Polaris Sportsman 9922581 Page 137 Owner'S Manual Download

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134

INDEX

Rack/Compartment, Front . . . . . . . . 27

Reverse Operation . . . . . . . . . . . . . . 51

Reverse Override Switch . . . . . . . . . 20

Rider Information Center. . . . . . . 32-41

Rider Safety . . . . . . . . . . . . . . . . . . 7-13

Riding Gear . . . . . . . . . . . . . . . . . 14-15

Safety Labels . . . . . . . . . . . . . . . 16-19

"No Passenger" Warning . . . . . 18

Age 16 Alert . . . . . . . . . . . . . . 16

Clutch Cover Alert. . . . . . . . . . 19

General Alert . . . . . . . . . . . . . . 17

Hill Operation Alert. . . . . . . . . 17

Hitch Capacity Label . . . . . . . . 19

Rack Warning, Front and Rear 19

Reverse Override Warning . . . 17

Tire Pressure/Load Alert . . . . . 18

Safety Training . . . . . . . . . . . . . . . . . 6

Severe Use . . . . . . . . . . . . . . . . . . . . 62

Side Panel Removal. . . . . . . . . . . . . 83

Sidehilling . . . . . . . . . . . . . . . . . . . . 54

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor . . . . . . . . . . . . . . . . . 98

Spark Arrestor Requirements . . . . . 61

Spark Plug Inspection . . . . . . . . . 95-96

Spark Plug Recommendations. . . . . 95

Spark Plugs . . . . . . . . . . . . . . . . . 95-96

Spring Adjustment, Shock . . . . . . . . 94

Standard/Metric Display . . . . . . . . . 35

Starting the Engine . . . . . . . . . . . . . 45

Steering Assembly . . . . . . . . . . . . . . 83

Steering Lock. . . . . . . . . . . . . . . . . . 26

Storage . . . . . . . . . . . . . . . . . . . 108-113

Storage Tips . . . . . . . . . . . . . . . 111-113

Switches

4X4 Switch . . . . . . . . . . . . . 20, 28

Engine Stop Switch . . . . . . . . . . 21

Hazard Warning. . . . . . . . . . . . . 20

Headlight Switch . . . . . . . . . . . . 21

Horn . . . . . . . . . . . . . . . . . . . . . . 21

Main Key Switch . . . . . . . . . . . . 21

Mode Switch . . . . . . . . . . . . . . . 20

Reverse Override Switch . . . . . . 20

Stop Switch . . . . . . . . . . . . . . . . 21

Turn Signal . . . . . . . . . . . . . . . . 21

Taillight . . . . . . . . . . . . . . . . . . . . . . . 91

Throttle Body Adjustment . . . . . . . . . 92

Throttle Cable Freeplay . . . . . . . . 92-93

Throttle Lever . . . . . . . . . . . . . . . . . . 22

Tire Tread Depth . . . . . . . . . . . . . . . . 84

Tires . . . . . . . . . . . . . . . . . . . . . . 84-85

Wheel Installation . . . . . . . . . . . 85

Wheel Nut Torque . . . . . . . . . . . 85

Wheel Removal . . . . . . . . . . . . . 84

Toe Alignment. . . . . . . . . . . . . . . . . . 82

Towing Loads . . . . . . . . . . . . . . . . . . 59

Training . . . . . . . . . . . . . . . . . . . . . . . . 6

Transmission Gear Selector. . . . . . . . 25

Transmission Oil . . . . . . . . . . . . . . . . 70

Transporting the Vehicle . . . . . . . . . 114

Turn Signal Lamp, Rear . . . . . . . . . . 90

Turn Signal Switch . . . . . . . . . . . . . . 21

Turning Around on a Hill . . . . . . 56-57

Turning the Vehicle . . . . . . . . . . . . . . 47

Vehicle Identification Numbers. . . . . . 5

Vehicle Immersion . . . . . . . . . . . . . . 97

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . 108-109

Wheel Hub Tightening . . . . . . . . . . . 84

Wheel Installation . . . . . . . . . . . . . . . 85

Wheel Nut Torque Specifications . . . 85

Wheel Removal . . . . . . . . . . . . . . . . . 84

Summary of Contents for Sportsman 9922581

Page 1: ...important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Pantone 426 C International Owner s Manual for Maintenance and Safety Sportsman 550 X...

Page 2: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 3: ...Pantone 426 C For your nearest Polaris dealer visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9922581 Rev 02 Printed in U S A...

Page 4: ...s Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manua...

Page 5: ...roduction components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended fo...

Page 6: ...ion 4 Safety 6 Features and Controls 20 Operation 42 Emission Control Systems 61 Maintenance 62 Troubleshooting 115 Polaris Products 119 Specifications 120 Declaration of Conformity 124 Warranty 125 M...

Page 7: ...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 8: ...rd your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank...

Page 9: ...a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone un...

Page 10: ...icle unless they have read and understand this manual and all product labels and have completed a certified safety training course Never allow anyone under 16 years of age to operate this vehicle Gaso...

Page 11: ...properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Tra...

Page 12: ...t on the footrests Always travel slowly when operating on unfamiliar terrain Use extra caution Always follow the procedures outlined in this manual for turning See page 47 Never turn sharply at excess...

Page 13: ...s Avoid climbing hills steeper than 25 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Always follow the procedures outlined in this manual for driving downhill and for bra...

Page 14: ...for operating over obstacles See page 50 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 4...

Page 15: ...capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for br...

Page 16: ...unlock the steering before starting the engine See page 26 Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the ex...

Page 17: ...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 distin...

Page 18: ...rsonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and...

Page 19: ...l carefully If a label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on...

Page 20: ...in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinni...

Page 21: ...a loss of control resulting in SEVERE INJURY or DEATH 7175378 Tire Pressure Load Alert TIRE PRESSURE IN PSI KPa Front 7 0 psi 48 3 kPa Rear 5 0 psi 34 5 kPa MAXIMUM WEIGHT CAPACITY 575 lbs 261 kg INC...

Page 22: ...pover 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...

Page 23: ...E button when held down for approximately one half second The transmission cannot be in reverse when using the override switch as a MODE button 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2...

Page 24: ...start or run when the switch is in the OFF position OFF RUN Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position High Beam Low...

Page 25: ...ehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to increase engine speed and vehicle movement Release...

Page 26: ...oth front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake...

Page 27: ...squeeze and hold 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever Operating the vehicle while...

Page 28: ...ar N Neutral R Reverse P Park Stop the vehicle release the throttle and move the shift lever to the desired gear See your dealer if you experience any shifting problems NOTICE Shifting gears with the...

Page 29: ...to unlock the steering The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before starting the engine Fuel Tank Always refuel with the engine...

Page 30: ...the illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following compo nents in the front compart ment Radiator cap Foot brake fluid reservo...

Page 31: ...the vehicle is in 4X4 and the 4X4 indicator icon in the instrument cluster display will be visible When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction Wh...

Page 32: ...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 33: ...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 34: ...quipped 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 vehicle compo...

Page 35: ...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 35 1 Gear Indicator This indicator displays g...

Page 36: ...the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 36 for resetting instructions 9 Under Over Voltage This w...

Page 37: ...also acts as a MODE button when held down for approximately one half second The transmission cannot be in reverse when using the over ride switch as a MODE button This feature does not contain a vehic...

Page 38: ...on 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 displaye...

Page 39: ...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 40: ...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 41: ...mp etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in th...

Page 42: ...Too High 523 3 Signal Fault 523 2 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Ignition Coil Primary Driver 1 MAG Driver Open Grounded 1268 5 Driver Circuit Short...

Page 43: ...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 44: ...1 6 Steering Excessive Current Error Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Partial Failure T1 Shorted to Ground 520223 4 T1 Shorted to Bus 520223 3 Steering Torque Sensor T2...

Page 45: ...en hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatmen...

Page 46: ...rottle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 44 6 Pull only light loads 7...

Page 47: ...sary 66 Steering Ensure free operation Tires Inspect condition and pressure 84 Wheels fasteners Inspect ensure fastener tightness 84 85 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil...

Page 48: ...it 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...

Page 49: ...with both feet on the footrests Keep both hands on the handlebars 6 Start the engine and allow it to warm up 7 Apply the brakes 8 Shift the transmission into gear 9 Check your surroundings and determ...

Page 50: ...in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest Use the same leaning tech nique for turning in reverse 3 Practice maki...

Page 51: ...he wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 3 Be alert Watch the trail Avoid quick sharp turns 4 Never apply th...

Page 52: ...anges NOTICE If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 5 Wet brake...

Page 53: ...tacles 1 Always check for obstacles before operating in a new area 2 Be alert Watch the terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branch...

Page 54: ...ping 4 Avoid turning at sharp angles 5 Never open the throttle suddenly 6 Do not use the override switch unless additional wheel speed is required for vehicle movement Use with caution NOTICE Excessiv...

Page 55: ...void steep hills 25 maximum 4 Avoid hills with slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill 7 Proceed at a steady rate of speed to avoid stalling 8 Be alert...

Page 56: ...en fully stopped lock the hydraulic parking brake 3 Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 4 Use the K turn to turn around See page 56 Always follow...

Page 57: ...d hills with slippery or loose surfaces 5 Avoid crossing the sides of steep hills 6 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill si...

Page 58: ...eed Slow down 4 Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 5 Shift your weight rearward 6 Apply the brakes slightly to aid in s...

Page 59: ...l See page 30 3 Lock the hydraulic parking brake 4 Leave the transmission in forward gear Turn the engine off 5 Dismount on the uphill side or on the left side if the vehicle is pointed straight uphil...

Page 60: ...rake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground Always follow the procedures outlined in this manual for driving on hills See page...

Page 61: ...ions Carrying loads on only one rack increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehi...

Page 62: ...any trailer on a grade steeper than 15 Always attach a towed load to the hitch point Remove the hitch from the vehicle when not towing a trailer If towing a load reduce rear rack cargo weight by the...

Page 63: ...N Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the do...

Page 64: ...hat this spark arrestor remain installed and functional when the vehicle is operated Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI...

Page 65: ...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 66: ...serious 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 rel...

Page 67: ...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 68: ...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 69: ...4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 15 17 ft lbs 20 23 Nm Page 67 850 Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 12 ft lbs 16 Nm Page 67 Transmission Oil Synthetic SPORTSMAN...

Page 70: ...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 t...

Page 71: ...n PARK 2 Start the engine 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...

Page 72: ...the o ring is 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 dipsti...

Page 73: ...drain plug is located on the bottom left side of the gearcase Oil Check 1 Remove the footwell see page 83 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the...

Page 74: ...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 75: ...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 76: ...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 77: ...e Extreme 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 Maintain th...

Page 78: ...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 79: ...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 80: ...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 81: ...s run dry check the level in the radiator Add coolant as needed Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before remo...

Page 82: ...s of Polaris products An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Und...

Page 83: ...Tip The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 If the fluid level is low remove the cover screws and add fluid to the fill line Do not overfill 4...

Page 84: ...systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 80 2 Check the brake systems regularly f...

Page 85: ...position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straig...

Page 86: ...operating the vehicle Seat Removal 1 Grasp one side of the seat near the rear edge 2 Pull upward abruptly to disengage the under seat fasteners 3 Remove the seat Side Panel Footwell Removal Remove the...

Page 87: ...ng on page 120 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 Front Wheel Hub Tightening Front wheel bearing tightness...

Page 88: ...the ground 5 Torque the wheel nuts to specification 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...

Page 89: ...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 90: ...rt 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 f...

Page 91: ...from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 4 Start the engine Turn the head light switch to high...

Page 92: ...ill shorten the life of the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK 2 Open the front rack cover 3 Remove the plug at the back of the headlight 4 Pull the harness plug t...

Page 93: ...1 Place the transmission in PARK 2 Rotate the turn signal socket counterclockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for prope...

Page 94: ...ent 1 Place the transmission in PARK 2 Rotate the taillight socket counterclockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for prop...

Page 95: ...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 96: ...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 recommended setting If...

Page 97: ...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...

Page 98: ...fter the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 96 A hot exhaust system and engine can cause burns Wear...

Page 99: ...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 100: ...to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times using the el...

Page 101: ...ated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the thro...

Page 102: ...al loads 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 prod...

Page 103: ...system s depen dence 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 160...

Page 104: ...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 105: ...ies produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN You...

Page 106: ...onnect the battery hold down strap 5 On conventional batteries remove the battery vent tube 6 Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spi...

Page 107: ...s and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte Battery gases could accumulate in an improperly installed vent tube and cause an explos...

Page 108: ...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 109: ...battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or...

Page 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...the vehicle with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow...

Page 117: ...on in PARK 3 Secure the fuel cap oil cap and seat 4 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt...

Page 118: ...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 119: ...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 120: ...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 121: ...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 122: ...872276 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 Grease...

Page 123: ...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...

Page 124: ...a Brakes Hand Lever All wheel hydraulic disc Brakes Foot All wheel hydraulic disc Brake Parking Transmission park lock and hydraulic lock all wheel Headlight 2 Hi Lo beam on bumper 37 5 watt Taillight...

Page 125: ...itch 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 c...

Page 126: ...5 kPa Brakes Hand Lever All wheel hydraulic disc Brakes Foot All wheel hydraulic disc Brake Parking Transmission park lock and hydraulic lock all wheel Headlight 2 Hi Lo beam on bumper 37 5 watt Taill...

Page 127: ...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 128: ...egistration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of regist...

Page 129: ...to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty...

Page 130: ...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 compatibl...

Page 131: ...ealer authorized to repair Polaris vehicles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALE...

Page 132: ...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 133: ...130 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 134: ...131 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 135: ...othing 15 C Clutching 550 XP 121 Clutching 850 XP 123 Cold Weather Operation 45 Coolant Bottle 77 Coolant Radiator 78 Cooling System 76 78 Corrosion Removal Chrome 110 D Demand Drive Fluid 71 Diagnost...

Page 136: ...er 31 41 K Key Switch 21 K Turn 56 57 L Lights 88 91 Headlight Beam Adjustment 88 Headlight Lamp 89 Position Light Lamp 89 Rear Turn Signal 90 Taillight Brakelight Worklight 91 Low Beam Adjustment 88...

Page 137: ...45 Steering Assembly 83 Steering Lock 26 Storage 108 113 Storage Tips 111 113 S Switches 4X4 Switch 20 28 Engine Stop Switch 21 Hazard Warning 20 Headlight Switch 21 Horn 21 Main Key Switch 21 Mode Sw...

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