Polaris 9922581 - Manual

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, inclu...

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 Rider Safety Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. See the OPERATION section of the owner’s manual for proper operating procedures. Read and understand all warnings, cautions and operating procedures i...

13 SAFETY Rider Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always unlock the steering before starting the engine. See page 26. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Al...

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

15 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 mark...

16 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided...

17 SAFETY Safety Labels and Locations General Alert (Multi-Lingual) Before you operate this vehicle, read the owner’s manual. 7173025 Reverse Override Warning/4X4 Caution WARNINGImproper use of the override button can lead to loss of control resulting in severe injury or death. Do not activate overr...

18 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 Alert TIRE PRESSURE IN PSI (KPa): Front: 7.0 psi (48.3 kPa)Rear: 5.0 psi (34.5 kPa) MAXIMUM WEIGHT CAP...

19 SAFETY Safety Labels and Locations Clutch Cover Alert 7175826 Rack Warning, Front and Rear WARNING• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 k...

20 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch. Pressing the override switch while the throttle is open can cause loss of c...

21 FEATURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. See page 45 for s...

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

23 FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.Read this owner's manual and understand the operation of all brake s...

24 FEATURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever.5. To release the parking brake lock, squeeze and r...

25 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 33 for EPS Warning Indicator information. Automatic Transmission Gear Selec...

26 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle.1. Turn the handlebars to the full left position. Tip: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise.3. Remove the key. Ti...

27 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...

28 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before as...

29 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If...

30 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatic...

31 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation.In addition to showing vehicle speed, the instrument c...

32 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 ...

34 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override switch also acts as a MODE button whe...

35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override switch also acts a...

36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is...

37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your Polaris dealer for all major repairs. The diagnostic mode is accessible only when the check engine...

38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the ...

39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center *Assumes unipolar configuration of stepper motor SPORTSMAN 550 XP 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 Vol...

40 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 ...

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

43 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 67. Add oil if necessary to maintain the level between the safe and add ma...

44 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 Hand brake/lever travel Ensu...

45 OPERATION Starting the Engine 1. Position the vehicle on a level surface2. Place the transmission in PARK. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. 3. Sit on the vehicle. Move the engine stop switch to RUN.4. Do ...

46 OPERATION Driving Procedures 1. Wear protective riding gear. See page 14.2. Perform the pre-ride inspection. See page 44.3. Place the transmission in PARK.4. Mount the vehicle from the left side.5. Sit upright with both feet on the footrests. Keep both hands on the handlebars. 6. Start the engine...

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

48 OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:1. Slow down when entering slippery areas.2. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if t...

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

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

51 OPERATION Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Avoid backing downhill.3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles.5. Never open the throttle suddenly.6. Do n...

52 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Drive straight uphill.3. Avoid steep hills (25 ° maximum). 4. Avoid hills with slippery or loose surfaces.5. Keep both feet ...

53 OPERATION Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually.2. When fully stopped, lock the hydraulic parking brake.3. D...

54 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:1. Slow down.2. Shift body weight uphill.3. Keep your feet on the footrests.4. Avoid hills with slippery or loose surfaces.5. Avoid cros...

55 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down. 4. Drive straight downhill. Avo...

56 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle. Keep your weight uphill.2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 3. Lock th...

57 OPERATION Turning Around on a Hill (K-Turn) 9. Lock the hydraulic parking brake.10. Remount from the uphill side. Keep your weight uphill.11. Apply the foot brake.12. With the transmission still in forward, start the engine.13. Squeeze and release the brake lever to release the parking brake. 14....

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

59 OPERATION Hauling Cargo Never exceed the weight capacities specified for your vehicle 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...

60 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. Always block the rear wheels on the downhill side.

61 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...

62 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...

63 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...

66 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 62. 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...

67 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 66 for fluid recommendations, capacities and plug torques.Oil may need to be changed more frequently if Pola...

68 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 66 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 62. Always change the oil filter whenever changing oil. 1. P...

70 MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic SPORTSMAN XP Transmission Fluid for this transmission. See the table on page 66 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Period...

71 MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 66 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 62. See page 119 for the part numbers of ...

72 MAINTENANCE Rear Gearcase Oil See the table on page 66 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 62. See page 119 for the part numbers of Polaris products.The ...

73 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...

75 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...

76 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...

77 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...

78 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...

79 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level m...

80 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the ...

81 MAINTENANCE Brake Inspections The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.Perform the following checks to keep the brake systems in good operat- ing condition. Check more ...

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

83 MAINTENANCE Steering Assembly The steering assembly should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for ser- vice before operating the vehicle. Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptl...

84 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...

85 MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK.2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped). 3. Install the wheel nuts and finger-tighten them.4. Lower the vehicle to the...

86 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...

87 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...

88 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward.1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK.3. Measure the distance from the floor to the center o...

89 MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lam...

90 MAINTENANCE Lights Rear Turn Signal Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the turn signal socket counterclockwise to remove it. 3. Remove the lamp.4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. Reinstall all compon...

91 MAINTENANCE Lights Taillight/Brakelight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp.4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. Reinstall all comp...

92 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay 1. Remove the three cover screws from the right han- dlebar control and remove the cover. 2. With the han...

93 MAINTENANCE Throttle Cable Freeplay 4. Place the transmission in PARK.5. Start the engine and allow the idle to stabilize. If necessary, tap the throttle lever to ensure the idle speed settles. 6. If idle speed remains above or below the recommended setting (see specification pages), verify the c...

94 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 you...

95 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 120 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...

96 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 ...

97 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 ...

99 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 modifica...

100 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...

101 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...

102 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...

103 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 ve...

104 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 106 before installing the battery.1. Ensure that the batter...

105 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...

106 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 103. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

107 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....

108 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...

109 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...

110 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...

111 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...

112 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 62.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase• Transmission• B...

113 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 62. Battery Maintenance Remove the battery and recharge it as outlined on page 106. Store the battery i...

114 MAINTENANCE Transporting the Vehicle 1. Stop the engine.2. Place the transmission in PARK.3. Secure the fuel cap, oil cap and seat.4. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm bolt pockets, rac...

115 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range or turn around using the K-turn (see page 56). Driving at low RPM or ground speed (3-7 MPH) Drive at ...

116 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...

117 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...

118 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...

119 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 ...

120 SPECIFICATIONS * Based on EU Directive 76/432/EC SPORTSMAN 550 XP Maximum Weight Capacity 575 lbs. (261 kg) Dry Weight 732 lbs. (332 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 7.1 oz. (210 ml) Demand Drive Flui...

121 SPECIFICATIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN 550 XP 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 / 7 psi (48...

122 SPECIFICATIONS * Based on EU Directive 76/432/EC SPORTSMAN 850 XP / XP EPS Maximum Weight Capacity 575 lbs. (261 kg) Dry Weight 784 lbs. (356 kg) (XP) 796 lbs. (361 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...

124 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...

125 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR 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 par...

127 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...

128 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 TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states...

129 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

132 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . 20, 28 A Access, Front Compartment . . . . . . 27 Accessories . . . . . . . . . . . . . . . . . . 113 Active Descent Control Fluid . . . 74-75 Active Descent Control System . . . . 30 ADC System . . . . . . . . . . . . . . . . . . 30 Age Restr...