Polaris Sportsman 9922452 Page 101 Owner'S Manual Download

Page: 101 / 148

MAINTENANCE

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight

harness counterclockwise and

pull the harness assembly away

from the headlight assembly.

2. Remove the headlamp and

install the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

4. Turn the 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 counterclockwise

to remove it.

3. Install the new lamp.
4. Reinstall the harness connector.
5. Test the light for proper opera-

tion.

Harness

Taillight

Summary of Contents for Sportsman 9922452

Page 1: ...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 XP Sportsman 550 XP...

Page 2: ...r 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...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...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 A...

Page 5: ...ation 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 about major repairs is outli...

Page 6: ...lity 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 in...

Page 7: ...fety 7 Features and Controls 26 Operation 49 Emission Control Systems 67 Maintenance 68 Adjustments 118 Troubleshooting 121 Polaris Products 125 Specifications 126 Declaration of Conformity 130 Warran...

Page 8: ...l 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...

Page 9: ...driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV K...

Page 10: ...ng your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame...

Page 11: ...V RiderCoursesm 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 enforc...

Page 12: ...eds established 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 m...

Page 13: ...protect arms and legs Riding 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 A...

Page 14: ...properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never...

Page 15: ...hange clothing Exposure to Exhaust Engine exhaust fumes are poisonous 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 e...

Page 16: ...d eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never co...

Page 17: ...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...

Page 18: ...tion 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 turni...

Page 19: ...heck 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 shar...

Page 20: ...ount following the procedure described in the owner s manual See page 60 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling ba...

Page 21: ...slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in...

Page 22: ...Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with im...

Page 23: ...a 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...

Page 24: ...argo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never opera...

Page 25: ...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 compone...

Page 26: ...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 WIT...

Page 27: ...s 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...

Page 28: ...n SEVERE INJURY or DEATH 7175378 Tire 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 press...

Page 29: ...PM which can result 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 f...

Page 30: ...jury or death Always release the throttle before pressing the override button The reverse override button also acts as a MODE button when held down for approximately one half second The transmission c...

Page 31: ...is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 53 for s...

Page 32: ...e control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms...

Page 33: ...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 a...

Page 34: ...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...

Page 35: ...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...

Page 36: ...ake system Should 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 s...

Page 37: ...r while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low...

Page 38: ...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...

Page 39: ...f 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 driv...

Page 40: ...ollow 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 g...

Page 41: ...equipped high beam status battery voltage warning temperature warning and diagnos tic display mode These features are outlined on the following pages NOTICE High water pressure may damage ATV compone...

Page 42: ...ome ter If this occurs take the ATV to your Polaris dealer for proper diagno sis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to...

Page 43: ...ting condition remains and the system will automatically reduce engine power 8 Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehi...

Page 44: ...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 button as a MODE button This feature does not contain a vehic...

Page 45: ...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 disp...

Page 46: ...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...

Page 47: ...nactive 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...

Page 48: ...PN 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 1...

Page 49: ...ering 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 Steer...

Page 50: ...gnal 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...

Page 51: ...ssive 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 Failur...

Page 52: ...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 flui...

Page 53: ...of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 33 Always exercise extreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 7...

Page 54: ...ect lubricate if necessary 72 Steering Ensure free operation Tires Inspect condition and pressure 88 Wheels fasteners Inspect ensure fastener tightness 88 90 Frame nuts bolts fasteners Inspect ensure...

Page 55: ...d visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly 8 Drive in a manner appropriate for your skills and operating condi tions Never operat...

Page 56: ...icle 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 alwa...

Page 57: ...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...

Page 58: ...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 th...

Page 59: ...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 whee...

Page 60: ...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...

Page 61: ...ays 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 st...

Page 62: ...erturn 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 foo...

Page 63: ...or descending a hill See page 36 2 Avoid steep hills 25 maximum 3 Shift body weight uphill 4 Drive straight downhill 5 Slow down Excessive speed when traveling downhill can cause loss of control 6 Squ...

Page 64: ...icle 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 slowl...

Page 65: ...gearcase oil 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 v...

Page 66: ...ing 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 unfami...

Page 67: ...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 in...

Page 68: ...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 r...

Page 69: ...wed load to the hitch point Remove the hitch from the ATV 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 wei...

Page 70: ...an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear whee...

Page 71: ...bject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases ar...

Page 72: ...vice 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 ap...

Page 73: ...ious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use E Emission related...

Page 74: ...er Daily Inspect clean often replace as needed Coolant Daily Check level daily change coolant every 2 years X ADC fluid Daily Check level daily add as needed X Power steering unit if equipped Daily In...

Page 75: ...on oil 100 H 12 M 1000 1600 Change fluid Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years X Engine mounts 100 H 12 M 1000 1600 Inspect Exhau...

Page 76: ...4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 15 17 ft lbs 20 23 Nm Page 73 850 Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 12 ft lbs 16 Nm Page 73 Transmission Oil Synthetic SPORTSMAN...

Page 77: ...brands 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 che...

Page 78: ...ngine 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 dr...

Page 79: ...in 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 pr...

Page 80: ...drain plug is located on the bottom left side of the gearcase Oil Check 1 Remove the footwell see page 87 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the...

Page 81: ...and drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recom mended fl...

Page 82: ...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 Oi...

Page 83: ...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 rec...

Page 84: ...e use includes operation in ADC mode for prolonged periods or in environments that necessitate primary operation in ADC mode We recommend the use of Polaris Demand Drive Plus Fluid for the ADC unit Ma...

Page 85: ...ctive caps from the bleeder valves 6 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 R...

Page 86: ...s 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 a...

Page 87: ...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 b...

Page 88: ...n 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...

Page 89: ...r brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operat...

Page 90: ...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 o...

Page 91: ...bruptly 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 footwel...

Page 92: ...n 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 Ref...

Page 93: ...our 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 co...

Page 94: ...icle 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...

Page 95: ...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...

Page 96: ...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 pa...

Page 97: ...n 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 an...

Page 98: ...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 headligh...

Page 99: ...hts 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 sc...

Page 100: ...arnesses 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...

Page 101: ...he 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 c...

Page 102: ...engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 99 CAUTION A hot exhaust system and engine can cause burns Wear...

Page 103: ...ine 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 ins...

Page 104: ...o 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 Turn the engine over several times using the ele...

Page 105: ...urge 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 rele...

Page 106: ...oads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product...

Page 107: ...e 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...

Page 108: ...ARK 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 10 seconds 5 Allow the engine RPM to settle to i...

Page 109: ...oduce 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 ATV...

Page 110: ...isconnect the battery hold down strap 5 On conventional batteries remove the battery vent tube 6 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill...

Page 111: ...d securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an ex...

Page 112: ...ery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if th...

Page 113: ...tery 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 mult...

Page 114: ...ndard amps 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...

Page 115: ...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 fi...

Page 116: ...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 furn...

Page 117: ...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 periodical...

Page 118: ...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 stabili...

Page 119: ...l minutes so the Carbon Clean reaches the injectors Stop the engine 2 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...

Page 120: ...the ATV 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 enou...

Page 121: ...Lock the parking brake 4 Secure the fuel cap oil cap and seat 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A...

Page 122: ...f 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...

Page 123: ...ase see your Polaris dealer for ser vice 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 recommende...

Page 124: ...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 se...

Page 125: ...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 larg...

Page 126: ...ouled 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 b...

Page 127: ...nked 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 E...

Page 128: ...ose 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...

Page 129: ...ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Gre...

Page 130: ...d and tongue weight not to exceed 240 lbs 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 Over...

Page 131: ...gle 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...

Page 132: ...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...

Page 133: ...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...

Page 134: ...009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___GJ52__ ___GP52__ OUTLAW 525 2008 2009 2010 80 7 ___LH...

Page 135: ...laris 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 receipt of this registration Polaris will re...

Page 136: ...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 Warranty app...

Page 137: ...y 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 compatib...

Page 138: ...ur 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 addit...

Page 139: ...ling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Co...

Page 140: ...s registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of a...

Page 141: ...omponents of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 142: ...ue to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing compet...

Page 143: ...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 TECH...

Page 144: ...140 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 145: ...141 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 146: ...7 Clutching 850 XP EPS 129 C Cold Weather Operation 53 Consumer Product Safety 7 Coolant Bottle 83 Coolant Radiator 84 Cooling System 82 84 Corrosion Removal Chrome 113 Crankcase Emission Control Syst...

Page 147: ...47 K Key Switch 27 K Turn 60 L Lights 93 97 Headlight Housing Replacement96 Headlight Lamp 93 High Beam Adjustment 94 Low Beam Adjustment 95 Lower Headlamp Replacement 97 Taillight Brakelight Worklig...

Page 148: ...tandard Metric Display 41 Starting the Engine 53 Steering Assembly 86 Storage 111 116 Storage Tips 114 116 Switches 26 27 4X4 Switch 26 34 Engine Stop Switch 27 Headlight Switch 27 Main Key Switch 27...

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