Page 2 - WARNING; The engine exhaust from this product contains
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 C...
Page 4 - Improper vehicle use can result in SEVERE INJURY or DEATH.
Pantone 426C WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle. S with a passenger - passengers affect bala...
Page 5 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles• All-terrain vehicles (ATVs)• RANGER ® utility vehicles • Victory Motorcycles ® We believe Polaris se...
Page 7 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Features and Controls . . . . . . . . . . . . . . . . . . . 26Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Emis...
Page 8 - INTRODUCTION; CAUTION; NOTICE
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 hazar...
Page 10 - Vehicle Identification Numbers; spaces provided. Remove the spare key and store it in a safe place. An
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 o...
Page 11 - SAFETY; Safety Training; encourages you and any family members who will be riding the ATV to; in the ATV; for a fee. Call ATV Enrollment Express at; FOR MORE INFORMATION ABOUT ATV SAFETY in the United
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 instruction to you about the authorize...
Page 12 - Safe Riding Gear; Helmet
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established ...
Page 13 - Eye Protection; Do not depend on eyeglasses or sunglasses for eye protection. When-; Gloves; Always wear long sleeves and long pants to protect arms and legs.; Equipment Modifications
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 marki...
Page 14 - Safety Warnings; Operating Without Instruction
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 pr...
Page 15 - Handling Gasoline; Exposure to Exhaust
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 spa...
Page 16 - Protective Apparel
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.Always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alco...
Page 17 - Operating on Pavement
13 SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.Avoid operating the ATV on pavement. ATV tires are des...
Page 18 - Physical Control of the ATV
14 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it co...
Page 19 - Descending Hills Improperly
15 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.• Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill. S...
Page 20 - Stalling While Climbing a Hill
16 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.• Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page ...
Page 21 - Operating on Slippery Terrain
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. Always use extra cau...
Page 22 - Operating Improperly in Reverse
18 SAFETY Safety Warnings 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 63. Before shifting into reverse gear, always check for obstacles or people...
Page 23 - Operating Over Obstacles
19 SAFETY Safety Warnings 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 foll...
Page 24 - Improper Cargo Loading
20 SAFETY Safety Warnings 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.•...
Page 25 - Operating a Damaged ATV; Hot Exhaust Systems
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 S...
Page 26 - Safety Labels and Locations; labels shown in this manual differ from the labels on your vehicle,; General Warning
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 ...
Page 27 - Age 16 Warning
23 SAFETY Safety Labels and Locations Discretionary Warning WARNING• Never operate this ATV on HILLS steeper than 25 degrees 25 ° . To pre- vent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering be...
Page 28 - “No Passenger” Warning
24 SAFETY Safety Labels and Locations “No Passenger” Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNINGImproper tire pressure or overloading can cause loss of control. Loss of control can re...
Page 29 - Clutch Cover Warning; Rack Warning, Front and Rear
25 SAFETY Safety Labels and Locations Clutch Cover Warning WARNING• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, whic...
Page 30 - FEATURES AND CONTROLS; Switches; Mode/Reverse Override Switch; the override button.; The reverse override button also acts as a MODE button when held
26 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button. WARNING! Pressing the override button while the throttle is open can cause ...
Page 31 - Engine Stop Switch
27 FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. Move the stop switch to the RUN position before attempt- ing to start the engine. The engine will not start or run when the switch is off.Both the main switc...
Page 32 - Throttle Lever
28 FEATURES AND CONTROLS Throttle Lever Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.Failure to...
Page 33 - Brake Lever
29 FEATURES AND CONTROLS Brake Lever Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward ...
Page 34 - Master Cylinder/Brake Fluid
30 FEATURES AND CONTROLS Master Cylinder/Brake Fluid An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, m...
Page 35 - Parking Brake; Locking the Parking Brake
31 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever.5. To release the parking brake ...
Page 36 - Auxiliary Foot Brake; reduce; Brake Fluid Level
32 FEATURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake ...
Page 37 - Automatic Transmission Gear Selector; Belt Life; Fuel Tank; Do not use fuel
33 FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 39 for EPS Warning Indicator information. Automatic Transmission Gear Selec...
Page 38 - All Wheel Drive System
34 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...
Page 39 - The 4X4 switch may be turned on or off while the vehicle is moving.
35 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If...
Page 40 - The ADC system allows engine braking to all four wheels when the; Engaging Active Descent Control; The ADC system will automatically engage when; Disengaging Active Descent Control; The ADC system will automatically disengage if
36 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...
Page 41 - Instrument Cluster
37 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation.In addition to showing vehicle speed, the instrument clust...
Page 42 - Rider Information Center; Gear Indicator; - This indicator displays gear shifter position.; Information Display Area; ters, engine hour meter and programmable service hour interval.
38 FEATURES AND CONTROLS Instrument Cluster 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 ...
Page 44 - Speed Display Area; Use the MODE button to toggle; Ground Speed Mode
40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override button also acts as a MODE button whe...
Page 45 - Standard/Metric Display
41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override button also acts a...
Page 46 - Method 1
42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is...
Page 47 - engine warning indicator appears in the display.; See pages 44-47 for code definitions and failure descriptions.
43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your Polaris dealer for all major repairs. The diagnostic mode is accessible only when the check engine...
Page 48 - Diagnostic Display Code Definitions; Sportsman 550 XP / XP EPS Diagnostic Codes
44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the ...
Page 50 - Sportsman 850 XP / XP EPS Diagnostic Codes
46 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman 850 XP / XP EPS 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 ...
Page 52 - Front Rack/Compartment
48 FEATURES AND CONTROLS Front Rack/Compartment Release the front rack latches and remove the rack to gain access to the front compart- ment. To reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches.Acc...
Page 53 - OPERATION; Engine and Drivetrain Break-in
49 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 ...
Page 54 - ATV before each use to make sure it's in safe operating condition.; Item
50 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 Brake system/lever travel Ensure prope...
Page 55 - Safe Operation Practices
51 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. Never carry a p...
Page 56 - Know Your Riding Area/Tread Lightly; terrain, avoid littering, and always stay on the designated trails.; Trail Etiquette; Always practice good etiquette when riding. Allow a safe distance
52 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...
Page 57 - Starting the Engine; Cold Weather Operation
53 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 engag...
Page 58 - Driving Procedures; brakes on level surfaces.
54 OPERATION Driving Procedures 1. Wear a helmet and eye protection.2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear.5. Check your surroundings and determine your path of travel.6. Releas...
Page 59 - Turning the Vehicle
55 OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.To ...
Page 60 - Driving on Slippery Surfaces; Never apply the brakes during a skid. Correct a skid by turning the
56 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 whe...
Page 61 - Driving Uphill; throttle suddenly could cause the ATV to flip over backwards.
57 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. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. S...
Page 62 - unavoidable
58 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. Shi...
Page 63 - Driving Downhill; may cause the rear wheels to lock, which could result in loss of con-
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 36. 2. Avoid steep hills (25 ° maximum). 3. Shift body weight uphill.4. Drive straight downhill.5. Slow down. Excessive speed when tr...
Page 64 - cle is pointing straight uphill.
60 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop 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. ...
Page 65 - Driving Through Water; If it’s unavoidable to enter water deeper than the footrest level:
61 OPERATION Driving Through Water Your ATV can operate through water with a maximum recom- mended depth equal to the bot- tom of the footrests. Follow these precautions when operat- ing through water:1. Determine water depths and current before entering water. 2. Choose a crossing where both banks ...
Page 66 - Driving Over Obstacles; ards such as logs, rocks and low hanging branches.
62 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 us...
Page 67 - Driving in Reverse; lightly
63 OPERATION Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.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...
Page 68 - Hauling Cargo
64 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:REDUCE SPEED AND ALLOW GREATER DIST...
Page 69 - Towing Loads
65 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 evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possi- ble. When operating over rou...
Page 70 - Parking on an Incline
66 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.
Page 71 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; Do not modify the engine, intake or exhaust components, as doing so; Crankcase Emission Control System; are forced back to the combustion chamber by the intake system. All; Exhaust Emission Control System; ponents are set at the factory for optimal performance and are not; Electromagnetic Interference
67 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...
Page 72 - MAINTENANCE; Periodic Maintenance Chart; serviced more frequently.; Severe Use Definition; cause or see your dealer.
68 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace par...
Page 73 - Maintenance Chart Key
69 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these op...
Page 76 - Lubrication Guide
72 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 68. Items not listed in the chart should be lubricated at the General Lubrication interval.The a-arms and lower control arms are lubricated at the facto...
Page 77 - Engine Oil; Oil Recommendations; PLUS; Oil Level; Never check the
73 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 72 for fluid recommendations, capacities and plug torques.Oil may need to be changed more frequently if Pola...
Page 78 - Oil and Filter Change; oil filter whenever changing oil.; on drain plug and crankcase should be clean and free of burrs, nicks
74 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 72 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 68. Always change the oil filter whenever changing oil. 1. P...
Page 80 - Transmission Oil; Oil Check
76 MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP Trans- mission Fluid for this transmission. See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Peri...
Page 81 - Fluid Check
77 MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 72 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 68. See page 125 for the part numbers of ...
Page 82 - Rear Gearcase Oil; Do not overfill
78 MAINTENANCE Rear Gearcase Oil See the table on page 72 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 68. See page 125 for the part numbers of Polaris products.The ...
Page 83 - Oil Change; Remove the fill plug. Add the proper amount of the recommended
79 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 pl...
Page 85 - Fluid Change
81 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...
Page 86 - Power Steering Unit
82 MAINTENANCE Power Steering Unit If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly. Cooling System The engine coolant level is controlled by the recovery system. Recovery system comp...
Page 87 - Cooling System; Recovery Bottle Coolant; coolant level between the minimum and maximum marks on the
83 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 rack.3. Remo...
Page 88 - Radiator Coolant; ant through the radiator filler
84 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 drai...
Page 89 - Brakes; Hand Brake
85 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...
Page 90 - Toe Alignment; Steering Assembly
86 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...
Page 91 - Seat Removal; Grasp one side of the seat; Side Panel/Footwell Removal
87 MAINTENANCE Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. Remove the seat. Side Panel/Footwell Removal Remove the seat before removing a side panel.Remove the screws and rivets securing the side panel or footwell (...
Page 92 - Tires; Tire Tread Depth; Always replace tires
88 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...
Page 93 - Front Wheel Hub Tightening
89 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.4...
Page 94 - Wheel Installation; Wheel Nut Torque Specifications; ened for maintenance service.; Wheel Type; Cast Aluminum
90 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...
Page 95 - Air Filter
91 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 filter...
Page 96 - Fuse Replacement; install a new fuse with the same amperage rating.; Fuse Box
92 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 t...
Page 97 - Lights; Headlight Lamp Replacement
93 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 Rep...
Page 98 - High Beam Adjustment
94 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. M...
Page 99 - Low Beam Adjustment; The low beam can be adjusted
95 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
Page 100 - Headlight Housing Replacement
96 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 mo...
Page 101 - Lower Headlamp Replacement
97 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 ...
Page 102 - Spark Plugs; Spark Plug Recommendations; Spark Plug Inspection; Plug Condition
98 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...
Page 103 - Normal Spark Plug; end. There may be a carbon layer over the entire nose. Generally, the
99 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 ...
Page 104 - Vehicle Immersion; filter with a new filter.
100 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 bel...
Page 105 - Spark Arrestor
101 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...
Page 106 - PVT System
102 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 modific...
Page 107 - force exerted on the movable drive sheave by the flyweights also
103 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to th...
Page 108 - When To Use Low Range and High Range; stall the drain plug.; Condition
104 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 the...
Page 109 - Battery; cleaning solution or tap water into a conventional battery.
105 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. Ba...
Page 110 - Battery Removal; battery sideways, which could spill electrolyte.
106 MAINTENANCE Battery Battery Removal 1. Remove the seat.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery cable last.4. Disconnect the battery hold-down strap.5. On conventional batteries, remove the battery vent tube.6. Lift the battery out of the AT...
Page 111 - Battery Installation; teries do not have a vent tube). The vent tube must be free of
107 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 109 before installing the battery.1. Ensure that the batter...
Page 112 - Battery Storage
108 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...
Page 113 - fully charged
109 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 106. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...
Page 114 - State of
110 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....
Page 115 - Cleaning and Storage; Washing the Vehicle; but it can also extend the life of various components.; and the lower parts last.; Washing Tips
111 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden h...
Page 116 - safety; Polishing the Vehicle; Polishing Tips
112 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...
Page 117 - Removing Corrosion
113 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscep...
Page 118 - Storage Tips; Clean the Exterior; Follow the instructions on the container for the recommended; Oil and Filter
114 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and then clean the vehic...
Page 119 - Fluid Levels
115 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 68.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase• Transmission• B...
Page 120 - Inspect and Lubricate; in the Periodic Maintenance Chart beginning on page 68.; Battery Maintenance; may promote corrosion and oxidation.; Accessories; install accessories that are approved for ATV use. Please see your
116 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 68. Battery Maintenance Remove the battery and recharge it as outlined on page 109. Store the battery i...
Page 121 - Transporting the ATV; with suitable straps or rope. Do not attach tie straps to the front A-
117 MAINTENANCE Transporting the ATV 1. Stop the engine.2. Place the transmission in PARK.3. Lock the parking brake.4. Secure the fuel cap, oil cap and seat.5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm...
Page 122 - ADJUSTMENTS; Throttle Body/Idle RPM; While
118 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay 1. Remove the three cover screws from the right han- dlebar control and remove the cover. 2. With the ha...
Page 123 - Throttle Cable Freeplay
119 ADJUSTMENTS 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 specifica...
Page 124 - Camber and Caster
120 ADJUSTMENTS 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 yo...
Page 125 - TROUBLESHOOTING; Possible Cause
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 ...
Page 126 - Engine Doesn't Turn Over
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...
Page 127 - Engine Pings or Knocks
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...
Page 128 - Engine Stops or Loses Power
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...
Page 129 - POLARIS PRODUCTS; Part
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 2877606 Synthetic ...
Page 130 - SPECIFICATIONS; Sportsman 550 XP / XP EPS
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 XP / XP EPS Maximum Weight Capacity 575 lbs. (261 kg) Dry Weight 730 lbs. (331 kg) (XP) 744 lbs. (337.5 kg) (XPS) Fuel Capacity 5.25 gal. (20...
Page 131 - Clutching
127 SPECIFICATIONS Clutching *EBS models require no helix/spring adjustment Sportsman 550 XP / XP EPS 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 Drive Ratio, Rear 3.7:1 Tires/Pressure, Front 26x8-14 AT / ...
Page 132 - Sportsman 850 XP / XP EPS
128 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 850 XP / XP EPS Maximum Weight Capacity 575 lbs. (261 kg) Dry Weight 767 lbs. (348 kg) (XP) 781 lbs. (354 kg) (XP EPS) Fuel Capacity 5.25 gal. (20 l) (XP) 4.5 gal. (17 l) (XP EPS) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts...
Page 134 - DECLARATION OF CONFORMITY
130 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 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 IDENTIFIC...
Page 135 - WARRANTY; LIMITED WARRANTY; REGISTRATION
131 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED 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 for...
Page 137 - LIMITATIONS OF WARRANTIES AND REMEDIES
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...
Page 138 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
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 state...
Page 139 - Exported Vehicles; How to Get Service
135 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 ex...
Page 140 - Notice
136 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. Notice If your vehicle is reg...
Page 143 - MAINTENANCE LOG
139 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
Page 146 - INDEX
142 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . 26, 34 A Access, Front Compartment . . . . . . 48 Accessories . . . . . . . . . . . . . . . . . . 116 Active Descent Control Fluid . . . 80-81 Active Descent Control System . . . . 36 ADC System . . . . . . . . . . . . . . . . . . 36 Air Filte...