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Polaris 9922581 Offroad Vehicle User Manual

1. Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 116 Engine Pings or Knocks TROUBLESHOOTING Possible Cause Poor qualitv or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregulariv Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low batterv voltage Recharge batterv to 12 8 VDC Kinked or plugged fuel tank vent line Incorrect fuel Inspect and replace Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed lim
2. 114 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 ata higher speed or use low range more frequentiv See page 101 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easv clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 101 Inspect clutch
3. Component Condition SPN FMI Chassis Relav Driver Circuit Open Grounded 520208 5 Driver Circuit Short to 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 520207 3 Driver Circuit Grounded 520207 4 Svstem Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safetv Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Open Grounded 520203 5 Driver Circuit Short to B 520203 3 Driver Circuit Grounded 520203 4 Idle Speed Speed Too High 520211 3 Speed Too Low 520211 4 EPS Models Only Steering Over Current Shut Down Current Above Normal Grounded 520221 6 Steering Excessive Current Error Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Partial T1 Shorted to Ground 520223 4 Failure T1 Shorted to Bus 520223 3 Steering Torque Sensor 2 Partial 2 Shorted to Ground 520224 4 Failure T2 Shorted to Bus 520224 3 Steering Torque Sensor Full T1 and T2 Shorted to Ground 520225 4 Failure T1 and T2 Shorted to Bus 520225 3 T1 Shorted to Ground amp T2 520225 16 Shorted to Bus T2 Shorted to Ground amp T1 520225 17 Shorted to Bus T1 and T2 are Shorted 520225 2 Steering Position Sensor P1 P1 Shorted to Ground 520226 4 Partial Failure P1 Shorted to Bus 520226 3 Steering Position
4. 25 Transmission Oil 70 Transporting the Vehicle 114 Turn Signal Lamp Rear 90 Turn Signal Switch 21 Turning Around ona Hill 56 57 Turning the Vehicle 47 V Vehicle Identification Numbers 5 Vehicle Immersion 97 Warning Symbols 4 Washing the Vehicle 108 109 Wheel Hub Tightening 84 Wheel Installation 85 Wheel Nut Torque Specifications 85 Wheel 84
5. 24 Brakelight 91 23 24 Break In Period 42 43 Camber Adjustment 94 win uoo aa Ee weiss 58 59 Caster Adjustment 94 Chrome Wheel Care 110 Cleaning and Storage 108 113 Clothing 15 132 Clutching 550 121 Clutching 850 XP 123 Cold Weather Operation 45 Coolant 77 Coolant Radiator 78 Cooling System 76 78 Corrosion Removal Chrome 110 D Demand Drive Fluid 71 Diagnostic Codes 550 XP EPS 39 Diagnostic Codes 850 XP EPS 40 41 Disengaging Active Descent Control 30 Display Standard Metric 35 Drive Belt Wear Burn 115 Drivetrain Break In 43 Driving Downhill 55 Driving in Reverse 51 Driving on a Sidehill 54 Driving on Slipperv Surfaces 48 Driving Over Obstacles 50 Driving Procedures 46 Driving Through Water 49 Driving Uphill 52 53 E Electromagnetic Interference 61 Electronic Power Steering 25 Electronic Throttle Control 22 Engaging 4X4 29 Engaging Active Descent Control 30 Engine Break In 43 Engine Fogging 112 Engine 67 69 EPS Sse A aa Wakes st
6. Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter svstem To gain additional wheel speed while backing release the throttle and depress the override switch A Pressing the override switch while the throttle is open can cause loss of control which result in serious injurv or death Alwavs release the throttle before pressing the override switch The reverse override switch also acts asa MODE button when held down for approximatelv one half second The transmission cannot be in reverse when using the override switch asa MODE button 4 4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 30 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Hazard Warning Switch A Push the hazard warning switch to cause all turn signal lights to flash simultaneously Use this feature to alert others of an emergency or other situation requiring caution 20 FEATURES AND CONTROLS Switches Main Kev Switch q End all electrical power to the vehicle D LIGHTS ON position turns the headlights on G Start the engine The headlights are not on in this position 20 0 After starting the engine release the key switch to the POSITION LIGHTS ON position See page 45 for starting procedures Engine Stop Switch Light Engine The engine will not start or run when Switch Stop Switch the switch 1s in the OFF position 9 OFF E
7. 17 Hitch Capacity Label 19 Rack Warning Front and Rear 19 Reverse Override Warning 17 Tire Pressure Load Alert 18 Safety Training 6 Severe USE osse 62 Side Panel Removal 83 Sidehilling L 54 Signal 4 Spark Arrestor 98 Spark Arrestor Requirements 61 Spark Plug Inspection 95 96 Spark Plug Recommendations 95 Spark Plugs 95 96 Spring Adjustment Shock 94 Standard Metric Display 35 Starting the Engine 45 Steering Assemblv 83 Steering 26 usse esee lata 108 113 Storage 111 113 134 S Switches 4X4 Switch 20 28 Engine Stop Switch 21 Hazard Warning 20 Headlight Switch 21 lolo Pn 21 Main Key Switch 21 Mode Switch 20 Reverse Override Switch 20 Stop Switch 21 Turn Signal 21 T Taillight eres 9 Throttle Body Adjustment 92 Throttle Cable Freeplav 92 93 Throttle 22 Tire Tread Depth 84 Tires E 84 85 Wheel Installation 85 Wheel Nut Torque 85 Wheel Removal 84 Toe Alignment 82 Towing Loads 59 Training 6 Transmission Gear Selector
8. Pantone 426 C Sportsman 550 XP Sportsman 850 XP Sportsman 850 XP EPS Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age 100 RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW wey CD CED lt gt ED CPD Pantone 426 C Before you operate this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehiculo lea el Manual del Propietario Lire le manuel du propri taire avant d utiliser ce v hicule Prima di usare il veicolo leggete il manuale di istruzioni Lue aina k ytt ohjekirja ennen taman ajoneuvon k ytt Antes de utilizar este veiculo leia o manual do proprietario Innan du kor detta fordon las handboken 7173025 PELARIS For your nearest Polaris dealer The Way Out visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9922581 Rev 02 Printed in U S A WELCOME Thank vou 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 e RANGER utility vehicles Victory Motorcycles Always follow the instructions and recommendati
9. RUN Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position Hom Turn Signal D High Beam Switch Switch 2D Low Beam Turn Signal Switch t Push the toggle switch either left or right to activate the corresponding turn signal light The indicator on the pod will also flash Return the toggle to the center position and push it inward to end the signal Horn Switch box Press the horn switch to sound the horn 21 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers Alwavs check and adjust the mirrors before driving Throttle Lever A Failure to check or maintain proper operation of the throttle svstem can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate the vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to Electronic Throttle Control increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement Electronic Throttle Control ETC ETC causes the engine to stop if the throttle cable sticks in an open posi tion when the operator releases the throttle lever A The Electronic Throttle Control ETC stops the engine in th
10. Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 23 58 Red Black Red White 52 BA 500 Feet 0 6000 PN 5632218 PN 7043500 PN 3235621 PN 3234620 1800 3700 23 54 Red Black Red White 52 BA 500 6000 12000 PN 5632219 PN 7043500 PN 3235621 PN 3234620 EBS models require no helix spring adjustment 121 SPECIFICATIONS SPORTSMAN 850 XP XP EPS Maximum Weight Capacity 575 Ibs 261 kg Dry Weight 784 Ibs 356 kg XP 796 Ibs 361 kg XP EPS Fuel Capacity 5 25 gal 20 1 XP 4 5 gal 17 1 XP EPS Engine Oil Capacity 2 qts 1 9 1 Coolant Capacitv 2 qts 1 9 1 Rear Gearcase Oil Capacity 7 1 oz 210 ml Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 950 ml Front Rack Storage Box Capacity 120 165 54 kg Rear Rack Capacity 240 Ibs 109 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear rack load and tongue weight not to exceed 240 Ibs 109 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO850LE Displacement 850 cc
11. Careful periodic maintenance will help keep vour 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 parts as necessarv When inspection reveals the need for replacement parts use genuine Polaris parts available from vour Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 129 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 62 MAINTENANCE Periodic Maintenance Chart A I
12. PN 7043349 PN 3235621 PN 3234620 1800 3700 24 60 Red White Red White 52 BA 500 6000 12000 PN 5632216 PN 7043349 PN 3235621 PN 3234620 EBS models require no helix spring adjustment 123 DECLARATION OF CONFORMITV 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 safetv requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinerv Directive EN 1050 hazard analvsis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 M92 EN 55012 2002 EN 61000 6 2 2001 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A KA05 OUTLAW 50 2008 2009 2010 76 8 _ KAO OUTLAW 90 2008 2009 2010 76 8 FA09 SPORTSMAN 90 2008 2009 2010 76 8 O VAM RZR 170 2009 2010 813 PB20 __ PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 CA3 _ TRAIL BOSS 330 2008 2009 2010 76 8 BAS0 SCRAMBLER 500 2008 2009 2010 79 6 G OUTLAW 450 2008 2009 2010 80 7 GJS2 GP52 OUTLAW 525 2008 2009 2010 80 7 OLH27 SPORTSMAN 300 2008 2009
13. you if inconsistent with controlling state law 127 WARRANTV ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITV 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 do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris dealer authorized to repair Polaris vehicles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 128 MAINTENANCE LOG Present this section of your manual to your dealer eac
14. 50 H 6M 1000 1600 Inspect for leaks gt Engine oil change 100 H 6M 1000 1600 Change the oil and filter gt Demand drive fluid 100 12M 1000 1600 Change fluid gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe t Spark plug 100 H 12M 1000 1600 Inspect replace as needed gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc W Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts W Front wheel 100 H 12M 1000 1600 jInspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years gt ADC fluid 200 H 24M 2000 3200 Change every two years everv 25 hours if extreme use conditions see page 74 Spark arrestor 300 H 36M 3000 4800 Clean out E Valve clearance 1000 H 10000 Inspect adjust E 16000 E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 65 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on pag
15. A An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 106 Batterv MAINTENANCE Batterv Charging Sealed Batterv Always verify battery condition before and 1 2 hours after the end of charging State of Charge Tune Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts need slight 3 6 hours charge if no charge given check in 3 months 5 11 hours 50 75 12 0 12 5 volts Needs charge 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 096 2596 11 5
16. 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 A Always follow the procedures outlined in this manual for operating over obstacles 50 OPERATION Driving in Reverse Follow these precautions when operating in reverse Alwavs check for obstacles or people behind the vehicle Avoid backing downhill Drive slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override switch unless additional wheel speed is required for vehicle movement Use with caution NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Qvcph ms DA Mar A Always follow the procedures outlined in this manual for driving in reverse 51 OPERATION Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions 1 es ta UK l 9 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 Drive straight uphill Avoid steep hills 25 maximum Avoid hills with slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed to avoid stalling Be alert Be prepared to take emergency action This may include dismounting quickly Never op
17. chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 110 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created bv fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessarv repairs and then clean the vehicle as recommended See page 108 Stabilize the Fuel 1 Fillthe fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to a
18. cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine ESSSOPLE Displacement 549 7 cc Bore x Stroke 96 6 x 75 Alternator Output 490w 1350 RPM Peak 630w Compression Ratio 9 6 1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1650 100 RPM Ignition Timing 13 3 BTDC 1350 RPM Engine warm Spark Plug Gap NGK BKRGE 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension Dual a arm with 9 2 23 cm travel Rear Suspension Progressive rate with 10 2 26 cm travel Based on EU Directive 76 432 EC 120 SPECIFICATIONS 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 3 kPa Tires Pressure Rear 26x10 14 5 psi 34 5 kPa Brakes Hand Lever All wheel hydraulic disc Brakes Foot All wheel hydraulic disc Brake Parking Transmission park lock and hydraulic lock all wheel Headlight 2 Hi Lo beam on bumper 37 5 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital LCD LED Clutching
19. end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 96 MAINTENANCE Vehicle Immersion If vour vehicle becomes immersed major engine damage can result if the machine is not thoroughiv inspected Take the vehicle to vour dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure 7 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 101 for drying out the PVT 97 MAINTENANCE Spark Arrestor A Failure to heed the following warnings while servicing the spark arrestor could result in serious injurv or death Never run the engine in an enclosed area Remove anv combustible materials from the area Wear eve protection and leather work gloves Do not stand b
20. exercise extreme caution whenever handling gasoline Check the engine oil level on the dipstick See page 67 Add oil if necessary to maintain the level between the safe and add marks Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 44 Pull only light loads Change both the oil and the filter at 20 hours one month or 500 miles 800 km whichever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 43 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 Alwavs inspect the vehicle before each use to make sure it s in safe operating condition Item Remarks Page Hand brake lever travel Ensure proper operation 81 Foot brake Ensure proper operation 81 Brake fluid Ensure proper levels 79 Front susp
21. fire explosions or any other cause beyond Polaris control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time 126 WARRANTV LIMITATIONS OF WARRANTIES AND REMEDIES This warrantv also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfection
22. footwell Oil Change 1 Remove the footwell 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Fill Plug Drain Plug Clean and reinstall the drain plug Torque to specification B Remove the fill plug Add the proper amount of the recommended oil Reinstall the fill plug Torque to specification Check for leaks Reinstall the footwell Dispose of used oil properly Qo 70 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 Polaris products Use the recommended fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads See below for capacity The fill plug is located on the right side of the S demand drive unit The 2 drain plug is located on the 0 Fill bottom right side of the Level unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level Eu 2 Add the recom 9 mended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Torque to specification Fluid Change 1 Position the vehicle on a
23. for turning Never turn sharplv at excessive speeds which can lead to vehicle 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 Steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest Use the same leaning tech nique for turning in reverse Practice making turns at slow speeds before attempt ing to turn at faster speeds overturn OPERATION A 47 OPERATION Driving on Slipperv Surfaces Sideways Turn in direction Skid of skid O O RA AY O 7 gt l Msc L 6 y x D 4 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 the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 3 Be alert Watch the trail Avoid quick sharp turns Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward A Always follow the procedures outlined in this manual for operating on s
24. level surface Remove the fill plug VA Drain Plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended fluid Reinstall the fill plug Torque to specification eU de c Check for leaks Dispose of used fluid properly 71 MAINTENANCE Rear Gearcase Qil 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 fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Fill Maintain the fluid level atthe Level bottom of the fill hole threads Do not overfill Oil Check 1 Position the vehicle on a m level surface L 2 Remove the fill plug Fill Plug Check the oil level Drain Plug 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to specification 72 MAINTENANCE Rear Gearcase 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
25. on a level surface The headlight should be approximately 7 6 m from a wall Place the transmission in PARK 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 4 Start the engine Turn the head light switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the three 3 headlight screws to adjust the beam upward or downward or to the left or right Screws 88 MAINTENANCE Lights A Poor lighting can result in loss of control or an accident Lights become dirtv 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 Lamp Replacement When servicing a halogen lamp do not touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK 2 Open the front rack cover 3 Remove the plug at the back of the headlight 4 Pull the harness plug to disconnect it from the back of the headlight 5 Position light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and rem
26. seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 43 115 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Solution Low batterv voltage Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter See your dealer Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires
27. used the fuel tank fuel lines and injectors should be completely drained of gasoline 112 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 Batterv Maintenance Remove the batterv and recharge it as outlined on page 106 Store the batterv in a cool drv place Storage Area Covers Set the tire pressure and safely support the vehicle with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your vehicle Always install accessories that are approved by Polaris for use on this vehicle 113 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 racks or handlebars 5 Remove the key to prevent loss during transporting
28. 2010 81 1 LH46 SPORTSMAN 400 2008 2009 2010 802 MN50 SPORTSMAN 500 EFI 2008 2009 2010 804 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55 _DNSS SPORTSMAN X2 TOURING 550 2010 712 MN 76 SPORTSMAN 800 2008 2009 2010 83 6 TN85 DN85 SPORTSMAN X2 TOURING 850 2010 712 CLI6 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85 7 85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HH76 RANGER 800 EFI 4X4 2010 76 5 WH76 RANGER 800 EFI CREW 2010 76 5 HR RANGER 800 6X6 2010 76 5 HY _ RANGER HD 800 4X4 2010 76 5 _ VH76 RANGER RZR 2008 2009 2010 85 8 Authorized Signatory Vr A T h Pamata Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 124 WARRANTV LIMITED WARRANTV Polaris Industries Inc 2100 Highwav 55 Medina MN 55340 givesa TWO VEAR LIMITED WARRANTV onall components of the Polaris vehicle against defects in material or workmanship This warrantv covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon recei
29. Bore x Stroke 87 x 71 5 Alternator Output 475w 01200 RPM Peak 575w Compression Ratio 11 1 Starting Svstem Electric Ignition Svstem Electronic Fuel Injection Idle RPM 1200 100 RPM Ignition Timing 6 5 BTDC 1200 RPM Engine warm Spark Plug Tvpe Gap Champion REA6MC 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension Dual a arm with 9 2 23 cm travel Rear Suspension Progressive rate with 10 2 26 cm travel Based on EU Directive 76 432 EC 122 SPECIFICATIONS SPORTSMAN 850 XP XP EPS Transmission H L N R P Gear Reduction Low 5 034 1 Gear Reduction Reverse 4 508 1 Gear Reduction High 2 367 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 7 1 Tires Pressure Front 26 8 14 7 psi 48 3 kPa Tires Pressure Rear 26x10 14 AT 5 psi 34 5 kPa Brakes Hand Lever All wheel hvdraulic disc Brakes Foot All wheel hvdraulic disc Brake Parking Transmission park lock and hvdraulic lock all wheel Headlight 2 Hi Lo beam on bumper 37 5 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital LCD LED Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 24 63 Red White Red White 52 BA 500 Feet 0 6000 PN5632215
30. H 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1600 1800 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc 100 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain Swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply varying throttle for 10 15 seconds to expel t
31. LT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on road Equipment Modifications The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power A The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only Polaris approved accessories Know their function and effect on the vehicle SAFETV Rider Safetv AWARNING 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 A 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 Contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com Never permit others to operate the vehicle unless they have read and understand this manual and all produc
32. 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 550 Drain OQ alil lt q to front o Plug Filter Access 1 Position the vehicle on a level surface Place the transmission in PARK 2 Start the engine Allow it to warm up at idle for two to three min utes Stop the engine Clean the area around the drain plug Place a drain pan under the crankcase ae Remove the drain plug Allow the oil to drain completelv A Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to specification 68 MAINTENANCE Engine Oil Oil and Filter Change 9 10 11 12 13 14 15 16 17 18 19 20 Place shop towels beneath the oil filter Using an oil filter wrench available from vour Polaris dealer turn the filter counter clockwise to remove it Using a clean drv cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure
33. S 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 cluster also dis plays the following items engine speed odometer resettable trip meters 2 total engine hours of operation service interval timer and indicator gear position fuel level AWD status EPS status if equipped high beam status battery voltage warning temperature warning and diagnos tic display mode These features are outlined on the following pages Directional Indicator Rider Information Center EPS Warning Indicator if equipped Neutral Over Temperature Indicator Indicator 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 alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster seg ments will light up for one second at start up If the instrument cl
34. Sensor P2 P2 Shorted to Ground 520227 4 Partial Failure P2 Shorted to Bus 520227 3 Steering Position Sensor Full P1 and P2 Shorted to Ground 520228 4 Failure P1 and P2 Shorted to bus 520228 3 EPAS Inverter Temperature Greater than 110 Degrees C 520229 16 Greater than 120 Degrees C 520229 0 EPAS CAN Comm Receive Error No RX Message for 2 Seconds 520230 9 EPAS CAN Comm Transmit Error No TX Message for 2 Seconds 520231 9 41 OPERATION A 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 your new Polaris vehicle is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 42 OPERATION Break In Period Engine and Drivetrain Break in 1 2 Fill the fuel tank with gasoline See page 26 Always
35. The PVT svstem has been precision balanced Anv modification will cause the svstem to be out of balance creating vibration and additional loads on components The PVT svstem rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safetv of this product However as the owner vou have the following responsibilities to make sure this svstem remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 99 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of cen trifugal force decreases reducing the amount of belt pinch The approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT espe cially at speeds less than 7 MPH 11 km h due to the system s depen dence on engine speed For example when operating at a ground speed of 3 MP
36. a 25 EPS Warning Indicator 33 Equipment Modifications 6 Exhaust Emission Control System 61 Eye 15 F Fluid ADC 74 75 Brake Fluid 79 80 Demand Drive Fluid 71 Engine Qil 67 Fluid Change ADC Fltides ccc e ee taw 75 Demand Drive Fluid 71 Engine Qil 68 69 Foot Brake Auxiliarv 23 Footwell Removal 83 Front Compartment 27 Front Gearcase Demand Drive 71 Front Rack Compartment 27 Fuel Tank 26 Fuse Replacement 87 G Gear 5 1 25 Gearcase Oil Rear 72 73 GIOV6S sce eee cee ee Aes 15 H Hand 80 Handlebar Adjustment 94 Hauling Cargo 58 59 Hazard Warning Switch 20 Headlight Lamp 89 Headlight Switch 21 Helmet ive IRIS 14 High Range Use 101 Horn Switch 21 l Idle RPM Adjustment 92 97 Instrument Cluster 31 41 K Key Switch 21 i RS 56 57 INDEX L DAIS 88 91 Headlight Beam Adjustment 88 Headlight Lamp 89 Position Light Lamp 89 Rear Turn Signal 90 Taillight Brakelight Workl
37. a level surface Before performing the fluid change allow the vehicle Cap to sit for at least 30 minutes Bleeder Thoroughly clean the areas Valve around and on the ADC reservoir and bleeder valves one on each side of the differential Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reservoir Debris in the reservoir may result in inadequate bleeding and reduced performance of the system Fill the reservoir to the maximum line with fresh recommended fluid Remove the protective caps from the bleeder valves Slowly loosen one of the screws turn counter clockwise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped air If the level drops below the minimum line add fluid to the maximum line and repeat step 6 before proceeding 7 8 Torque the valves to 80 in lbs 9 Nm Reinstall the valve caps Add fresh recommended fluid to the reservoir until the level is between the minimum and maximum marks Make sure the reser voir is free of debris Reinstall the cap securely Clean up any drips or spills 75 MAINTENANCE Power Steering Unit If your model is equipped with powe
38. ake Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 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 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground A Always follow the procedures outlined in this manual for driving on hills See page 52 Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 57 OPERATION H auling Cargo A 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 58 Read and understand the load distribution warnings listed on the vehicle warning labels Never exceed the stated load capacity for this vehicle When determining the weight you are adding to the vehicle include th
39. anual A Keep both hands on the handlebars Keep both feet on the footrests A Always travel slowly when operating on unfamiliar terrain Use extra caution A Always follow the procedures outlined in this manual for turning See page 47 Never turn sharply at excessive speeds which can lead to vehicle overturn A If the vehicle has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems SAFETV Rider Safetv A Never attempt jumps or other stunts A Always follow the procedures outlined in this manual for driving on hills See page 52 Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill A Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 55 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 54 Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual See page 56 10 SAFETV Rider Safetv A Always follow the procedures outlined in this manual for braking if vou stall or roll backw
40. ards while climbing a hill Never back down a hill See page 53 A Always follow the procedures outlined in this manual for operating over obstacles See page 50 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 48 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 49 A Always follow the procedures outlined in this manual for driving in reverse See page 51 11 SAFETV Rider Safetv A Alwavs use the size and tvpe of tires specified for vour vehicle Maintain the proper tire pressure A Never modifv this vehicle through improper installation or use of accessories A Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking A Never operate the vehicle on a frozen body of water A Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control Avoid sudden turns or swift movement of the handlebars 12 SAFETV Rider Safetv A Alwavs remove the ignition kev when the vehicle is not in use to prevent unauthorized use or acciden
41. d clutch damage 7175512 A Hill Operation Alert Never operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually 7173026 17 SAFETV Safetv Labels and Locations No Passenger Warning Tire Pressure Load Warning Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 A 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 CAPACITY 575 Ibs 261 kg INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES 7175820 18 SAFETV Safetv Labels and Locations Rack Warning Rack Warning Clutch Cover Warning under seat A Clutch Cover Alert 7175826 A 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 Ibs 54 kg Rear 240 Ibs 109 kg 7175448 A Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG 7170509 19 FEATURES AND CONTROLS Switches Mode Reverse Override Switch Engine Stop Switch Turn Signal Switch j Main Ke Horn Switch Switch
42. e Alwavs 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 may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A Operating the vehicle with a spongy brake can result in loss of braking which could cause an accident Never operate the vehicle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 119 for the part numbers of Polaris products A An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle o
43. e 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 factorv and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion washing or submerging Item Recommended Capacity Fill Plug Drain Plug Inspection Lubricant at Fluid Torque Torque Procedure Change 550 Engine Oil JPS 4 PLUS 2 qt 15 17 ft Ibs 67 Performance 1 9 1 20 23 Nm Synthetic 2W 50 850 Engine Oil PS 4 PLUS 2 qt 12 ft lbs 67 Performance 1 9 1 16 Nm Synthetic 2W 50 Transmission Synthetic 32 oz 10 14 ft Ibs 10 14 ft Ibs 70 Oil SPORTSMAN 950 ml 14 19 Nm 14 19 Nm XP Transmission Fluid Demand Drive Demand Drive 9 3 oz 8 10 ft Ibs 11 ft lbs 71 Fluid Front Plus Fluid 275 ml 11 14 Nm 15 Nm Gearcase Rear ATV Angle Drive 7 1 10 14 ft Ibs 10 14 ft Ibs 72 Gearcase Oil JFluid or GL5 80 210 ml 14 19 Nm 14 19 Nm 90 weight gear lube Brake Fluid DOT 4 Only 79 ADC Fluid Demand Drive 74 Plus Fluid Front Prop Polaris Premium JGrease fittings 3 pumps maximum every 500 miles Shaft Yoke U Joint Lube before long periods of storage or after pres
44. e active Press and hold the MODE button to tog gle through all currently active diagnostic codes 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Displav Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internallv Short to Batterv The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at batterv voltage 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 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 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage High 102 3 Voltage Too Low 102 4 Crankshaft Position Sensor Circuit Fault 636 8 Gear Sensor Signal Voltage Too Low to Calibrate 523 4 Voltage Too Hig
45. e event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 22 FEATURES AND CONTROLS Brakes A Aggressivelv applving the brakes when backing down a hill mav cause rear tipover Aggressivelv applving the brakes while moving forward mav cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake svstems on this vehicle Always use caution whenever applying the brakes Foot Brake The all wheel foot brake is located on the right footrest The foot brake operates both front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates both front and rear brakes Squeeze the brake lever toward the handlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake reduce lever pressure A 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 23 FEATURES AND CONTROLS Brakes Parking Brake 1 2 Place the transmission in PARK Squeeze and release the brake lever two or three times then squeeze a
46. e transmission in PARK 3 Loosen the wheel nuts slightly A Do not service axle nuts that have a cotter pin installed See your Polaris dealer 4 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 5 Remove the wheel nuts 6 Remove the wheel 84 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 ground 5 Torque the wheel nuts to specification A Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 75 ft Ibs 102 Nm Cast Aluminum Steel 45 ft Ibs 61 Nm Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Wheel Type Nut Type Nut Torque Aluminum Lug Nut 75 ft Ibs 102 Nm Steel Lug Nut 45 ft Ibs 61 Nm 85 MAINTENANCE Mir Filter 1 2 86 Remove the seat Remove the air box cover screws and remove the air box cover Remove the filter Remove the fabric tvpe pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry Reinstall the pre fil
47. e weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capac ity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that require backing downhill CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on only one rack increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehi cle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverabil
48. ecialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 02 185 ml 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 LoctiteTM 565 Thread Sealant 2859044 Polaris Battery Tender Charger 119 SPECIFICATIONS SPORTSMAN 550 XP Maximum Weight Capacitv 575 Ibs 261 kg Drv Weight 732 Ibs 332 kg Fuel Capacity 5 25 gal 20 I Engine Oil Capacity 2 qts 1 9 1 Coolant Capacitv 2 qts 1 91 Rear Gearcase Oil Capacitv 7 1 oz 210 ml Demand Drive Fluid Capacitv 9 3 oz 275 ml Transmission Oil Capacitv 32 oz 950 ml Front Rack Storage Box Capacitv 120 Ibs 54 kg Rear Rack Capacitv 240 Ibs 109 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear rack load and tongue weight not to exceed 240 Ibs 109 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1786 Ibs 810 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129
49. ed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte A Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 conventional batteries coat the terminals with dielectric grease or petroleum jelly Secure the battery hold down strap Connect and tighten the red positive cable first Connect and tighten the black negative cable last Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 9 Install the seat 9o Xen 104 MAINTENANCE Batterv Batterv Storage Whenever the vehicle is not used for a period of three months or more remove the batterv from the vehicle ensure that it s fullv charged and store it out of the sun in a cool drv place Check batterv voltage each month during storage and recharge as needed to maintain a full charge Polaris recommends maintaining batterv charge bv using a Polaris Bat terv Tender charger or bv charging about once a month to make up for normal self discharge Batterv Tender can be left connected during the storage period and will automaticallv charge the batterv if the voltage drops below a pre determi
50. ehind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust svstem can get extremelv hot Do not perform service on the spark arrestor while the svstem is hot Allow components to cool sufficientiv before proceeding Use the following procedure to periodicallv purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge car bon from the system 5 Ifcarbon comes out of the exhaust cover or plug the Clean Out Plug exhaust outlet s Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Place the transmission in PARK Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor clean out plug and remove the exhaust outlet cover or plug 98 MAINTENANCE PVT Svstem A Failure to complv with the instructions in this warning can result in severe injurv or death Do not modifv anv component of the PVT svstem Doing so mav reduce its strength so that a failure mav occur at a high speed
51. en the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 52 OPERATION Driving Uphill If all forward speed is lost Keep vour weight uphill If the vehicle begins rolling downhill never apply engine power Never applv the brakes aggressivelv while rolling backwards 1 Apply the brakes gradually 2 When fully stopped lock the hydraulic parking brake 3 Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 4 Use the K turn to turn around See page 56 A Always follow the procedures outlined in this manual for driving on hills Avoid climbing hills steeper than 25 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 53 OPERATION Driving on a Sidehill Sidehilling Avoid crossing the side of a hill sidehilling if possible If sidehilling is necessary follow these precautions Slow down Shift body weight uphill Keep your feet on the footrests Avoid hills with slippery or loose surfaces Avoid crossing the sides of steep hills gv Ue l If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately A Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the vehicle around on any hil
52. ension Inspect lubricate if necessarv 66 Rear suspension Inspect lubricate if necessarv 66 Steering Ensure free operation Tires Inspect condition and pressure 84 Wheels fasteners Inspect ensure fastener tightness ae Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels ze Coolant level Ensure proper level a Coolant hoses Inspect for leaks Throttle Ensure proper operation 25 Indicator lights switches Ensure proper operation 20 Engine stop switch Ensure proper operation 21 Nir filter pre filter Inspect clean 86 Headlamp Check operation 21 Brake light tail lamp Check operation 91 Riding gear Wear approved helmet goggles and 14 protective clothing ADC Fluid Ensure proper level 74 Mirrors Adjust for best side rear vision 44 OPERATION Starting the Engine 1 Position the vehicle on a level surface 2 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 not press the throttle while starting the engine 5 Turn the ignition key past the POSITION LIGHTS ON position to engage the starter Activate the starter for a maximum of five sec onds releasing the key when the engine starts 6 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the
53. ering 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 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 see illustration Plastic Rivet Torx Head Screw TOR M WES V Hex Head Screw 83 MAINTENANCE Tires A 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 manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 120 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less 22 WS 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 th
54. f brake fluid always discard any unused portion 79 MAINTENANCE Brake Fluid Hand Brake Indicator The master cvlinder is located on Master Window the left handlebar Maintain the fluid level 6 mm below the top edge of the master cvlinder Do not overfill 1 Position the vehicle level surface Make sure the handlebars are straight 2 View the fluid level through the indicator window eye on the top of the master cyl inder Tip The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Ifthe fluid level is low remove the cover screws and add fluid to the fill line Do not overfill 4 Reinstall the cover Torque screws to 7 in lbs 8 Nm Foot Brake Brake Fluid Reservoir The foot brake fluid reservoir is located under the front rack The brake fluid reservoir cap is black NOTICE Do not use ADC fluid in the brake fluid reservoir ADC fluid will damage the rubber components of the brake system 80 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 often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 80 2 Check the brake systems reg
55. h 523 3 Signal Fault 523 2 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Circuit Short to 651 3 Ignition Coil Primarv Driver 1 MAG Driver Open Grounded 1268 5 Driver Circuit Short to 1268 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to 1347 3 Fan Relav Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to 1071 3 Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load 520193 11 Starter Enable Circuit Driver Circuit Short to 1321 3 All Wheel Drive Control Driver Circuit Short to 520207 3 System Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Short to B 520203 3 Assumes unipolar configuration of stepper motor 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 XP XP EPS Diagnostic Codes 40 Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolu
56. h 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 129 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 130 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 131 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 Restrictions 6 Air Filter esna nosso seemai 86 All Wheel Drive System 28 29 B Battery 102 107 Charging Conventional 106 Charging Sealed Battery 107 Charging Sealed 106 Fluid Conventional Battery 105 Installation 104 Removals ss eta sew 103 Stora Des Lee 105 eee rn 25 me 15 Brake Fluid 79 80 Brake Inspections 81 Brake 23 Brake Foot 23 80 Brake Hand Lever 80 Brake Parking
57. he 4X4 switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest 29 FEATURES AND CONTROLS Active Descent Control ADC Svstem The ADC svstem allows engine braking to all four wheels when the Vehicle descends a hill or incline Alwavs move the 4X4 switch to ADC AXA before ascending or descending a hill Engaging Active Descent Control The ADC svstem will automaticallv engage when all four of the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 25 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 position Vehicle speed exceeds 15 mph 25 km h The throttle is open throttle is applied The transmission is shifted to neutral or park 30 FEATURE
58. he moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 101 MAINTENANCE Batterv A 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 A Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional batter
59. ight 91 Low Beam Adjustment 88 Low Range Use 101 Lubrication Guide 66 M Maintenance Chart 62 65 Metric Standard Display 35 MIE OIS e o epi D Pipes 22 Mode Switch 20 Modifications 6 N Noise Emission Control Svstem 61 E BMET sa ye Res 67 69 Rear Gearcase 72 73 Transmission 70 Oil and Filter Change 68 69 Oil Level Engine 67 Oil Recommendations 67 Override Switch 20 P Parking 24 Parking on an Incline 60 Periodic Maintenance Chart 62 65 Polaris Product List 119 Polishing the Vehicle 109 Position Light Lamp 89 Power Steering 25 Power Steering Unit Cleaning 76 Pre Ride Checklist 44 PVT 43 PVT Drying srt ur Lu aed 101 PVT System 99 101 133 INDEX R Rack Compartment Front 27 Reverse Operation 51 Reverse Override Switch 20 Rider Information Center 32 41 Rider Safetv 7 13 Riding 14 15 S Safety Labels 16 19 No Passenger Warning 18 Age 16 Alert 16 Clutch Cover Alert 19 General Alert 17 Hill Operation Alert
60. ing speed Standard Metric Displav The displav can be viewed in either standard or metric units of measure ment To change units 1 Press and hold the MODE button until vehicle speed is displayed 2 Toggle through the information area using the SELECT button until the odometer is displaved 3 Press and hold the MODE button until the displayed units change Release the button 4 New settings remain until changed using the same procedure 12 Hour 24 Hour Clock Display 1 Press and hold the MODE button until RPM is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new clock format either 24 hour or 12 hour Release the button 4 New settings remain until changed using the same procedure Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meters record the distance traveled by the vehicle on each trip if reset before each trip To reset a trip meter select the trip meter 1 or trip meter 2 mode Press and hold the MODE button on the instrument clus ter until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays with out a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 35 FEATURES AND CONTROLS Instrument Cl
61. iter malfunction See vour dealer Electronic throttle control malfunction See vour dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See vour dealer Solution Add or change fuel clean the fuel svstem Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter See your dealer Incorrect fuel Fuel is very high octane Replace with recommended fuel Possible Rich Fuel Cause Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 117 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh reco
62. ity may be adversely affected causing the vehicle to overturn TOWING is approved OFF ROAD ONLY TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descend ing hills Hauling Cargo Never exceed the weight capacities specified for vour 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 rough or hillv terrain reduce speed and cargo weight to maintain stable driving condi OPERATION tions Use low forward gear when hauling or towing heavv cargo to extend belt life 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 vehicle when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can res
63. l until you ve mastered on level ground the turning technique outlined in this manual 54 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 Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 5 Shift your weight rearward 6 Apply the brakes slightly to aid in slowing A Always follow the procedures outlined in this manual for driving downhill and for braking on hills A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 55 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 56 Stop the vehicle Keep your weight uphill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 Lock the hydraulic parking brake Leave the transmission in forward gear Turn the engine off Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill Stay uphill of the vehicle and turn the handlebars full left Squeeze the brake lever to release the parking br
64. laris dealer for service Directional Indicator This indicator illuminates when the hazard switch or a turn signal switch is turned on 33 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Displav Area Use the MODE button to toggle through the speed displav options MODE button operation is locked out at speeds above approximatelv 15 MPH 25 km h Tip The reverse override switch also acts as a MODE button when held down for approximately one half second The transmission cannot be in reverse when using the over ride switch as a MODE button MODE SELECT This feature does not contain a Button Button vehicle speed lockout function and can be used at any operating speed Ground Speed Mode Ground speed is displayed in either miles per hour MPH or kilometers per hour km h Engine Speed Mode Engine speed is displayed in revolutions per minute RPM 34 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area Use the SELECT button SEL to toggle through the information area options SELECT button operation is locked out at speeds above approximatelv 15 MPH 25 km h Tip The reverse override switch also acts as the SELECT button when pressed and released quickiv The transmission cannot be in reverse when using the override switch as a SELECT button This feature does not contain a vehi cle speed lockout function and can be used at anv operat
65. lippery or loose surfaces Use extra caution Always avoid skidding or sliding 48 OPERATION Driving Through Water Follow these procedures when driving through water 1 Check water depth and cur rent before crossing 2 Choose crossing where both banks have gradual inclines 3 Drive slowly Avoid rocks and obstacles 4 Avoid operating in water 2 deeper than the bottom of Maximum the footrests If it s unavoid Depth able travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes NOTICE If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 5 Wet brakes may have reduced stopping ability Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action 1s normal 6 If your vehicle becomes fully immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 97 Have the vehicle serviced by your dealer promptly A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water 49 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in
66. llow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 68 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 111 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 everv two vears Rear gearcase Transmission Brake fluid change everv two vears and anv time the fluid looks dark or contaminated Coolant test strength Fog the Engine 1 Treat the fuel svstem with Polaris Carbon Clean following the instructions on the container Run the engine for several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Reinstall the spark plugs Torque to specification Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs Turn the engine over several times using electric start Oil will be forced in and around the piston rings and ring lands coating the cyl inder with a protective film of fresh oil If Polaris fuel system additive is not
67. lter Weekly Inspect replace as needed E main element gt Engine oil change 20H 1 Month 500 800 Perform a break in oil and filter change see page 42 gt Brake pad wear 10H Monthly 100 160 Inspect periodically Battery 20H Monthly 200 320 Check terminals clean test E ADC fluid 25H Change fluid if extreme use conditions see page 74 gt Demand drive fluid 25 Monthly 250 400 Inspect level gt Rear gearcase oil 25 H Monthly 250 400 Inspect level gt Transmission oil 25H Monthly 250 400 Inspect level gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 64 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate E JETC Switch replace if necessarv E Throttle Body 50 H 6M 500 800 Inspect duct for proper seal Intake Duct ing air leaks Drive belt 50 H 6M 500 800 jInspect replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Radiator 50 H 6M 1000 1600 Inspect clean external surfaces gt Cooling hoses
68. mmended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen Clean the screen Plugged Radiator Use a garden hose to flush anv debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiencv 118 POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil 12 02 355 ml Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 95 1 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 l Gearcase Transmission Lubricants 2877606 Synthetic SPORTSMAN XP Transmission Fluid qt 95 1 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 I 2877922 Demand Drive Plus Fluid 95 1 2877923 Demand Drive Plus Fluid 3 8 1 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 1 2870465 Pump for Gallon 3 8 1 Jug Coolant 2871323 60 40 Coolant gal 3 8 1 2871534 60 40 Coolant qt 95 1 Grease Sp
69. mproperly 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 Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions B Have an authorized Polaris dealer perform these services 63 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Pre Ride See Pre Ride Checklist on Front suspension Pre Ride page 44 Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake svstem Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level Pre Ride gt Air filter pre filter Dailv Inspect clean often replace E as needed Coolant Dailv Check level dailv change coolant everv 2 vears gt ADC fluid Dailv Check level dailv add as needed gt Power steering unit Daily Inspect daily clean often if equipped Headlamp taillight Daily Check operation gt Air fi
70. nauthorized 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 Tip Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 4 Reverse the procedure to unlock the steering A The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before starting the engine Fuel Tank Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap and add fuel Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 per cent such as E 85 fuel The fuel tank is designed to allow for the normal expansion of fuel Do not over fill Do not fill the tank neck 26 FEATURES AND CONTROLS Front Rack Compartment Release the front rack latches 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 Access the following compo nents in the front compart ment e Radiator cap Foot brake fluid reservoir ADC fluid reservoir Coolant recover
71. nd hold Push the parking brake lock forward to engage the lock Release the brake lever To release the parking brake lock squeeze and release the brake lever A Operating the vehicle while the parking brake is engaged could result in an accident and serious injurv or death Alwavs release the parking brake lock before operating 24 FEATURES AND CONTROLS Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition kev 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 Selector The transmission gear selector is Gear located on the right side of the Selector vehicle High Gear Low Gear Neutral Reverse Park Stop the vehicle release the throttle and move the shift lever to the desired gear See your dealer if you experience any shifting problems NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s in PARK Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour 11 km h for extended periods of time 25 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent u
72. ned point See page 119 for the part numbers of Polaris products Batterv Fluid Conventional Batterv A poorlv maintained batterv will deteriorate rapidly Check the battery MET ub eA fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 105 MAINTENANCE Batterv Batterv Charging Conventional Batterv 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 needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 104 Make sure the positive terminal polarity is properly connected Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage
73. ng the water stream at the follow ing items Wheel bearings Electrical components Radiator Switches and controls Transmission seals Fuel system components Cab and body panels Labels and decals If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 109 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 manv vears Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properlv cleaned Clean chrome wheels more often if thev re exposed to salt or other corrosive elements 1 Wash
74. on 4 Set the time as outlined in steps 3 5 of Method 1 36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area Diagnostic Displav Mode The EFI diagnostic display mode is for informational purposes only Please see your Polaris dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the deter mination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the transmission in PARK 2 Press and release the SELECT button until the flashing check engine warning indicator appears in the display 3 set of two numbers will also appear in the display The 2 6 digit suspect parameter number SPN in the information area indicates which component is generating the fault code The 1 2 digit failure mode indicator FMI number in the clock area indi cates the fault mode such as open or short circuit 4 See pages 38 41 for code definitions and failure descriptions Tip More than one fault may b
75. ons in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Please see your dealer for all of your service needs during and after the warranty period For more information about Polaris visit us online at www polarisin dustries com POLARIS The Way Out POLARIS THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 SPORTSMAN 550 850 XP 850 XP EPS International Owner s Manual P N 9922581 TABLE OF CONTENTS Introduction 4 Safety Li a A ia Sees 6 Features and Controls 20 Operation si ia a 42 Emission Control S
76. ove the rubber cover from the back of the headlight Turn the collar counter clockwise and carefully remove the collar and socket 6 Remove the lamp Apply dielectric grease to the socket and install a new lamp 7 Reverse all steps to reassemble the headlight gt Headlamp 89 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 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order 90 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 components in reverse order 91 MAINTENANCE Throttle Body ldle 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 handlebars straight ahead place very light pressure on the throt tle lever A gap of 2 3 mm should be visible between the throttle arm stop pin and the
77. plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks 8 Dispose of used oil properly 73 MAINTENANCE Active Descent Control ADC Fluid If vour vehicle is equipped with Active Descent Control there are two fluid levels that must be maintained demand drive fluid and ADC fluid See page 71 for demand drive fluid maintenance Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 62 NOTICE Change the ADC fluid everv 25 hours if the ADC unit is exposed to extreme use Extreme use includes operation in ADC mode for prolonged periods or in environments that necessitate primarv operation in ADC mode We recommend the use of Polaris Demand Drive Plus Fluid Maintain the fluid level between the minimum and maximum marks on the reser See page 119 for the part numbers of Polaris products NOTICE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system 1 Remove the front rack 2 View the fluid level in the reservoir 3 Ifthe level is below the minimum mark remove the cap and add the recommended fluid 4 Reinstall the cap 5 Reinstall the front rack 74 MAINTENANCE Active Descent Control ADC Fluid Fluid Change 1 Position the vehicle on
78. pt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehcile is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 125 WARRANTV WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to
79. r format If the engine is turned off press the MODE button The time will dis play for 5 10 seconds See page 36 for resetting instructions Engine Overheat Warning This indicator flashes to indicate an overheated engine If the indicator stops flashing but remains illu minated the overheating condition remains and the system will automatically reduce engine power Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 36 for resetting instructions Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Check Engine Warning Indicator This indicator appears if an EF I related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 EPS Warning Indicator This indicator illuminates when the key is turned to the ON position and goes off when the engine is started If the light remains on after starting the engine the EPS system is inoperative See your authorized Po
80. r 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 components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose Clean Often As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 119 for the part numbers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 76 MAINTENANCE Cooling Svstem Recoverv Bottle Coolant The recoverv bottle fluid level can be viewed from inside the front right wheel well Access the recoverv bot
81. rk plugs can result in serious engine damage Alwavs use Polaris recommended spark plugs a Torque Specification Plug Condition 550 XP 850 XP XP EPS New Spark Plug 9 11 ft Ibs 18 20 ft Ibs 12 15 Nm 24 27 Nm Previously Installed 17 20 ft Ibs 18 20 ft Ibs Spark Plug 23 27 Nm 24 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 96 A A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 95 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is grav tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper tvpe and heat range for the engine and the service The tip should not be flakv and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing
82. s are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 15 SAFETV Safetv Labels and Locations Warning labels have been placed on the vehicle for vour 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 by Polaris at no charge The part number is printed on the label The following pages repeat the information found on each label A ESD Ps KE ill TEN ene f aO Operation EN 3 90 O _ Y BAY ote f posee 4 29 Alert Reverse Override Warning 16 SAFETV Safetv Labels and Locations A General Alert Multi Lingual Before vou operate this vehicle read the owner s manual 7173025 A Reverse Override Warning 4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injurv or death Do not activate override while throttle is engaged Alwavs applv throttle graduallv while in reverse CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft an
83. s caused bv external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warrantv period expires or bv an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to
84. starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the vehicle is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 45 OPERATION Driving Procedures 46 Wear protective riding gear See page 14 Perform the pre ride inspection See page 44 Place the transmission in PARK Mount the vehicle from the left side Sit upright with both feet on the footrests Keep both hands on the handlebars Start the engine and allow it to warm up Apply the brakes Shift the transmission into gear Check your surroundings and determine your path of travel Release the brakes Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Turning the Vehicle 1 Always follow the procedures outlined in this manual
85. sure Front Prop Shaft Yoke 66 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Svn 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 mav need to be changed more frequentiv if Polaris oil is not used Alwavs use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 119 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil mav cause serious engine damage Alwavs use the recommended oil Never substitute or mix oil brands Oil Level Check the oil level when the engine is cold Never check the oil with the engine running Access the oil dipstick and fill tube from the left side of the vehicle 1 Position the vehicle AX level surface Place the trans Dipstick mission in PARK 2 Remove the dipstick Wipe it Full drv with a clean cloth Add 3 Po and tighten the dip EUR E 4 Remove the dipstick and 850 check the oil level fi H 5 Add recommended fluid 2 1188 as needed Maintain the oil level in the safe range between the FULL and ADD Full Add marks Do not overfill 6 Reinstall and tighten the dipstick AW 550 67 MAINTENANCE Engine Oil
86. t labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle A Gasoline is highly flammable and explosive under certain conditions Use extreme caution whenever handling gasoline Refuel with the engine stopped Refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing A Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injurv or death Never run an engine in an enclosed area SAFETV Rider Safetv A Never carrv a passenger on this vehicle A Alwavs wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants A Never consume alcohol or drugs before or while operating this vehicle A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience SAFETV Rider Safetv A Always inspect your vehicle before each use to verify that it s in safe operating condition See page 44 Follow the inspection and maintenance procedures outlined in this m
87. tal starting A Alwavs unlock the steering before starting the engine See page 26 A Hot components can cause serious burns and fire Do not touch hot exhaust svstem components Alwavs keep combustible materials awav from the exhaust svstem For more information about safetv contact an authorized Polaris dealer or visit the Polaris web site at www polarisindustries com 13 SAFETV Safe Riding Gear Alwavs wear protective clothing to reduce the chance of injurv Eve Protection Gloves Long Pants Helmet Alwavs wear a helmet that meets or exceeds established safetv stan dards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 14 SAFETV Safe Riding Gear Eve Protection Do not depend on eveglasses or sunglasses for eve protection When ever riding a Polaris vehicle alwavs wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eve wear is kept clean Gloves Off road style gloves with knuckle pad
88. te Pressure Sensor Voltage High 102 3 Voltage Too Low 102 4 Signal Out of Range 102 2 Crankshaft Position Sensor Circuit Fault 636 8 Plausibility Fault 636 2 Vehicle Speed Signal Speed Too High 84 8 Plausibility Fault 84 2 Gear Sensor Signal Voltage Too Low 523 4 Voltage too high 523 3 Signal fault 523 2 Injector 1 MAG SDI Part Load Driver Circuit Open Grounded 651 5 Driver Circuit Short to 651 3 Driver Circuit Grounded 651 4 Injector 2 PTO SDI Part Load Driver Circuit Open Grounded 652 5 Driver Circuit Short to 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to 1347 3 Driver Circuit Grounded 1347 4 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to 1071 3 Driver Circuit Grounded 1071 4 Idle Air Control Driver Circuit Open Grounded 634 5 Driver Circuit Short to B 634 3 Driver Circuit Grounded 634 4 Position Out of Range 634 7 Starter Enable Circuit Driver Circuit Open Grounded 1321 5 Driver Circuit Short to 1321 3 Driver Circuit Grounded 1321 4 FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 XP XP EPS Diagnostic Codes
89. ter over the main filter Install a new main filter if needed Reinstall the filter into the air box Reinstall the air box cover and the seat Fuse Replacement If the engine stops or will not start or if vou experience other electrical failures a fuse mav need replacement Locate and correct anv short cir cuits that mav have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 2 3 Remove the front rack Remove the fuse box cover MAINTENANCE Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating Reinstall the fuse box cover Reinstall the front rack BUMPER FAN EFI Af START FAN EF LIGHTS RELAY RELAY A t SOLENOID RELAY A RELAY t RELAY RELAY RELAY MERI WIRES LIGHTS DRIVE LIGHTS DRIVE ACCESSORY CHASSIS 20A 20 A CHASSIS 20 20 10 P RELAY EFI UNSWITCH SPARE E RELAT EFI UNSWITCH SPARE 1175140 20A 10A 20A 1175141 20A 10A 20A BUMPER P sony LIGHTS 0 RELAY RELAY RELAY 8 WIRES gt LIGHTS DRIVE JACCESSORV s CHASSIS 20A 20A 20A RELAY EFI UNSWITCH EPAS 7175806 20A 10A 30A 87 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward 1 Position the vehicle
90. the o ring is in good condition Oil Filter Install the new filter and rotate it clockwise bv hand until the filter gasket contacts the sealing sur face then turn it an additional 1 2 turn Remove the dipstick Add the proper amount of the recommended oil Do not overfill Reinstall the dipstick Place the transmission in PARK Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 69 MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic SPORTSMAN 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 Periodic Maintenance Chart beginning on page 62 See page 119 for the part numbers of Polaris products Maintain the oil level at the bot tom of the fill plug hole The fill plug is located on the right side of the vehicle behind the footwell The drain plug is located on the bottom left side of the gearcase Oil Check 1 Remove the footwell see page 83 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification 5 Reinstall the
91. throttle arm If adjustment is needed 1 Locate the throttle cable Canis adjuster Squeeze the end Adjuster of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut Arm Stop Pin 2 3 mm Gap 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 2 3 mm of freeplay is achieved between the stop pin and the throttle arm While Boot adjusting freeplay flip the throttle lever back and forth repeatedly continued on next page Lock Nut Adjuster 92 MAINTENANCE Throttle Cable Freeplav 4 2 6 10 Place the transmission in PARK Start the engine and allow the idle to stabilize If necessary tap the throttle lever to ensure the idle speed settles If idle speed remains above or below the recommended setting see specification pages verify the correct gap If gap is correct and idle speed is still not satisfactory please see your Polaris dealer for ser vice With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommended setting If idle speed increases it may be necessary to increase the gap between the stop pin and throttle arm but do not exceed the recommended 2 3 mm gap When adjustments are complete tighten the locknut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Ensure the con
92. tle cap under the front storage com partment 1 View the fluid level in the bottle 2 Ifthelevelis low remove the front rack 3 Remove the bottle cap and add coolant as needed Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 4 Reinstall the cap 5 Reinstall the front rack Maximum Mark Minimum Mark Recovery Bottle Cap 77 MAINTENANCE Cooling Svstem Radiator Coolant To ensure that the coolant maintains its abilitv to protect the engine Polaris recommends that vou drain the svstem completelv everv two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed A Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use ofa non standard pressure cap will not allow the recovery system to func tion properly Contact your dealer for the correct replacement part 5 Reinstall the front rack Radiator Cap 78 MAINTENANCE Brake Fluid Check brake fluid levels for both brake svstems before each rid
93. trol cover seal is in place then reinstall the cover and screws 93 MAINTENANCE Camber and Caster The camber and caster are non adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted bv rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessorv springs are available through vour Polaris dealer Handlebars The handlebars can be adjusted for rider preference A Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right Handlebar 4 Torque the front two bolts to Bolts 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 94 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 120 for the recom mended spark plug tvpe and gap for vour vehicle Torque spark plugs to specification NOTICE Using non recommended spa
94. ularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to 1 mm 5 Check the security and surface condition of the disc 81 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 A Severe injurv or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer 1 Position the vehicle ona level surface Ye 2 Place the handlebars ina Stand straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 2 4 Measure the distance from string to the XE Er rim at the front 1 and rear 2 of the front rim O The rear measurement should be 1 5 mm more than the front measurement on each side of the vehicle to obtain the recommended 0 to 1 8 0 3 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle If you discover improper alignment see your Polaris dealer for ser vice 82 MAINTENANCE Ste
95. ult in serious damage to the vehicle and will void your vehicle warranty Never install a hitch longer than 10 cm Never install automotive accessories on your Polaris vehicle Always install Polaris approved or equivalent accessories designed for use on this vehicle Maximum 10 cm 59 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 60 EMISSION CONTROL SVSTEMS Noise Emission Control Svstem 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 operation It is required that this spark arrestor remain installed and functional when the vehicle is operated Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 61 MAINTENANCE Periodic Maintenance Chart
96. ur vehicle including safe operating procedures Ride responsibly Know all laws and regulations concerning the opera tion of this vehicle in your area Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETV Failure to follow the warnings in this manual can result in serious injurv or death This Polaris vehicle is not a tov and can be hazardous to operate A collision or rollover can occur quickiv even during routine maneuvers if vou fail to take proper precautions Read and understand your owner s manual and all warnings before operating this Polaris vehicle Safety Training When you purchased your new Polaris vehicle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this informa tion on a regular basis If you purchased a used Polaris vehicle from a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is ADU
97. uster Rider Information Center Information Displav 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 enabled it provides a convenient reminder to perform routine maintenance The service interval is pro grammed at 50 hours at the factorv Use the following procedure to change the service interval 1 Press the SELECT button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the SELECT button to advance the hours to the desired setting including OFF When the digits stop flashing the interval has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1 Select the Hour Meter Mode 2 Press and hold the mode button on the instrument cluster until the hour display flashes Release the button 3 Press and release the SELECT button to advance the hours After the hours are set press and release the MODE button to move to the minutes Use the same procedure to reset the minutes 5 When the digits stop flashing the clock has been set Method 2 1 With the key turned off press and hold the MODE button 2 While still holding the MODE button turn the key to the ON posi tion 3 Continue to hold the MODE button until the hour display flashes Release the butt
98. uster fails to illuminate a batterv over voltage mav have occurred and the instrument cluster mav have shut off to protect the electronic speedome ter If this occurs please see vour Polaris dealer The information center is set to displav standard units of measurement anda 12 hour clock at the factory To change to metric and or a 24 hour clock see page 35 2 3 4 13 12 6 11 7 10 9 9 8 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 2 Information Display Area This area displays odometer tripme ters engine hour meter and programmable service hour interval 3 Speed Display This area displays vehicle ground speed or engine rotational speed when the corresponding display is selected See page 34 32 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4 10 11 12 13 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer High Beam Indicator This indicator appears when the lights are set to high beam Clock The clock displays time in a 12 hour or 24 hou
99. volts or less Needs charge with desulfating charger At least 20 hours 107 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 108 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water mav damage components and could remove paint and labels Avoid directi
100. y has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 102 MAINTENANCE Batterv Batterv Removal Remove the seat Disconnect the black negative batterv cable first Disconnect the red positive batterv cable last Disconnect the batterv hold down strap On conventional batteries remove the batterv vent tube Lift the batterv out of the vehicle Be careful not to tip a conven tional batterv sidewavs which could spill electrolvte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle DP BN 103 MAINTENANCE Batterv Batterv Installation Using a new batterv that has not been fullv charged can damage the bat terv and result in a shorter life It can also hinder vehicle performance Follow the batterv charging instructions on page 106 before installing the batterv 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube seal
101. y bottle cap e Electrical fuse relay components Brake Fluid Reservoir ADC Fluid Reservoir Bottle Cap Radiator Electrical Fuse Relav Cap 27 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch ADC 4X4 Mode When the switch is on ADC 4X4 the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 4X4 Mode When the switch is on 4X4 the vehicle is in 4X4 and the 4X4 indicator icon in the instrument cluster display will be visible When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage ADC 4X4 There is no limit to the length of time the vehicle may remain in 4X4 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position 2X4 Mode When the switch is on 2X4 the vehicle is in two wheel drive at all times 28 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch be turned on or off while the vehicle is moving Initiallv the vehicle s electronic svstem will not enable 4X4 until the engine RPM is below 3100 Once enabled 4X4 remains enabled until t
102. ystems 61 Maintenance 62 Troubleshooting 115 Polaris Products 119 lt 120 Declaration of Conformitv 124 Warranty i dota ese dda eee eae es 125 Maintenance Log 129 Ind8x volore uv EE VOR MEE 132 INTRODUCTION The following signal words and svmbols 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 A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION As the operator of the vehicle vou are responsible for vour personal safetv the safetv of others including vour passenger and the protec tion of our environment Read and understand vour owner s manual which includes valuable information about all aspects of yo

Polaris 9922581 Offroad Vehicle User Manual

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