Polaris 2014 Sportsman 550 EPS Owner'S Manual Download Page 110 | Manualshive

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108

MAINTENANCE

Fuse Replacement

If the engine stops or will not start, or if you experience other electrical
failures, a fuse may need replacement. Locate and correct any short cir-
cuits that may have caused the blown fuse, then replace the fuse. Spare
fuses are provided in the fuse box.

1. Remove the front rack.

2. Remove the fuse box cover.

3. Remove the suspect fuse from the fuse panel. If the fuse is blown,

install a new fuse with the same amperage rating.

4. Reinstall the fuse box cover.

5. Reinstall the front rack.

Fuse Box

SPORTSMAN 550 EPS

SPORTSMAN XP 850 EPS

SPORTSMAN 550

SPORTSMAN XP 850

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Summary of Contents for 2014 Sportsman 550 EPS

Page 1: ...y It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety Sportsman 550 EPS Sportsman XP 850 H O Sportsman XP 850 H O EPS ...

Page 2: ...er s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...onal vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information abo...

Page 4: ...ay result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle...

Page 5: ...Introduction 4 Safety 7 Features and Controls 24 Operation 53 Winch Guide 71 Emission Control Systems 83 Maintenance 84 Troubleshooting 133 POLARIS Products 137 Specifications 138 Warranty 142 Maintenance Log 150 Index 154 ...

Page 6: ...situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicat...

Page 7: ...eration is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured per prEN 15997 The operating conditions of the machinery du...

Page 8: ...g keys The ignition switch must be replaced if all keys are lost The manufacturer s label is located on the front right side of the vehicle behind the radiator Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number ____________...

Page 9: ...iderCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A POLARIS ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We stron...

Page 10: ...eds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the l...

Page 11: ... protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS ATV is terminated if any equipment ...

Page 12: ...s vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Even though a child may be within the recommended age group for operating some ATVs he she may not have the skill...

Page 13: ...onous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Protective Apparel Riding in this vehicle without wearing an approved helmet and protective ey...

Page 14: ... on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public stree...

Page 15: ...ction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or ...

Page 16: ...check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the s...

Page 17: ...mount following the procedure described in the owner s manual See page 64 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uph...

Page 18: ...ent or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 67 Before shifting into reverse gear always check for obstacles o...

Page 19: ...ra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 65...

Page 20: ...esult in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Variances in snow depth and or water currents may result in uneven ice thickn...

Page 21: ...l disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry gra...

Page 22: ... the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenge...

Page 23: ...is ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 Reverse Override Warning 4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse CAUTION Do not...

Page 24: ...re Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa Maximum weight capacity 575 lbs 261 kg Lug nut torque values Steel rims 45 ft lbs 61 Nm Aluminum rims 75 ft lbs 102 Nm No Passenger Warning Tire Pressure Load Warning ...

Page 25: ...sult in serious injury or death 7175488 Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 120 lbs 54 kg Rear 240 lbs 109 kg 7175448 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 1...

Page 26: ...or approximately one half second See the instrument cluster information beginning on page 34 The transmission cannot be in reverse when using the override button as a MODE button 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 33 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Headlight Switch Use the headlight switch ...

Page 27: ...dures Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ...

Page 28: ...lease switch could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle release switch or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle release switch Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle le...

Page 29: ...e the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected be...

Page 30: ... failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master cylinder before each ride 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator win dow on the top of the master cylinder The eye will appear dark when the ...

Page 31: ... unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option i...

Page 32: ...ould the main system fail use the auxiliary foot brake The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level fre quently for the auxiliary brake sys tem The reservoir is...

Page 33: ...ne Do not use fuel with ethanol content greater than 10 such as E 85 fuel The fuel tank is designed to allow for the normal expansion of fuel Do not overfill Do not fill the tank neck Extreme Use 30 AH Battery If your factory installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso ries please see your POLARIS dealer to purchase a 30...

Page 34: ...n 4X4 the ATV is in 4X4 and the 4X4 indi cator icon in the instrument clus ter 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 There is no limit to the length of time the vehicle may remain in 4X4 The vehicle automatically engages 4X4 wh...

Page 35: ...s switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest Active Descent Control ADC System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Engaging Active Descent Control The ADC system will automatically engage when all four of the follow ing conditi...

Page 36: ...the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Digital Analog Gauge Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h Trip 1 km mi RPM F E 88 88 Rider Information Cente...

Page 37: ...utomatically reduce engine power EPS Warning 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 POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam ...

Page 38: ...t cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the ATV to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 39 Trip 1 km mi...

Page 39: ...uit See your dealer 3 Information Display This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval 4 Active Descent Control Display This icon displays when ADC is active See page 33 5 Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See pa...

Page 40: ...rd or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automati cally exits and returns to the odometer display 1 Turn the key to the OFF position 2 Place the transmission in neutral 3 Press and hold the MODE button while turning the key to the ON position 4 When the display flashes the distance setting tap the MODE button to advance to the desired se...

Page 41: ... Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip To...

Page 42: ... button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check eng...

Page 43: ...he dis play Please see your Polaris dealer for all major repairs 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the numbers displayed in the gear position if any clock and odometer displays 4 Press the MODE button to advance to the next error code...

Page 44: ...V to your Polaris dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 45 1 Gear Display This area displays gear shifter posi tion H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 2 Information Display This area displa...

Page 45: ...tions 8 Service Reminder Display A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehi cle should be brought to your dealer for scheduled maintenance See page 46 for resetting instructions 9 Under Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is ...

Page 46: ...n held down for approximately one half second The reverse override but ton also acts as the SELECT but ton when pressed and released quickly The transmission cannot be in reverse when using the override but ton as a MODE or SELECT button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Speed Display Use the MODE button to toggle through the spee...

Page 47: ...h 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 ATV Trip Meter Mode The trip meters record the distance tra...

Page 48: ...utton 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 4 After...

Page 49: ...ctive 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 A set of two numbers will also appear in the display The 2 6 digit ...

Page 50: ...le Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Crankshaft Position Sensor Circuit Fault 636 8 Gear Se...

Page 51: ... 6 Steering Torque Sensor T1 Partial Failure T1 Shorted to Ground 520223 4 T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Partial Failure T2 Shorted to Ground 520224 4 T2 Shorted to Bus 520224 3 Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Shorted to Ground T2 Shorted to Bus 520225 16 T2 Shorted to Ground T1 Shorted to Bus 5202...

Page 52: ...23 3 Signal fault 523 2 Injector 1 MAG SDI Part Load Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Driver Circuit Grounded 651 4 Injector 2 PTO SDI Part Load Driver Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short ...

Page 53: ...ng Excessive Current Error Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Par tial Failure T1 Shorted to Ground 520223 4 T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Par tial Failure T2 Shorted to Ground 520224 4 T2 Shorted to Bus 520224 3 Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Short to Ground T2 Short...

Page 54: ... illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following components in the front compartment Radiator cap Brake fluid reservoir ADC fluid reservoir Battery Coolant recovery bottle cap Electrical fuse relay components Latches ADC Fluid Reservoir Brake Fluid Reservoir Radiator Cap Coolant Bottle Cap Electrical Fuse Relay Battery ...

Page 55: ...xtreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 89 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels c...

Page 56: ...t lubricate if necessary 88 Steering Ensure free operation Tires Inspect condition and pressure 104 Wheels fasteners Inspect ensure fastener tightness 104 106 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 31 89 Coolant level Ensure proper level 99 100 Coolant hoses Inspect for leaks Throttle Ensure proper operation 26 122 Indicator lights switches Ensure ope...

Page 57: ... headlamps promptly 8 Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests 9 Never consume alcohol or drugs before or while operating an ATV 10 Always use the size and type of tires specified for yo...

Page 58: ...hicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to onc...

Page 59: ... engine starts 7 If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle ...

Page 60: ... handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 61: ...r in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This tech nique alters the balance of trac tion between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turni...

Page 62: ... traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handl...

Page 63: ...ways check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill 8 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 9 Never go over the top of any hill at high speed An obstacle a sharp drop or another ...

Page 64: ...verturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Shift body weight uphill 3 Keep your feet on the footrests 4 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately ...

Page 65: ...5 Slow down Excessive speed when traveling downhill can cause loss of control 6 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake...

Page 66: ...hicle or on the left if the vehi cle is pointing straight uphill 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 7 Lock the parking brake and remount the vehicle from the uphill side keeping body weight up...

Page 67: ...rcase oil ADC fluid and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 116 then see your dealer for...

Page 68: ...ting in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees ...

Page 69: ... 6 Never open the throttle suddenly 7 Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in ...

Page 70: ...ERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle 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 PR...

Page 71: ...perating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions 4 NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg 5 NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 lbs 45 kg 6 Do not obstruct the headlight beam with cargo...

Page 72: ...ht capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your POLARIS ATV Always install POLARIS approved or equivalent accessories designed for ATV use Maximum Towing Capacities Do not exceed ...

Page 73: ... and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 80 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while oper...

Page 74: ...feed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s rated capacity 15 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during ...

Page 75: ...ways inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons 25 Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life ...

Page 76: ...g strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 77: ...cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load ...

Page 78: ...r can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned t...

Page 79: ... frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle I Stop winching as soon as the stuck ve...

Page 80: ... is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook...

Page 81: ... cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in...

Page 82: ... in an attempt to move an object This is a dangerous practice It gener ates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and gener...

Page 83: ...ly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the w...

Page 84: ...ctivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be ...

Page 85: ...crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissio...

Page 86: ...rm these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and ser viced 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 id...

Page 87: ...e will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride See Pre Ride Checklist on page 54 Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Wheels fasteners Frame fasteners Engine oil level Ź E Ai...

Page 88: ...el check Ź General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 500 800 Inspect lubricate D Steering 50 H 6 M 500 800 Lubricate Ź Front suspension 50 H 6 M 500 800 Lubricate Ź Rear suspension 50 H 6 M 500 800 Lubricate D E Throttle Cable Throttle Release Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Throttle Body Intake Duct...

Page 89: ...iring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24 M 2000 3200 Change every two years Ź D ADC fluid 200 H 24 M 2000 3200 Change every two years Spark ...

Page 90: ...7 ft lbs 20 23 Nm 89 850 Engine PS 4 5W 50 4 Cycle Oil 2 qt 1 9 l 12 ft lbs 16 Nm 89 Transmission Oil AGL Gearcase Lubricant Transmission Fluid 37 oz 1100 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm 92 Demand Drive Fluid Front Gearcase Demand Drive Fluid 9 3 oz 275 ml 8 10 ft lbs 11 14 Nm 11 ft lbs 15 Nm 93 Rear Gearcase Oil ATV Angle Drive Fluid or GL5 80 90 weight gear lube 7 1 oz 210 ml 10 1...

Page 91: ...nds or using a non recommended oil may cause serious engine damage Always 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 1 Position the vehicle on a level surface 2 Access the oil dipstick and fill tube from the left side of the ATV Remove the dip stick Wipe it dry with a clean cloth 3 Rei...

Page 92: ...ine Allow it to warm up at idle for two to three min utes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be cl...

Page 93: ... good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing sur face then turn it an additional 1 2 turn 13 Remove the dipstick Add the proper amount of the recommended oil Do not overfill 14 Reinstall the dipstick 15 Place the transmission in PARK 16 Lock the parking brake 17 Start the engine Allow it to idle for one to two minutes 18 Sto...

Page 94: ...e drain plug is located on the bottom rear of the gearcase Oil Check 1 Remove the footwell see page 103 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification 5 Reinstall the footwell Oil Change 1 Remove the footwell 2 Place a drain pan under the gearcase Remove the...

Page 95: ...vice 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 The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level sur face Remove the fill plug Check the fluid level 2 Add the...

Page 96: ...the fluid level between the minimum and maximum marks on the reservoir See page 137 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system Fluid Check 1 Remove the front rack 2 View the fluid level in the reservoir 3 If the level is below the minimum mark remove the cap and add the recommended fluid 4 Reinstall the c...

Page 97: ...eeder valves 6 Slowly loosen one of the bleeder valve screws turn counter clock wise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valve screws before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped a...

Page 98: ... products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Maintain the fluid level at the bottom of the fill hole threads Do not overfill Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overf...

Page 99: ... 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks 8 Dispose of used oil properly ...

Page 100: ...xpanding 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 rec...

Page 101: ... cap under the front storage com partment 1 View the fluid level in the bottle 2 If the level is low remove the front rack 3 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 Recovery Bottle Cap Maximum Mark Minimum Mark ...

Page 102: ...un dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add cool ant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pr...

Page 103: ...overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 28 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when...

Page 104: ...so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 8 1 4 inch 3 6 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 4 1 2 inch 6 12 mm toe out alignment 5 Repeat...

Page 105: ...asteners 3 Remove the seat Side Panel Footwell Removal Remove the seat before removing a side panel To remove a side panel or footwell remove the fasteners securing it to the frame Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Hex Head Screw Plastic Rivet Plastic Rivet Torx Head Screw ...

Page 106: ...in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 138 for recom mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less WARNING 1 8 3 mm...

Page 107: ... your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel ...

Page 108: ...ehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Wheel Type Nut Type Nut Torque Aluminum...

Page 109: ...e filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main filter if needed 6 Reinstall the filter into the air box 7 Reinstall the air box cover and the seat Main Filter Pre Filter Strap ...

Page 110: ... have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Remove the front rack 2 Remove the fuse box cover 3 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating 4 Reinstall the fuse box cover 5 Reinstall the front rack Fuse Box SPORTSMAN 550 EPS SPORTSMAN XP 850 EPS SPORTSMAN 550 SPORTSMAN XP 850 ...

Page 111: ...in leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 Remove the five 5 headlight pod screws 2 Lift the pod cover and disconnect the speedom eter harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 3 Unplug the headlamp from the wiring harness Be sure ...

Page 112: ...er of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring 5 The adjustment screw is located on the right side of the headlight pod To adjust the bea...

Page 113: ...ghts Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw Phillips Screw ...

Page 114: ...harnesses from the speedometer 3 Unplug the headlamp from the wiring harness 4 Use a small screwdriver to remove the o rings from the headlight mounting tabs 5 Pull the headlight housing up to release it from the locking tabs 6 Carefully pull the assembly up and out of the pod 7 Reverse the steps to install the new housing and reassemble the pod ...

Page 115: ...the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the head lamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light assembly 2 Turn the lamp counter clock wise to remove it 3 Install the new lamp 4 Reinstall the harness connector 5 Test the light for proper opera tion Harness Ta...

Page 116: ...n 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 115 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counter clockwise to remove it 3 Re...

Page 117: ...ngine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of no...

Page 118: ...ter Make sure the E ring is on the drain plug and reinstall the drain plug NOTICE Serious damage could occur if the air box drain plug is not reinstalled and tightened properly 3 Remove the spark plugs 4 Turn the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying proce dure N...

Page 119: ...purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge car bon from the system 5 If carbon comes out of the exhaust cover or plug the exhaust outlet s Wear protective gloves 6 Lightly tap on the exhaust pipe ...

Page 120: ...speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the ...

Page 121: ...due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1600 1800 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too lo...

Page 122: ...PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 5 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 Con...

Page 123: ...correct 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...

Page 124: ...of 2 3 mm should be visible between the throttle arm stop pin and the throttle arm If adjustment is needed 1 Locate the throttle cable adjuster Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 2 3 mm of freeplay is achieved between the stop pin and the throttle arm...

Page 125: ...ease see your POLARIS dealer for service 7 With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommended setting If idle speed increases it may be necessary to increase the gap between the stop pin and throttle arm but do not exceed the recommended 2 3 mm gap 8 When adjustments are complete tighten the...

Page 126: ...n of the battery could result in electrolyte leakage which would shorten the life of the battery considerably Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with diele...

Page 127: ... jelly 4 Secure the battery hold down strap 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 8 Install the front rack Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the ...

Page 128: ...DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the batt...

Page 129: ...mps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 ...

Page 130: ...s to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not...

Page 131: ...r 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...

Page 132: ...ntenance Chart beginning on page 85 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for...

Page 133: ...RIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 107 2 Clean the air box Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 85 Battery Maintenance...

Page 134: ...ps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for...

Page 135: ... 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 contro...

Page 136: ...ark 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 Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap...

Page 137: ...inked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kin...

Page 138: ...oose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen a...

Page 139: ...8 l 2877922 Demand Drive Fluid qt 95 l 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle...

Page 140: ...bs 109 kg Hitch Towing Rating 1500 lbs 680 4 kg Unbraked Trailer Towing Capacity 1786 lbs 810 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 ES550PLE Displacement 549 7 cc Bore x Stroke 96 6 x 75 Alternator Output 490w 1350 RPM Peak 630w Compr...

Page 141: ...e Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital LCD LED Digital Analog EPS Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 600...

Page 142: ... Hitch Towing Rating 1500 lbs 680 4 kg Unbraked Trailer Towing Capacity 1914 lbs 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 Bore x Stroke 87 x 71 5 Alternator Output 475w 1200 RPM Peak 630w Compression Rati...

Page 143: ...ngle Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital LCD LED XP Digital Analog XP EPS Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1...

Page 144: ...ansfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verif...

Page 145: ... other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or work...

Page 146: ... PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FA...

Page 147: ...the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be...

Page 148: ...utside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warra...

Page 149: ...dar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related p...

Page 150: ...MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caus...

Page 151: ...supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identifie...

Page 152: ... section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 153: ...151 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 154: ...152 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 155: ...153 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 156: ...Coolant Radiator 100 Cooling System 98 100 Crankcase Emission Control System 83 D Demand Drive Fluid 93 Diagnostic Codes 550 48 49 Diagnostic Codes 850 50 51 Disengaging Active Descent Control 33 Display Units Standard Metric 38 45 Drive Belt Wear Burn 133 Drivetrain Break In 53 Driving Downhill 63 Driving in Reverse 67 Driving on a Sidehill 62 Driving on Slippery Surfaces 60 Driving Over Obstacle...

Page 157: ...ent 121 Hauling Cargo 68 70 Headlight Housing Replacement 112 Headlight Lamp Replacement 109 Headlight Switch 24 Helmet 8 High Beam Adjustment 110 High Range Use 120 I Idle RPM Adjustment 122 Immersion 116 Indicator Lamps 35 Instrument Cluster 34 51 K Key Switch 25 K Turn 64 L Lights 109 113 Headlight Housing 112 Headlight Lamp 109 High Beam Adjustment 110 Low Beam Adjustment 111 Lower Headlamp Re...

Page 158: ...k Warning Front and Rear 23 Reverse Override Warning 21 Tire Pressure Load Warning 22 S Safety Training 7 Safety Warnings 10 19 Safety Winch Maintenance 82 Severe Use 84 Shock Loading the Winch 80 81 Side Panel Removal 103 Sidehilling 62 Signal Words 4 Spark Arrester 117 Spark Plug Inspection 114 115 Spark Plug Recommendations 114 Spark Plugs 114 115 Speedometer 34 Spring Adjustment Shock 121 Star...

Page 159: ...ication Numbers 6 Vehicle Immersion 116 W Warning Symbols 4 Washing the Vehicle 128 129 Wheel Hub Tightening 105 Wheel Installation 106 Wheel Nut Torque Specifications 106 Wheel Removal 105 Winch Cable Care 79 Winch Maintenance Service Safety 82 Winch Operation 74 78 Winch Safety Precautions 71 73 Winch Shock Loading 80 81 ...

Page 160: ...r your skills or the conditions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS S use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns S avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INS...

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