Polaris 2011 ATV Sportsman Touring 550 INTL- Manuals

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...

5 INTRODUCTION As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protec-tion of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, includ...

6 SAFETY Failure to follow the warnings in this manual can result in serious injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.Read and understand your o...

7 SAFETY Restrictions Towing is approved OFF-ROAD ONLY. Towing a trailer with this vehi-cle on public roads is prohibited. See your POLARIS dealer about con-figuring the vehicle to be certified to tow a trailer on-road. Equipment Modifications The warranty on your Polaris vehicle may be terminated i...

8 SAFETY Rider Safety Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor...

15 SAFETY Rider Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always unlock the steering before starting the engine. See page 31. Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always...

16 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Always wear a helmet that meets or exceeds established safety stan-dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia an...

17 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 marki...

18 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 ...

19 SAFETY Safety Labels and Locations General Alert (Multi-Lingual) Before you operate or ride this vehicle, read the owner’s manual. 7174362 Reverse Override Warning/4X4 Caution WARNINGImproper use of the override button can lead to loss of control resulting in severe injury or death. Do not activa...

20 SAFETY Safety Labels and Locations Rack/Box Warning WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg) 7175448 Clutch Cover Alert Hitch...

21 FEATURES AND CONTROLS Switches Main Key Switch Use the main key switch to start the engine. See page 52. End all electrical power to the vehi-cle. LIGHTS ON position turns the head- lights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key...

22 FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. OFF RUN Push the stop switch down to stop the engine quickly. Pull the stop switch up to the RUN position before attempt- ing to start the engine.Both the main switch and the...

23 FEATURES AND CONTROLS Switches Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch. Pressing the override switch while the throttle is open can cause loss of control, which m...

24 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation...

25 FEATURES AND CONTROLS Brake Lever Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever...

26 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, ...

27 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...

28 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 f...

29 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE...

30 FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 37 for EPS Warning Indicator information. Passenger Seat Always make sure the passenger s...

31 FEATURES AND CONTROLS Fuel Tank Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap and add fuel. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with ...

32 FEATURES AND CONTROLS Front Storage Box Open the front storage box to access the under-compartment area. 1. Release the front box cover latches and lift the cover. 2. Release the plunger latches that secure the box to the frame. 3. Close the cover and lift the unlatched edge of the box to disenga...

33 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 as...

35 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 automatic...

36 FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use ...

37 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps Lamp Indicates Condition VehicleSpeed 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...

38 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...

39 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. Gear Display - This area displays gear shifter position. H = High GearL = Low GearN = NeutralR = Reverse GearP = Park-- = Gear Signal Error (or shifter between gears) 2. Fuel Gauge Display - The segments of ...

40 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...

41 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 th...

42 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 ena...

44 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 a...

48 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for y...

49 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 75. Add oil if necessary to maintain the level between the safe and add ma...

50 OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condi-tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Passenger seat latch Ensure l...

51 OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 6. 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 f...

52 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 enga...

53 OPERATION Driving Procedures 1. Wear protective riding gear. See page 16. 2. Perform the pre-ride inspection. See page 50. 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 ha...

54 OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while su...

55 OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle. Make sure any passenger is tall enough to com-fortably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you have at least two hours of driv...

56 OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, 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 ...

57 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 2. Drive straight uphill. 3. Avoid steep hills (15  maximum). 4. Always check the terrain carefully before ascending any hill...

58 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before r...

59 OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 2. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 3. Slow ...

61 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board...

62 OPERATION Driving Through Water Follow these procedures when driving through water: 1. Check water depth and current before cross-ing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the...

63 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. 5...

64 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. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning...

65 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.

66 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: • Read and understand the load distribution warnings listed on the vehicle warn...

67 OPERATION Hauling Cargo Never exceed the weight capacities specified for your vehicle on warn-ing labels and in the specifications section of this manual. 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. 2. When operatin...

68 OPERATION Hauling Cargo Towing Loads Towing is approved OFF-ROAD ONLY. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road.• Do not tow any trailer on a grade steeper than 15  • Always attach a towed load to the hitch point. Remove the hitch from the ...

69 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operatio...

70 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 PO...

71 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  Perform more o...

74 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 70. 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 facto...

75 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 74 for fluid recommendations, capacities and plug torques. Oil may need to be changed more frequently if POLAR...

76 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 74 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 70. Always change the oil filter whenever changing oil. 1. P...

77 MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil fil-ter wrench (available from your POLARIS dealer), turn the filter counter-clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate...

78 MAINTENANCE Transmission Oil POLARIS recommends the use of POLARIS AGL PLUS Transmission Fluid for this transmission. See the table on page 74 for fluid recom-mendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic Maintenanc...

79 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....

80 MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 74 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 70. See page 125 for the part numbers of P...

81 MAINTENANCE Active Descent Control (ADC) Fluid Check and change the ADC fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. We recommend the use of POLARIS Demand Drive Plus Fluid for the ADC unit. Maintain the fluid level between the minimum and maximum marks ...

82 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 d...

83 MAINTENANCE Rear Gearcase Oil See the table on page 74 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 70. See page 125 for the part numbers of POLARIS products. The...

84 MAINTENANCE Power Steering Unit If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly. Steering Assembly The steering assembly of the vehicle should be checked periodically for loose nu...

85 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. See page 32. 1. View the fluid level in the bottle. 2. If the level is low, remove the bottle cap and add co...

86 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 dra...

87 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...

88 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). Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments ...

89 MAINTENANCE Seats Passenger Seat Removal 1. Pull the latch at the rear of the seat. 2. Pivot the rear of the seat upward and remove the front legs of the seat base from the frame. 3. To reinstall the seat, position the front legs of the seat base under the frame. Pivot the rear of the seat downwa...

90 MAINTENANCE Seats Passenger Seat Suspension 1. Remove the passenger seat. 2. Remove the fastener retaining the passenger seat shock to the passenger seat support. 3. Pivot the seat support upward to access the lower shock fastener. Remove the lower shock fastener. 4. Remove the shock from the veh...

91 MAINTENANCE Side Panel/Footwell Removal 1. Remove the seat before removing a side panel. 2. To remove a side panel or footwell, remove the fasteners securing it to the frame. Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Hex Head Screw Plastic Rivet

92 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this ma...

93 MAINTENANCE Tires 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....

94 MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the...

95 MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover screws, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filt...

96 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. Access t...

97 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean head-lights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight...

98 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. ...

99 MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw. Phillips Screw

100 MAINTENANCE Lights Headlight Housing Replacement 1. Remove the five (5) headlight pod screws. 2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 3. Unplug the headlamp from the wiring harness. 4. Use a small screwdriver to remove the o-rings from the headlight m...

101 MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn th...

102 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 126 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 u...

103 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 ...

104 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined...

105 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...

106 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 modifi...

108 MAINTENANCE PVT System When To Use Low Range and High Range PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat-ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow th...

109 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. Yo...

110 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 111 before installing the battery. 1. Ensure that the batter...

111 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...

112 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos....

113 MAINTENANCE Camber and Caster The camber and caster are non-adjust-able. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer. Hand...

114 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 hand...

115 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 specific...

116 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 ...

117 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow-ing items: If an informational ...

118 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...

119 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. After stabilizing the fuel, remove the spark plug and add 2-3 table- spoons of engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-mea-sured amount of oil. 2. ...

120 MAINTENANCE Cleaning and StorageAccessories 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 vehicle. Always install accessories that are approved b...

121 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 60). Driving at low RPM or ground speed (3-7 MPH) Drive at ...

122 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 Possib...

123 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 Cau...

124 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 s...

125 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 T...

126 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 Touring Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 765 lbs. (347 kg) Front Rack/...

127 SPECIFICATIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN 550 Touring Lubrication System Pressurized Wet Sump Transmission Type Automatic PVT (POLARIS Variable Transmis-sion)In-Line H-L-N-R-P Front Suspension Dual a-arm, 9" (22.9 cm) travel Rear Suspension Dual a-arm ...

128 SPECIFICATIONS * Based on EU Directive 76/432/EC SPORTSMAN 850 Touring Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 798 lbs. (362 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weig...

130 DECLARATION OF CONFORMITY POLARIS Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500April 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. PRO...

131 WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective pa...

133 WARRANTY 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, te...

134 WARRANTY 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...

135 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

137 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . . 21, 33 A Accessories . . . . . . . . . . . . . . . . . . . 120 Active Descent Control Fluid . . . 81-82 Active Descent Control System . . . . 35 ADC System . . . . . . . . . . . . . . . . . . . 35 Age Restrictions . . . . . . . . . . . . . ....