.
Transmission
Oil
AGL PLUS
Transmission
Fluid
32 oz.
(950 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 90.
Demand Drive
Fluid (Front
Gearcase)
Demand Drive
Plus Fluid
9.3 oz.
(275 ml)
8-10 ft. lbs.
(11-14 Nm)
11 ft. lbs.
(15 Nm)
Page 92.
Rear
Gearcase Oil
ATV Angle Drive
Fluid (or GL5 80-
90 weight gear
lube)
6.1 oz.
(180 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 96.
Brake Fluid DOT 4 Only --- --- --- Page 32.
ADC Fluid Demand Drive
Plus Fluid
--- --- --- Page 94.
Front Prop
Shaft Yoke
POLARIS
Premium U-Joint
Lube
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
Premium All-
Season Grease
Grease fittings after extreme use or if suspension
becomes squeaky.
Front Prop Shaft Yoke
Front
86
MAINTENANCE
Engine Oil
Oil Recommendations
POLARIS recommends the use of POLARIS PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table
on page 85 for fluid recommendations, capacities and plug torques.
Oil may need to be changed more frequently if POLARIS oil is not
used. Always use 2W-50 oil. Follow the manufacturer's recommenda-
tions for ambient temperature operation. See page 137 for the part num-
bers of POLARIS products.
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.
87
MAINTENANCE
Engine Oil
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
550
Full
Add
850
88
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 85 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 81. Always change the
oil filter whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three min-
utes.
3. Stop the engine.
4. Clean the area around the drain plug.
5. Place a drain pan under the crankcase.
6. Remove the drain plug. Allow the oil to drain completely.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque to specification.
550
Drain
Plug
to front
Filter Access
850
Drain
Plug
89
MAINTENANCE
Engine Oil
Oil and Filter Change
9. Place shop towels beneath the
oil filter. Using an oil filter
wrench (available from your
POLARIS dealer), turn the filter
counterclockwise to remove it.
10. Using a clean dry cloth, clean
the filter sealing surface on the
crankcase.
11. Lubricate the o-ring on the new
filter with a film of fresh engine
oil. Check to make sure the o-
ring is in good condition.
12. Install the new filter and rotate it
clockwise by hand until the fil-
ter gasket contacts the sealing
surface, then turn it an additional 1/2 turn.
13. Remove the dipstick. Add the proper amount of the recommended
oil. Do not overfill.
14. Reinstall the dipstick.
15. Place the transmission in PARK.
16. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
21. Dispose of used filter and oil properly.
Oil Filter
550 850
90
MAINTENANCE
Transmission Oil
POLARIS recommends the use of POLARIS AGL PLUS Transmission
Fluid for this transmission. See the table on page 85 for fluid recom-
mendations, capacities and plug torques. Always check and change the
transmission oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 81. See page 137 for the part numbers of
POLARIS products.
Maintain the oil level at the bottom of the fill plug hole. The fill plug is
located on the right side of the ATV behind the footwell. The drain plug
is located on the bottom left side of the gearcase.
Oil Check
1. Remove the footwell (see
page 103).
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
91
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.
92
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 85 for fluid recommendations, capacities and plug
torques. Always check and change the demand drive fluid at the inter-
vals outlined in the Periodic Maintenance Chart beginning on page 81.
NOTICE: Change the demand drive fluid every 25 hours if the ADC unit is
exposed to extreme use.
ADC Extreme Use Definition
• 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.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. See page 137 for the part numbers of
POLARIS products.
Maintain the fluid level at
the bottom of the fill hole
threads. See below for
capacity. The fill plug is
located on the right side of
the demand drive unit. The
drain plug is located on the
bottom right side of the
unit.
Drain Plug
Fill
Plug
Fill
Level
93
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
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 bot-
tom 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.
94
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Level
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 81.
We recommend the use of POLARIS Demand Drive Plus Fluid for the
ADC unit. Maintain the fluid level between the minimum and maximum
marks on the reservoir. See page 137 for the part numbers of POLARIS
products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
1. Remove the front box.
2. View the fluid level in the
reservoir.
3. If the level is below the
minimum mark, remove
the cap and add the
recommended fluid.
4. Reinstall the cap.
5. Reinstall the front box.
ADC Fluid
Reservoir
95
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-clock-
wise) 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
96
MAINTENANCE
Rear Gearcase Oil
See the table on page 85 for fluid recommendations, capacities and plug
torques. Always check and change the rear gearcase oil at the intervals
outlined in the Periodic Maintenance Chart beginning on page 81. See
page 137 for the part numbers of POLARIS products.
The fill plug is located on the
rear of the gearcase. The drain
plug is located on the bottom
of the gearcase.
Maintain the fluid level at the
bottom of the fill hole threads.
Do not overfill.
Oil Check
1. Position the vehicle on a
level surface.
2. Remove the fill plug.
Check the oil level.
3. Add the recommended oil
as needed to bring the
level to the bottom of the
fill hole threads. Do not overfill.
4. Reinstall the fill plug. Torque to specification.
Drain Plug
Fill Plug
Fill
Level
97
MAINTENANCE
Rear Gearcase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. Torque
to specification.
5. Remove the fill plug. Add the proper amount of the recommended
oil. Do not overfill.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
98
MAINTENANCE
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 con-
tracting (cooled) coolant is drawn back up from the bottle, past the pres-
sure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS Premium 60/40 anti-
freeze/coolant or a 50/50 mixture of high quality aluminum compatible
anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is
already premixed and ready to use. Do not dilute with water. See page
137 for the part numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
99
MAINTENANCE
Cooling System
Recovery Bottle Coolant
The recovery bottle fluid level can be viewed from inside the front right
wheel well. Access the recovery bottle cap under the front storage com-
partment.
1. View the fluid level in the bottle.
2. If the level is low, remove the front box.
3. Remove the bottle cap and add coolant as needed. Maintain the
coolant level between the minimum and maximum marks on the
bottle (when the fluid is cool).
4. Reinstall the cap.
5. Reinstall the front box.
Maximum
Mark
Minimum
Mark
Recovery
Bottle Cap
100
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. Remove the front box.
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 func-
tion properly. Contact your dealer
for the correct replacement part.
5. Reinstall the front box.
Radiator
Cap
101
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 32.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).
5. Check the security and surface condition
of the disc.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 34.
3/64" (1 mm)
102
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 0" to 1/8" (0-3 mm).
WARNING! Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized POLARIS dealer.
1. Position the vehicle on a
level surface.
2. Place the handlebars in a
straight-ahead position.
3. Tie a length of string
between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long 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 1.5 mm more than the front measurement on each side of
the vehicle to obtain the recommended 0" to 1/8" (0-3 mm) toe out
alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for
service.
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.
String
Stand
2
1
103
MAINTENANCE
Seat Removal
1. Remove any cargo from the
cargo box before removing the
seat.
2. Stand beside the vehicle. Pull
the cargo box release strap
upward. Lift the front of the
cargo box.
3. Grasp edge of the seat near the
opposite rear corner.
4. Pull upward abruptly to disen-
gage the under-seat fasteners.
5. Remove the seat.
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
Screw
104
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 138 for recom-
mended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com-
ponent 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.
WARNING
1/8" (3 mm)
105
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 (if
equipped).
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 loos-
ened 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)
106
MAINTENANCE
Air Filter
1. Remove the seat. See page
103.
2. Remove the air box cover
screws, and remove the air
box cover.
3. Remove the filter.
4. Remove the fabric type pre-
filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.
5. Reinstall the pre-filter over
the main filter. Install a new
main filter if needed.
6. Reinstall the filter into the air
box.
7. Reinstall the air box cover
and the seat.
Main
Filter
Pre-Filter
Screws
107
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 cir-
cuits that may have caused the blown fuse, then replace the fuse. Spare
fuses are provided in the fuse box.
1. Remove the front box.
2. Remove the fuse box cover.
3. Remove the suspect fuse from the fuse panel. If the fuse is blown,
install a new fuse with the same amperage rating.
4. Reinstall the fuse box cover.
5. Reinstall the front box.
Fuse Box
550 850
108
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps 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 fin-
gers. 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 speedom-
eter 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 wir-
ing.
4. Turn the lamp counterclockwise to remove it.
5. Install the new lamp. Make sure the tab on the lamp locates properly
in the housing.
6. Reassemble the pod.
109
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 approxi-
mately 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 screw is
located on the right side of
the headlight pod. To adjust
the beam, loosen the screw.
Adjust the headlamp to the
desired position, then
tighten the screw.
2" (5 cm)
Lamp Center Height
25 ft. (7.6 m)
Adjustment
Screw
110
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.
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.
Phillips Screw
111
MAINTENANCE
Lights
Lower Headlamp Replacement
1. Turn the back of the headlight
harness counterclockwise 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 head-
lamp.
Taillight/Brakelight Lamp Replacement
1. Open the tailgate.
2. Remove the two screws near the
tailgate latch.
3. Grasp the entire taillight assembly
and pull it away from the vehicle.
4. Remove the harness connector
from the back of the light assem-
bly.
5. Turn the lamp counterclockwise to
remove it.
6. Apply dielectric grease to the
socket and install the new lamp.
7. Reinstall the harness connector.
8. Test the light for proper operation.
9. Reinstall the taillight assembly.
10. Reinstall the two screws.
Harness
Screws
Lamp
112
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 138 for the recom-
mended 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 113.
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. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specifi-
cation.
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)
113
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 indi-
cates 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.
114
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.
3. Remove the spark plugs.
4. Turn the engine over several times using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying proce-
dure.
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 118 for drying out the PVT.
115
MAINTENANCE
Spark Arrestor
Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrestor while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrestor clean-
out plug from the bottom of
the muffler.
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and
release the throttle lever
several times to purge car-
bon from the system.
5. If carbon comes out of the
exhaust, cover or plug the
exhaust outlet(s). Wear
protective gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 4.
7. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
8. Place the transmission in PARK. Lock the parking brake. Repeat
steps 4 to 6 until no more particles are expelled.
9. Stop the engine. Allow the arrestor to cool.
10. Reinstall the arrestor plug and remove the exhaust outlet cover or
plug.
WARNING
Clean-Out
Plug
116
MAINTENANCE
PVT System
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer as
outlined in the owner's manual.
• This PVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
WARNING
117
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 fly-
weights 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 oper-
ation 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 tempera-
ture inside the clutch cover greatly extends the life of the PVT compo-
nents (belt, cover, etc.).
118
MAINTENANCE
PVT System
When To Use Low Range and High Range
The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the tempera-
ture inside the clutch cover greatly extends the life of the PVT compo-
nents (belt, cover, etc.).
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 operat-
ing.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Rein-
stall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the trans-
mission to the lowest available range.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
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
119
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 main-
tenance. 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 termi-
nals with dielectric grease or petroleum jelly.
Battery Removal
1. Remove the front box.
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
120
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the bat-
tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 122 before installing
the battery.
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. Install the front box.
121
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
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 137 for the
part numbers of POLARIS products.
122
MAINTENANCE
Battery
Battery Charging
The following battery charging instructions apply only to the installa-
tion 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. 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 manufac-
turer's instructions for recharging. When using a constant current
charger, use the guidelines on the next page for recharging.
123
MAINTENANCE
Battery
Battery Charging
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
124
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 han-
dlebar control and remove
the cover.
2. With the handlebars
straight ahead, place very
light pressure on the throt-
tle 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 in-line 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
125
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.
126
MAINTENANCE
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.
Handlebar
Bolts
127
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Front and Rear Springs
The front and rear shock absorber
springs are adjusted by rotating the
adjuster either clockwise or counter-
clockwise to increase or decrease
spring tension. Accessory springs are
available through your POLARIS
dealer.
Adjuster
128
MAINTENANCE
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. Always secure the seat in the 1-up position to prevent loss during
transporting.
5. Secure the fuel cap and oil cap.
6. 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.
7. Remove the key to prevent loss during transporting.
Accessories
Auxiliary power outlets provide 12-volt power for operating accesso-
ries. 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.
129
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its appear-
ance 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 gar-
den 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.
130
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the follow-
ing items:
If an informational or graphic label becomes illegible or comes off, con-
tact 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
131
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 129.
Oil and Filter
Change the oil and filter. See page 88.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 81.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
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 recom-
mended 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.
132
MAINTENANCE
Cleaning and Storage
Storage Tips
Fog the Engine
1. After stabilizing the fuel, remove the spark plugs and add 2-3 table-
spoons of engine oil. To access the plug holes, use a section of clear
1/4" hose and a small plastic squeeze bottle filled with the pre-mea-
sured amount of oil.
2. Reinstall the spark plugs. Torque to specification.
3. Apply dielectric grease to the inside of each spark plug cap and rein-
stall the caps onto the plugs.
4. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protec-
tive 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.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
106.
2. Clean the air box.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 81.
Battery Storage
See pages 121-122 for storage and charging procedures.
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 condensa-
tion, and may promote corrosion and oxidation.
133
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
70).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 118.
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 118. 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 57.
134
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Clogged fuel filter See your dealer
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark 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
135
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
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank vent line Inspect and replace
Low octane fuel Replace with recommended fuel
Clogged fuel filter See your dealer
Incorrect fuel Replace with recommended fuel
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Stopping/starting without adequate
warm-up
Allow engine to warm up before operat-
ing and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
136
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. NOTE: High pres-
sure washers can deform the radiator fins
and reduce cooling efficiency.
137
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz./355 ml Aerosol)
2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL PLUS Transmission Fluid (qt./.95 l)
2878069 AGL PLUS Transmission Fluid (gal./3.8 l)
2877922 Demand Drive Plus Fluid (qt./.95 l)
2877923 Demand Drive Plus Fluid (gal./3.8 l)
2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)
2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)
2870465 Pump for Gallon (3.8 l) Jug
Coolant
2871323 60/40 Coolant (gal./3.8 l)
2871534 60/40 Coolant (qt./.95 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 Premium All Season Grease (3 oz./89 ml cartridge)
2871423 Premium All Season Grease (14 oz./414 ml cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)
2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)
2871329
Dielectric Grease (Nyogel
TM
)
Additives / Miscellaneous
2871326 Carbon Clean Plus
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956
Loctite
TM
565 Thread Sealant
2859044
POLARIS Battery Tender
TM
Charger
138
SPECIFICATIONS
* Based on EU Directive 76/432/EC
**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.
Sportsman 550 X2
Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger,
cargo, accessories)
Dry Weight 799 lbs. (362.4 kg)
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Transmission Oil Capacity 32 oz. (948 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Rear Gearcase Oil Capacity 6.1 oz. (180 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Storage Box Capacity 400 lbs. (181 kg)
Hitch Tongue Weight 150 lbs. (68 kg) (Rear box capacity and tongue
weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating 1500 lbs. (680 kg) on level ground
Unbraked Trailer Towing
Capacity*
1995 lbs. (905 kg)
Overall Length 93.25 in. (237 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 49.5 in. (125.7 cm)
Wheelbase 57 in. (145 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 96 in. (244 cm) unloaded
82 in. (208 cm) (in TURF mode)
Engine ES550PLE
Displacement 549.7 cc
Bore x Stroke 96.6 x 75
Alternator Output 490w @ 1350 RPM/Peak 630w
Compression Ratio 9.6:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM** 1750 +/- 50
Ignition Timing 13 +/- 3 BTDC @ 1350 RPM, Engine warm
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Front Suspension Dual A-Arm with 9" (22.9 cm) travel
Rear Suspension Progressive rate with 10.25" (26 cm) travel
139
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
Sportsman 550 X2
Transmission H/L/N/R/P
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.693:1
Drive Ratio, Front 3.818:1
Tires/Pressure, Front Maxxis AT 26 x 8 - 14 / 7 psi (48.3 kPa)
Tires/Pressure, Rear Maxxis AT 26 x 10 - 14 / 5 psi (34.5 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)
Taillights 8.26 watts
Brake Light 27 watts
Instrument Cluster Digital/Analog
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
23-58
PN 1322911
Red/Black
PN 7043500
Red/White
PN 3235088
105-165 BA3
PN 3235092
1800-3700
(6000-12000)
23-54
PN 1322914
Red/Black
PN 7043500
Red/White
PN 3235088
105-165 BA3
PN 3235092
140
SPECIFICATIONS
* Based on EU Directive 76/432/EC
**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.
Sportsman 850 X2
Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger,
cargo, accessories)
Dry Weight 839 lbs. (380.6 kg)
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Transmission Oil Capacity 32 oz. (948 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Rear Gearcase Oil Capacity 6.1 oz. (180 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Storage Box Capacity 400 lbs. (181 kg)
Hitch Tongue Weight 150 lbs. (68 kg) (Rear box capacity and tongue
weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating 1500 lbs. (680 kg) on level ground
Unbraked Trailer Towing
Capacity*
1995 lbs. (905 kg)
Overall Length 93.25 in. (237 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 49.5 in. (125.7 cm)
Wheelbase 57 in. (145 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 96 in. (244 cm) unloaded
82 in. (208 cm) (in TURF mode)
Engine EHO850LE
Displacement 850 cc
Bore x Stroke 87 x 71.5
Alternator Output 475w @1200 RPM/Peak 630w
Compression Ratio 11:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM 1200 +/- 100
Ignition Timing 6 +/- 5 BTDC @ 1200 RPM, Engine warm
Spark Plug Type / Gap Champion REA8MCX / .035 in. (0.9 mm)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Front Suspension Dual A-Arm with 9" (22.9 cm) travel
Rear Suspension Progressive rate with 10.25" (26 cm) travel
141
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
Sportsman 850 X2
Transmission H/L/N/R/P
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.693:1
Drive Ratio, Front 3.818:1
Tires/Pressure, Front Maxxis AT 26 x 8 - 14 / 7 psi (48 kPa)
Tires/Pressure, Rear Maxxis AT 26 x 10 - 14 / 5 psi (34.5 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)
Taillights 8.26 watts
Brake Light 27 watts
Instrument Cluster Digital/Analog
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
24-60
PN5632216
Red/White
PN 7043349
Red/White
PN 3235088
105-165 BA3
PN 3235092
1800-3700
(6000-12000)
24-56
PN 5632394
Red/White
PN 7043349
Red/White
PN 3235088
105-165 BA3
PN 3235092
142
DECLARATION OF CONFORMITY
Polaris Industries Inc.,
2100 Hwy 55, Medina, MN 55340 U.S.A.
Telephone 763-542-0500
April 22, 2010
We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health
and safety requirements applicable to off-road all-terrain vehicles.
PRODUCT IDENTIFICATION
APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS
2006/42/EC as amended (Machinery Directive) EN 1050 hazard analysis
prEN 15997 driver-perceived noise level
prEN 15997 vibration
2004/108/EC as amended (EMC Directive) CISPR 12:2009
CAN/CSA-C108.4-M92
EN 55012:2007
EN 61000-6-2:2005
VEHICLE SERIES TRADE NAME MODEL YEARS
___KA05__ / ___KA09__ OUTLAW 50 / 90 2008, 2009, 2010, 2011
___FA09__ SPORTSMAN 90 2008, 2009, 2010, 2011
___VA17__ RZR 170 2009, 2010, 2011
___PB20__ PHOENIX 200 2008, 2009, 2010, 2011
___BA32__, ___NA32__ TRAIL BLAZER 330 2008, 2009, 2010, 2011
___CA32__, ___EA32__ TRAIL BOSS 330 2008, 2009, 2010, 2011
___BA50__, ___BG50__ SCRAMBLER 500 2008, 2009, 2010, 2011
___GJ45__ OUTLAW 450 2008, 2009, 2010, 2011
___GJ52__, ___GP52__ OUTLAW 525 / 525 S 2008, 2009, 2010, 2011
___LH46__ SPORTSMAN 400 2008, 2009, 2010, 2011
___MH50__ SPORTSMAN 500 HO 2008, 2009, 2010, 2011
___DH50__ SPORTSMAN 500 HO TOURING 2010, 2011
___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009, 2010, 2011
___TN55__, ___TX55__ SPORTSMAN 550 X2 2010, 2011
___DN55__, ___DX55__ SPORTSMAN 550 TOURING 2010, 2011
___MN76__ SPORTSMAN 800 2008, 2009, 2010, 2011
___CL76__, ___CF76__ SPORTSMAN 800 6X6 2009, 2010, 2011
___ZN85__, ___ZX85__ SPORTSMAN 850 EFI 2009, 2010, 2011
___TN85__, ___TX85__ SPORTSMAN 850 X2 2010, 2011
___DN85__, ___DX85__ SPORTSMAN 850 TOURING 2010, 2011
___RH45__ RANGER 400 2010, 2011
___WH45__ RANGER 400 CREW 2011
___RH50__ RANGER 500 4X4 2010, 2011
___TH76__ RANGER 800 EFI 4X4 2010, 2011
___WH76__ RANGER 800 EFI CREW 2010, 2011
___HR76__ RANGER 800 6X6 2010, 2011
___HY76__, ___TY76__ RANGER HD 800 4X4 2010, 2011
___TH90__ RANGER DIESEL 2011
___WH90__ RANGER DIESEL CREW 2011
___VH76__, ___VY76__ RANGER RZR / RZR S 2008, 2009, 2010, 2011
___XH76__ RANGER RZR 4 2011
European Community Person
Authorized to Compile the Technical File:
Ross Clifford, General Manager
Polaris Britain Ltd
Forge Mills Park, Station Road
Coleshill, Warwickshire B46 1HT
Authorized Manufacturer Signatory
Empowered to Draw up the EC Declaration of
Conformity:
Lawrence E. Keller, Product Compliance Manager
7290 East Viking Blvd.
Wyoming, MN 55092
143
WARRANTY
LIMITED WARRANTY
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH
LIMITED WARRANTY on all components of the POLARIS All Terrain Vehicle (ATV)
against defects in material or workmanship. POLARIS also gives a one year limited
warranty on the final drive chain (if equipped) for failure due to defects. This warranty
covers the parts and labor charges for repair or replacement of defective parts which are
covered by this warranty. This warranty begins on the date of purchase. This warranty is
transferable to another consumer during the warranty period through a POLARIS dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days. 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 the warranty entitle-
ment. 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 ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV 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.
144
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The POLARIS limited warranty excludes any failures that are not caused by a defect in
material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any ATV that
has been altered structurally, modified, neglected, improperly maintained, used for rac-
ing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the ATV due to fire, explosions or any other cause beyond
POLARIS' control.
Warranty does not apply to 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:
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
• 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
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps
• Spark Plugs • Lubricants such as oil, grease, etc.
• Filters • Batteries (unless defective)
• Fuel • Cosmetic damage/repair
• Sealants • Coolants
• Hotel fees • Meals
• Towing charges • Shipping/ handling fees
• Mileage • Product pick-up/delivery
• Rentals/Loss of product use • Loss of vacation/personal time
145
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty also excludes 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; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the ATV. The exclusive remedy for breach of this warranty shall
be, at POLARIS' exclusive option, repair or replacement of any defective materials, or
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 DESCRIP-
TION, 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 DAM-
AGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT
THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. Some states
do not permit the exclusion or limitation of incidental or consequential damages or
implied warranties, so the above limitations or exclusions may not apply to you if incon-
sistent with controlling state law.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX
MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-
tations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling state law.
146
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a POLARIS dealer authorized
to repair POLARIS ATVs. When requesting warranty service you must present your
copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA-
TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS sug-
gests that you use your original selling dealer; however, you may use any POLARIS
Servicing Dealer to perform warranty service.
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.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-
ommend the use of POLARIS engine oil for your ATV.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
SPARK ARRESTOR
POLARIS warrants that the spark arrestor in this vehicle will meet the efficiency
requirements of USFS standard 5100-1c for at least 1000 hours when subjected to nor-
mal use and when maintenance and installation are in accordance with POLARIS rec-
ommendations.
147
WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
POLARIS Industries. Dealers may not give authorization for export. You should consult
an authorized dealer to determine this vehicle's warranty or service bulletin coverage if
you have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Bulletins.
How to Get Service
In the Country where your vehicle 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 vehicle was purchased, War-
ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer
who sells the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle 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. Vehicles importa-
tion rules vary considerably from country to country. You may be required to present
documentation of your move to POLARIS Industries in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS Industries
in order to register your vehicle in your new country. You should warranty register your
vehicle at a local POLARIS dealer in your new country immediately after you move to
continue your warranty coverage and to ensure that you receive safety information and
notices regarding your vehicle.
148
WARRANTY
Exported Vehicles
How to Get Service
If Purchased From A Private Party:
If you purchase a POLARIS product from a private citizen, to be kept and used outside
of the country in which the vehicle was originally purchased, all warranty coverage will
be denied. You must nonetheless warranty register your vehicle under your name and
address with a local POLARIS dealer in your country to ensure that you receive safety
information and notices regarding your vehicle.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles reg-
istered to Government officials or military personnel on assignment outside of the
country where the vehicle was purchased will continue to be covered by the basic war-
ranty.)
For questions call POLARIS Customer Assistance:
United States: 1-888-704-5290
Canada: 1-204-925-7100
149
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited war-
ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur-
chased, 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 this emissions-certified vehicle starts on the date the vehicle is
first purchased and continues for a period of 500 hours of engine operation, 5000 kilo-
meters (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase,
whichever comes first.
This emissions limited warranty covers components whose failure increases the vehi-
cle’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 war-
ranty 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 emis-
sions:
The following parts are considered emission-related components for evaporative emis-
sions:
*As related to the evaporative emission control system.
• Air-induction system • Ignition system
• Fuel system • Exhaust gas recirculation systems
• Aftertreatment devices • Sensors
• Crankcase ventilation valves • Electronic control units
• 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
150
WARRANTY
U.S.A. EPA Emissions Limited Warranty
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 WAR-
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-
DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY 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 PUR-
POSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-
TIES 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 incon-
sistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workman-
ship.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.
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 con-
trol 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 vehi-
cle. 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.
If you have any questions regarding your warranty rights and responsibilities, please
contact the POLARIS Warranty Department at 1-888-704-5290.
151
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 ser-
vices performed.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
152
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
153
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
154
INDEX
0-9
4X4 Switch . . . . . . . . . . . . . . . . . . . 29
A
Accessories . . . . . . . . . . . . . . . . . . 128
Active Descent Control Fluid . . . 94-95
Active Descent Control System. . . . 40
ADC System . . . . . . . . . . . . . . . . . . 40
Air Filter . . . . . . . . . . . . . . . . . . . . 106
All Wheel Drive System . . . . . . . 38-39
Auxiliary Foot Brake . . . . . . . . . . . 101
B
Battery . . . . . . . . . . . . . . . . . . 119-123
Charging . . . . . . . . . . . . . 122-123
Installation . . . . . . . . . . . . . . . 120
Removal. . . . . . . . . . . . . . . . . 119
Storage . . . . . . . . . . . . . . . . . . 121
Belt Life. . . . . . . . . . . . . . . . . . . . . . 36
Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9
Box/Compartment, Front. . . . . . . . . 43
Brake Fluid, Auxiliary Foot Brake . 35
Brake Fluid, Main Brake System. . . 32
Brake Lever . . . . . . . . . . . . . . . . . . . 31
Brake, Foot . . . . . . . . . . . . . 34-35, 101
Brake, Hand Lever. . . . . . . . . . . . . 101
Brake, Parking . . . . . . . . . . . . . . . . . 33
Brakelight Lamp Replacement . . . 111
Brakes . . . . . . . . . . . . . . . . . . . . . . 101
Break-In Period . . . . . . . . . . . . . . 56-57
C
Camber Adjustment . . . . . . . . . . . . 127
Cargo . . . . . . . . . . . . . . . . . . . . . . 77-79
Cargo Loading . . . . . . . . . . . . . . . . . 76
Caster Adjustment . . . . . . . . . . . . . 127
Check Engine Indicator . . . . . . . . . . 51
Cleaning and Storage. . . . . . . . 129-132
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching
550 . . . . . . . . . . . . . . . . . . . . . 139
850 . . . . . . . . . . . . . . . . . . . . . 141
C
Cold Weather Operation . . . . . . . . . . 61
Consumer Product Safety . . . . . . . . . . 7
Coolant Bottle . . . . . . . . . . . . . . . . . . 99
Coolant, Radiator. . . . . . . . . . . . . . . 100
Cooling System . . . . . . . . . . . . . 98-100
Crankcase Emission Control System. 80
D
Demand Drive Fluid . . . . . . . . . . 92-93
Diagnostic Codes, 550. . . . . . . . . . . . 53
Diagnostic Codes, 850. . . . . . . . . 54-55
Disengaging Active Descent Control 40
Display Units, Standard/Metric . . . . . 48
Drive Belt Wear/Burn . . . . . . . . . . . 133
Drivetrain Break-In . . . . . . . . . . . . . . 57
Driving Downhill. . . . . . . . . . . . . . . . 69
Driving in Reverse. . . . . . . . . . . . . . . 74
Driving on a Sidehill . . . . . . . . . . . . . 68
Driving on Slippery Surfaces . . . . . . 66
Driving Over Obstacles . . . . . . . . . . . 73
Driving Procedures . . . . . . . . . . . . . . 62
Driving Through Water . . . . . . . . . . . 72
Driving Uphill . . . . . . . . . . . . . . . . . . 67
Driving with a Passenger. . . . . . . 64-65
E
Emissions Limited Warranty . . 149-150
Engaging 4X4 . . . . . . . . . . . . . . . . . . 39
Engaging Active Descent Control . . . 40
Engine Break-In. . . . . . . . . . . . . . . . . 57
Engine Fogging . . . . . . . . . . . . . . . . 132
Engine Oil . . . . . . . . . . . . . . . . . . 86-89
Engine Stop Switch . . . . . . . . . . . . . . 28
Equipment Modifications . . . . . . . . . . 9
Error Codes, Engine . . . . . . . . . . . . . 51
Etiquette, Trail Riding . . . . . . . . . . . . 60
Exhaust Emission Control System . . 80
Eye Protection . . . . . . . . . . . . . . . . . . . 9
155
INDEX
F
Fluid
ADC . . . . . . . . . . . . . . . . . . 94-95
Brake. . . . . . . . . . . . . . . . . . . . . 32
Coolant . . . . . . . . . . . . . . . . . . . 98
Demand Drive. . . . . . . . . . . 92-93
Engine Oil . . . . . . . . . . . . . . . . . 86
Rear Gearcase . . . . . . . . . . . . . . 96
Recommended Lubricants . . . . 85
Transmission. . . . . . . . . . . . . . . 90
Fluid Change
ADC . . . . . . . . . . . . . . . . . . . . . 95
Demand Drive. . . . . . . . . . . . . . 93
Engine Oil . . . . . . . . . . . . . . 88-89
Rear Gearcase . . . . . . . . . . . . . . 97
Transmission Oil. . . . . . . . . . . . 91
Fluid Level
ADC . . . . . . . . . . . . . . . . . . . . . 94
Brake. . . . . . . . . . . . . . . . . . 32, 35
Coolant Bottle. . . . . . . . . . . . . . 99
Demand Drive. . . . . . . . . . . . . . 93
Engine Oil . . . . . . . . . . . . . . . . . 87
Radiator. . . . . . . . . . . . . . . . . . 100
Rear Gearcase . . . . . . . . . . . . . . 96
Transmission Oil. . . . . . . . . . . . 90
Foot Brake, Auxiliary . . . . . . . . . 34-35
Footwell Removal. . . . . . . . . . . . . . 103
Front Box/Compartment . . . . . . . . . . 43
Front Gearcase (Demand Drive). 92-93
Fuel Recommendations. . . . . . . . . . . 37
Fuel Safety . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 37
Fuse Replacement . . . . . . . . . . . . . . 107
G
Gasoline Handling . . . . . . . . . . . . . . 11
Gauge, Code Definitions. . . . . . . 52-55
Gauge, Digital/Analog . . . . . . . . 44-51
Gear Selector. . . . . . . . . . . . . . . . . . . 36
Gearcase Oil, Rear . . . . . . . . . . . 96-97
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
H
Hand Brake . . . . . . . . . . . . . . . . . . . 101
Handlebar Adjustment . . . . . . . . . . 126
Hauling Cargo. . . . . . . . . . . . . . . 76-79
Headlight Housing Replacement . . 110
Headlight Lamp Replacement . . . . 108
Headlight Switch . . . . . . . . . . . . . . . 29
Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8
High Beam Adjustment . . . . . . . . . 109
High Range Use . . . . . . . . . . . . . . . 118
Hub Tightening . . . . . . . . . . . . . . . . 104
I
Idle RPM Adjustment . . . . . . . . . . . 124
Immersion Maintenance . . . . . . . . . 114
Indicator Lamps . . . . . . . . . . . . . . . . 45
Instrument Cluster . . . . . . . . . . . 44-55
K
Key Switch . . . . . . . . . . . . . . . . . . . . 29
K-Turn . . . . . . . . . . . . . . . . . . . . 70-71
L
Lights . . . . . . . . . . . . . . . . . . . 108-111
Headlight Housing . . . . . . . . . 110
Headlight Lamp . . . . . . . . . . . 108
High Beam Adjustment . . . . . 109
Low Beam Adjustment . . . . . . 110
Lower Headlamp Replacement 111
Taillight/Brakelight. . . . . . . . . 111
Low Range Use. . . . . . . . . . . . . . . . 118
Lower Headlamp Replacement. . . . 111
Lubrication Guide. . . . . . . . . . . . . . . 85
M
Maintenance Chart . . . . . . . . . . . 81-84
Master Cylinder . . . . . . . . . . . . . . . . 32
Metric Display . . . . . . . . . . . . . . . . . 48
Mode Switch . . . . . . . . . . . . . . . . . . . 28
Modifications . . . . . . . . . . . . . . . . . . . 9
156
INDEX
N
Noise Emission Control System . . . 80
O
Oil
Engine . . . . . . . . . . . . . . . . . 86-89
Rear Gearcase . . . . . . . . . . . 96-97
Transmission . . . . . . . . . . . . 90-91
Oil Change
Engine Oil and Filter . . . . . . 88-89
Rear Gearcase . . . . . . . . . . . . . 97
Transmission . . . . . . . . . . . . . . 91
Oil Level
Engine . . . . . . . . . . . . . . . . . . . 87
Rear Gearcase . . . . . . . . . . . . . 96
Transmission . . . . . . . . . . . . . . 90
Oil Recommendations . . . . . . . . . . . 86
Operation on Public Lands . . . . . . . 80
Override Switch . . . . . . . . . . . . . . . . 28
P
Parking Brake . . . . . . . . . . . . . . . . . 33
Parking on an Incline. . . . . . . . . . . . 75
Passenger Seat . . . . . . . . . . . . . . . 41-42
Periodic Maintenance Chart . . . . 81-84
Polaris Product List . . . . . . . . . . . . 137
Polishing the Vehicle. . . . . . . . . . . 130
Pre-Ride Checklist. . . . . . . . . . . . . . 58
PVT Break-In. . . . . . . . . . . . . . . . . . 57
PVT Drying . . . . . . . . . . . . . . . . . . 118
PVT System. . . . . . . . . . . . . . . 116-118
R
Reverse Operation . . . . . . . . . . . . . . 74
Reverse Override Switch . . . . . . . . . 28
Rider Information Center. . . . . . . 46-51
Riding Area . . . . . . . . . . . . . . . . . . . 60
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9
S
Safe Operation Practices . . . . . . . . . . 59
Safety Labels . . . . . . . . . . . . . . . 22-27
Age 16 Warning. . . . . . . . . . . . . 23
AWD Caution . . . . . . . . . . . . . . 23
Box Warning . . . . . . . . . . . . . . . 27
Clutch Cover Warning. . . . . . . . 26
Discretionary Warning . . . . . . . 24
General Warning . . . . . . . . . . . . 22
Passenger Safety Warning. . . . . 24
Rack Warning, Front and Rear . 26
Reverse Override Warning . . . . 23
Tire Pressure/Load Warning . . . 25
Safety Training . . . . . . . . . . . . . . . . . . 7
Safety Warnings. . . . . . . . . . . . . 10-21
Age Restrictions . . . . . . . . . . . . 10
Carrying a Passenger . . . . . . . . . 12
Carrying Multiple Passengers . . 12
Crossing Hillsides . . . . . . . . . . . 15
Deep Water . . . . . . . . . . . . . . . . 19
Descending Hills Improperly. . . 15
Excessive Speeds. . . . . . . . . . . . 13
Exhaust Exposure . . . . . . . . . . . 11
Failure to Inspect . . . . . . . . . . . . 11
Frozen Bodies of Water. . . . . . . 20
Handling Gasoline . . . . . . . . . . . 11
Hot Exhaust Systems . . . . . . . . . 21
Improper Cargo Loading . . . . . . 19
Improper Hill Climbing . . . . . . . 15
Improper Tire Maintenance. . . . 18
Jumps and Stunts . . . . . . . . . . . . 14
Operating a Damaged ATV. . . . 21
Operating on Pavement . . . . . . . 13
Operating on Public Roads . . . . 13
Operating on Steep Hills . . . . . . 16
Operating Over Obstacles . . . . . 18
Operating Without Instruction. . 10
157
INDEX
S
Safety Warnings . . . . . . . . . . . . 10-21
Passenger in the Cargo Box . . . 13
Physical Control of the ATV . . 14
Physical Skills. . . . . . . . . . . . . . 21
Poor Visibility. . . . . . . . . . . . . . 20
Protective Apparel . . . . . . . . . . 12
Reverse Operation. . . . . . . . . . . 17
Skidding or Sliding . . . . . . . . . . 18
Slippery Terrain . . . . . . . . . . . . 17
Stalling While Climbing a Hill . 16
Turning Improperly. . . . . . . . . . 14
Unauthorized Use . . . . . . . . . . . 21
Unfamiliar Terrain . . . . . . . . . . 17
Using Alcohol or Drugs . . . . . . 12
Seat Removal . . . . . . . . . . . . . . . . . 103
Severe Use . . . . . . . . . . . . . . . . . . . . 81
Side Panel Removal . . . . . . . . . . . . 103
Sidehilling . . . . . . . . . . . . . . . . . . . . . 68
Signal Words. . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor. . . . . . . . . . . . . . . . . 115
Spark Plug Inspection . . . . . . . 112-113
Spark Plug Recommendations . . . . 112
Spark Plugs . . . . . . . . . . . . . . . 112-113
Speedometer . . . . . . . . . . . . . . . . . . . 44
Spring Adjustment, Shock . . . . . . . 127
Starting the Engine . . . . . . . . . . . . . . 61
Steering Assembly . . . . . . . . . . . . . 102
Storage . . . . . . . . . . . . . . . . . . 129-132
Storage Tips . . . . . . . . . . . . . . 131-132
Switches . . . . . . . . . . . . . . . . . . . 28-29
4X4 Switch . . . . . . . . . . . . . . . . 29
Engine Stop Switch. . . . . . . . . . 28
Headlight Switch. . . . . . . . . . . . 29
Main Key Switch . . . . . . . . . . . 29
Mode/Reverse Override Switch 28
T
Taillight Lamp Replacement . . . . . 111
Throttle Body Adjustment . . . . . . . 124
Throttle Cable Freeplay . . . . . 124-125
Throttle Lever . . . . . . . . . . . . . . . . . . 30
Tire Tread Depth. . . . . . . . . . . . . . . 104
Tires . . . . . . . . . . . . . . . . . . . . 104-105
Wheel Installation. . . . . . . . . . 105
Wheel Nut Torque . . . . . . . . . 105
Wheel Removal . . . . . . . . . . . 104
Toe Alignment . . . . . . . . . . . . . . . . 102
Towing Capacities . . . . . . . . . . . . . . 78
Towing Loads . . . . . . . . . . . . . . . . . . 78
Trail Etiquette . . . . . . . . . . . . . . . . . . 60
Training. . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission. . . . . . . . . . . . . . . . . . . 36
Transmission Oil. . . . . . . . . . . . . 90-91
Transporting the ATV. . . . . . . . . . . 128
Tread Lightly . . . . . . . . . . . . . . . . . . 60
Turning Around on a Hill . . . . . . 70-71
Turning the Vehicle . . . . . . . . . . . . . 63
V
Vehicle Identification Numbers . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . 114
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . 129-130
Wheel Installation . . . . . . . . . . . . . . 105
Wheel Nut Torque Specifications. . 105
Wheel Removal . . . . . . . . . . . . . . . 104
