Polaris Sportsman Forest 550 Owner'S Manual Download

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130

TROUBLESHOOTING

Engine Stops or Loses Power

Engine Overheating

Possible Cause

Solution

Out of fuel

Refuel, cycle key to ON position three
times for 5 seconds each, then start

Kinked or plugged fuel vent line

Inspect and replace

Water is present in fuel

Replace with new fuel

Fouled or defective spark plugs

Inspect, clean and/or replace spark plug

Worn or defective spark plug wires

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

Loose ignition connections

Check all connections and tighten

Low battery voltage

Recharge the battery to 12.8 VDC

Incorrect fuel

Replace with fresh 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 and core, clean
engine exterior, see your dealer

Possible Cause

Solution

Debris lodged in screen

Clean the screen.

Plugged Radiator

Use a garden hose to flush any debris
from the radiator fins. NOTE: High pres-
sure washers can deform the radiator fins
and reduce cooling efficiency.

Summary of Contents for Sportsman Forest 550

Page 1: ... Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Sportsman Forest 550 Sportsman Forest 850 ...

Page 2: ...oducts Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs RANGER utility vehicles RZR sport vehicles VICTORY motorcycles GEM electric vehicles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory ce...

Page 3: ...epancies may result between the actual vehicle and the information presented in this publication 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 thi...

Page 4: ...Introduction 4 Safety 6 Features and Controls 20 Operation 42 Winch Guide 61 Emission Control Systems 73 Maintenance 74 Troubleshooting 127 POLARIS Products 131 Specifications 132 Warranty 136 Maintenance Log 140 Index 142 ...

Page 5: ...ituation 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 indicate...

Page 6: ...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 using 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 ___________________________________________________ Fr...

Page 7: ... polarisindustries com Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on road Equipment Modifications The warranty on yo...

Page 8: ... 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 Gasoline is highly flammable and explosive under certain conditions Use extreme caution whenever handling gasoline Refuel with the engine stopped Refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the ...

Page 9: ... 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 Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience ...

Page 10: ...et 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 excessive speeds which can lead to vehicle overturn If the vehicle has been involved in an accident always have an authorized POLARIS dealer inspect the entire vehicle for possible damage including but not...

Page 11: ...ls 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 braking on hills See page 55 Always follow the procedures outlined in this manual for crossing the side of a hill See page 54 Never attempt to turn the vehicle around on any hill until you ve mastered o...

Page 12: ...l 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 48 Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 49 Always follow the procedures outlined in this manual for dr...

Page 13: ... and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking Never operate the vehicle 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 vehicle you and your cargo together with any other vehicles in your party Operating on paved surfaces may affect the h...

Page 14: ... 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 exhaust system For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polarisindustries com ...

Page 15: ... 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 label Helmet Eye Protection Gloves Boots Long Pants Long Sleeves E4 05103...

Page 16: ...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 protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jer...

Page 17: ...arefully If a label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label The following pages repeat the information found on each label 2x4 OUT IN General Alert Age 16 Alert Hill Operation Alert Reverse Override Warning ...

Page 18: ... 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 spinning This may cause severe drive shaft and clutch damage 7175512 Hill Operation Alert Never operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flip over on hilly terrain when going up ...

Page 19: ...FRONT 7 0 48 3 REAR 7 0 48 3 MAXIMUM WEIGHT CAPACITY 575 lbs 261 kg INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES 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 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 7177981 No Passenger Warning...

Page 20: ...g 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 Clutch Cover Warning under seat Rack Warning Rack Warning ...

Page 21: ...s a MODE 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 2X4 See page 30 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Momentary High Beam Switch Press this switch with your left forefinger...

Page 22: ...unless the main key switch is on and the engine stop switch is in the RUN position High Beam Low Beam Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light The indicator on the pod will also flash Return the toggle to the center position to end the signal Horn Switch Press the horn switch to sound the horn Hazard Warning Switch Push the haza...

Page 23: ...the vehicle 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 the lever to reduce engine speed and vehicle movement Throttle Release Switch The throttle release switch causes the engine to stop if the throttle cable sticks in an open position when the opera...

Page 24: ...both front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates both front and rear brakes Squeeze the brake lever toward the handlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake red...

Page 25: ...n 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 the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating ...

Page 26: ...r 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 engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s...

Page 27: ...ea Refuel on a level surface Remove the fuel tank cap and add fuel Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent 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 ...

Page 28: ...n the 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 Foot brake fluid reservoir ADC fluid reservoir Coolant recovery bottle cap Electrical fuse relay components Latches ADC Fluid Reservoir Brake Fluid Reservoir Radiator Cap Coolant Bottle Cap Electrical Fuse Relay ...

Page 29: ...e 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 in forward or reverse 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 engage...

Page 30: ...If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gea...

Page 31: ... following conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 25 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the following conditions occur The 4X4 switch is moved out of the ADC 4X4 pos...

Page 32: ...S status high beam status battery voltage warning temperature warning and diagnostic display mode These features are outlined on the following pages NOTICE High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use a...

Page 33: ... 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 gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 2 Information Display Area This area displays odometer tripmeters engine hour met...

Page 34: ...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 warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessorie...

Page 35: ... also acts as a MODE button when held down for approximately one half second The transmission cannot be in reverse when using the override switch as a MODE button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Ground Speed Mode Ground speed is displayed in either miles per hour MPH or kilometers per hour km h Engine Speed Mode Engine speed is ...

Page 36: ...ton until the displayed units change Release the button 4 New settings remain until changed using the same procedure 12 Hour 24 Hour Clock Display 1 Press and hold the MODE button until RPM is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new clock format either 24 hour or 12 hou...

Page 37: ...T button to advance the hours to the desired setting including OFF When the digits stop flashing the interval has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1 Select the Hour Meter Mode 2 Press and hold the mode button on the instrument cluster until the hour display flashes Release the button 3 Press and release the SELECT button to advance the hours 4 Af...

Page 38: ... Inactive codes are stored in the history of the unit Please see your POLARIS dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the transmission in PARK 2 Press and release the SELECT button until the flashing check engine warning indicator appears in the display 3 A set of two numbers will also appear in the display The 2 6 di...

Page 39: ...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 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 ...

Page 40: ...rque 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 520225 17 T1 and T...

Page 41: ...nal 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 to B 126...

Page 42: ...ing 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 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 Shor...

Page 43: ... new POLARIS vehicle is the first 20 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and...

Page 44: ...lar checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 44 6 Pull only light loads 7 Change both the oil and the filter at 25 hours 8 Check the fluid level of the transmission after the first 25 hours of operation and every 100 hours thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life an...

Page 45: ...sure free operation Tires Inspect condition and pressure 96 Wheels fasteners Inspect ensure fastener tightness 96 97 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 26 79 Coolant level Ensure proper level 89 90 Coolant hoses Inspect for leaks Throttle Ensure proper operation 22 104 Indicator lights switches Ensure proper operation 20 Engine stop switch Ensure ...

Page 46: ...ait 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 Cold Weather Operation If the vehicle is used year round check the oil level frequentl...

Page 47: ...t 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 determine your path of travel 10 Release the brakes 11 Slowly depress the throttle with your right thumb and begin driving 12 Drive slowly Practice maneuvering and using the throttle and brakes on level su...

Page 48: ...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 Use the same leaning technique for turning in reverse 3 Practice making turns at slow speeds before attempting to turn at faster speeds Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle ov...

Page 49: ...the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 3 Be alert Watch the trail Avoid quick sharp turns 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Always follow the procedures outlined in this manual for operating o...

Page 50: ...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 brakes may have reduced stopping ability Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action is normal 6 If your vehicle becomes fully immersed and it s ...

Page 51: ...stacles 1 Always check for obstacles before operating in a new area 2 Be alert Watch the terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as logs rocks and low branches Always follow the procedures outlined in this manual for operating over obstacles ...

Page 52: ...pping 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 Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Always follow the procedures outlined in this manual for dri...

Page 53: ...Avoid 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 Be prepared to take emergency action This may include dismounting quickly 9 Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 25 Maximum ...

Page 54: ...hen 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 the procedures outlined in this manual for driving on hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for braking if you stall or roll backwards while ...

Page 55: ...id 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 side immediately Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turn...

Page 56: ...peed Slow down 4 Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 5 Shift your weight rearward 6 Apply the brakes slightly to aid in slowing Always follow the procedures outlined in this manual for driving downhill and for braking on hills Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visib...

Page 57: ...ll 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 uphill 6 Stay uphill of the vehicle and turn the handlebars full left 7 Squeeze the brake lever to release the parking brake 8 Slowly release the brake lever and allow the vehicle to roll around to your r...

Page 58: ...brake 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 52 Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 Always follow the procedures ou...

Page 59: ...SIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the...

Page 60: ...s low as possible 3 When operating 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 Use low forward gea...

Page 61: ...eight capacity of the vehicle FOREST 550 Unbraked Trailer Towing Capacity is 1786 lbs 810 kg based on EU Directive 76 432 EC FOREST 850 Unbraked Trailer Towing Capacity is 1914 lbs 868 kg based on EU Directive 76 432 EC NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your vehicle warranty Never install a hitch...

Page 62: ... 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 70 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while oper...

Page 63: ...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 64: ...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 65: ...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 66: ...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 67: ... 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 to the new mid po...

Page 68: ... 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 69: ... 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 70: ... 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 71: ... 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 72: ...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 73: ...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 74: ...ng Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle European Vibration and Noise The driver perceived noise and hand arm and whole body vibration leve...

Page 75: ...rvice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high R...

Page 76: ...aler perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride See Pre Ride Checklist on page 44 Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Wheels fasteners Frame fasteners Engine oil level Winch See pages 61 72 Ź E Air filter pre filter Daily Inspect clean often replace as needed Coolant D...

Page 77: ... level check Ź Rear gearcase oil 25 H 1 M 250 400 Break in oil level check Ź Transmission oil 25 H 1 M 250 400 Break in oil level 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 Th...

Page 78: ...Ź Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect D E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Ź Wiring 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 ...

Page 79: ...17 ft lbs 20 23 Nm Page 79 850 Engine Oil PS 4 5W 50 4 Cycle Oil 2 qt 1 9 l 12 ft lbs 16 Nm Page 79 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 Page 82 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 Page 83 Rear Gearcase Oil ATV Angle Drive Fluid or GL5 80 90 weight gea...

Page 80: ... 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 Access the oil dipstick and fill tube from the left side of the vehicle 1 Position the vehicle on a level surface Place the transmission in PARK 2 Remove the dipstick Wipe it dry with a c...

Page 81: ...PARK 2 Start the engine Allow it to warm up at idle for two to three minutes 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 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 s...

Page 82: ... o ring is in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface 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 Start the engine Allow it to idle for one to two minutes 17 Stop the engine 1...

Page 83: ...the gearcase Oil Check 1 Remove the footwell see page 95 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 drain plug Allow the oil to drain completely 3...

Page 84: ... recommended fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads See below for capacity The fill plug is located on the right side of the 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 surface Remove the fill plug Check the fluid level...

Page 85: ...e use 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 Fluid Maintain the fluid level between the minimum and maximum marks on the reservoir See page 131 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damage rubber components in the...

Page 86: ...ective 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 Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped...

Page 87: ... 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 88: ... 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 89: ... bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Antifreeze 60 40...

Page 90: ... cap under the front storage compartment 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 91: ...as 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 removing the pressure cap 1 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressur...

Page 92: ...rs 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 Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ...

Page 93: ...r 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 Reinstall the cover Torque screws to 7 in lbs 8 Nm Foot Brake The foot brake fluid reservoir is located under the front rack The brake fluid reservoir cap is black NOTICE Do not use ADC fluid in the ...

Page 94: ...ep brake fluid at an adequate level See page 92 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to 1 mm 5 Check the security and surface condition of the disc Clean any grease using a recommended brake cleaner or alcohol Do not use s...

Page 95: ...ht ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 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 3 6 mm more than the front measurement on ...

Page 96: ...operating the vehicle Seat Removal 1 Grasp one side of the seat near the rear edge 2 Pull upward abruptly to disengage the under seat fasteners 3 Remove the seat Side Panel Footwell Removal Remove the seat before removing a side panel Remove the screws and rivets securing the side panel or footwell see illustration Plastic Rivet Hex Head Screw Plastic Rivet Plastic Rivet Torx Head Screw ...

Page 97: ...ning on page 132 for recommended 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 and spindle nut retention are critical component operations All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Loosen t...

Page 98: ... 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 specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Wheel Type Nut Type Nut Torque Aluminum Lug Nut 75 ft lbs...

Page 99: ...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 100: ...ct any short circuits 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 850 550 ...

Page 101: ...ce 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 headlight switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the three 3 headlight screws to adjust the beam...

Page 102: ... will shorten the life of the lamp Hold the plastic part of the lamp 1 Place the transmission in PARK 2 Open the front rack cover 3 Remove the plug at the back of the headlight 4 Pull the harness plug to disconnect it from the back of the headlight 5 Position light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight...

Page 103: ...d Replace the entire signal lamp assembly Rear Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Rotate the turn signal socket counterclockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order ...

Page 104: ...ment 1 Place the transmission in PARK 2 Rotate the taillight socket counterclockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order ...

Page 105: ...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 locknut 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 106: ...ur 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 locknut 9 ...

Page 107: ...e adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any o...

Page 108: ...ition 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 108 A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counterclockwise to remove it 3 Reverse...

Page 109: ...gine 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 non...

Page 110: ...ilter If equipped remove the air box drain plug to drain water 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 s...

Page 111: ...ulated 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 carbon 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 with a rubbe...

Page 112: ...igh 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 ...

Page 113: ...he 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 low to pro...

Page 114: ...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 idle speed then shift the transmission 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 Cond...

Page 115: ...eries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional ...

Page 116: ...sconnect 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 conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle ...

Page 117: ...ry in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury o...

Page 118: ...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 the voltage drops below a pre determined point See page 131 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the bat...

Page 119: ... battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 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 Allo...

Page 120: ...andard 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 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 l...

Page 121: ...s to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not ...

Page 122: ... 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 123: ...t Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the produ...

Page 124: ...e fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery sys...

Page 125: ...ral 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 plastic squeeze bottle filled with the pre measured amount of oil 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the...

Page 126: ...t 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 materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accessories Accessory outlets are available ...

Page 127: ...ion in PARK 3 Secure the fuel cap oil cap and seat 4 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 5 Remove the key to prevent loss during transporting ...

Page 128: ... 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 129: ...Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap...

Page 130: ...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 131: ...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 132: ... 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 Drive Fluid qt 95 l 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 l 2871460 Premium Starter Grease 28715...

Page 133: ...m Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine ES550PLE 4 Stroke Low Torque Capacity Displacement 549 7 cc Engine Power 30 kW Bore x Stroke 96 6 x 75 Alternator Output 490w 1350 RPM Peak 630w Compression Ratio 9 6 1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1425 50 Ignition Timing 13 3 BTDC 1350 RPM ...

Page 134: ...ntrol handlebar hydraulic disc on all wheels Brakes Auxiliary Foot Activated Hydraulic Disc on all wheels Brake Parking Hydraulic lock on all wheels Mechanical Lock in Park Hitch Rear mounting for attachment of coupling devices Winch Front permanent installed winch with 2500 lbs 1125 kg capacity Headlight 2 Hi Lo beam on bumper 55 60 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster ...

Page 135: ...m Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO850LE 4 Stroke Low Torque Capacity Displacement 850 cc Engine Power 51 5 kW Bore x Stroke 87 x 71 5 Alternator Output 475w 1200 RPM Peak 575w Compression Ratio 11 1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1200 50 Ignition Timing 6 5 BTDC 1200 RPM En...

Page 136: ...ntrol handlebar hydraulic disc on all wheels Brakes Auxiliary Foot Activated Hydraulic Disc on all wheels Brake Parking Hydraulic lock on all wheels Mechanical Lock in Park Hitch Rear mounting for attachment of coupling devices Winch Front permanent installed winch with 2500 lbs 1125 kg capacity Headlight 2 Hi Lo beam on bumper 55 60 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster ...

Page 137: ... the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVE...

Page 138: ...ANY 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...

Page 139: ...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 140: ...y to Safety Bulletins NOTICE If your product is registered outside 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 wa...

Page 141: ... 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 services performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 142: ...141 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 143: ...0 XP 133 850 XP 135 C Cold Weather Operation 45 Coolant Bottle 89 Coolant Radiator 90 Cooling System 88 90 Corrosion Removal Chrome 122 D Demand Drive Fluid 83 Diagnostic Codes 550 XP EPS 38 39 Diagnostic Codes 850 XP EPS 40 41 Disengaging Active Descent Control 30 Display Standard Metric 35 Drive Belt Wear Burn 127 Drivetrain Break In 43 Driving Downhill 55 Driving in Reverse 51 Driving on a Side...

Page 144: ...mentary High Beam Switch 20 Position Light Lamp 101 Rear Turn Signal 102 Taillight Brakelight Worklight 103 L Low Beam Adjustment 100 Low Range Use 113 Lubrication Guide 78 M Maintenance Chart 74 77 Metric Standard Display 35 Mirrors 22 Mode Switch 20 Modifications 6 N Noise Emission Control System 73 O Oil Engine 79 81 Rear Gearcase 86 87 Transmission 82 Oil and Filter Change 80 81 Oil Level Engi...

Page 145: ... Override Switch 20 Stop Switch 21 Turn Signal 21 Winch Switch 20 T Taillight 103 Throttle Body Adjustment 104 Throttle Cable Freeplay Adjustment 104 105 Throttle Lever 22 Tire Tread Depth 96 Tires 96 97 Wheel Installation 97 Wheel Nut Torque 97 Wheel Removal 96 Toe Alignment 94 Towing Loads 60 Training 6 Transmission Gear Selector 25 Transmission Oil 82 Transporting the Vehicle 126 Turn Signal La...

Page 146: ...For your nearest Polaris dealer visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Part No 9924662 Rev 01 Printed in USA 9924662 Before you operate this vehicle read the owner s manual ...

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Polaris Sportsman Forest 550, Owner'S Manual

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