Pantone 426 C Sportsman 550 XP Sportsman 850 XP Sportsman 850 XP EPS International Owner's Manual for 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.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER® utility vehicles • Victory Motorcycles® Always follow the instructions and recommendations in this manual.
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Emission Control Systems . . . . . . . . . . . . . . . 61 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 115 Polaris Products. . .
INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
INTRODUCTION As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
SAFETY WARNING Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating this Polaris vehicle. Safety Training When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course.
SAFETY Rider Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. See the OPERATION section of the owner’s manual for proper operating procedures. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. Take a training course.
SAFETY Rider Safety Never carry a passenger on this vehicle. Always wear an approved helmet that fits 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.
SAFETY Rider Safety Always inspect your vehicle before each use to verify that it's in safe operating condition. See page 44. Follow the inspection and maintenance procedures outlined in this manual. Keep both hands on the handlebars. Keep both feet 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.
SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving on hills. See page 52. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 55.
SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 53. Always follow the procedures outlined in this manual 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.
SAFETY Rider Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this vehicle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. Never operate the vehicle on a frozen body of water.
SAFETY Rider Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always 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.
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Sleeves Gloves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label. The following pages repeat the information found on each label.
SAFETY Safety Labels and Locations General Alert (Multi-Lingual) Before you operate this vehicle, read the owner’s manual. 7173025 Reverse Override Warning/4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse. CAUTION Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning.
SAFETY Safety Labels and Locations “No Passenger” Warning Tire Pressure/Load Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause 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) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES.
SAFETY Safety Labels and Locations Rack Warning Rack Warning + + + Clutch Cover Warning (under seat) Clutch Cover Alert 7175826 Rack Warning, Front and Rear WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg) 7175448 Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX.
FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Engine Stop Switch Turn Signal Switch 2x4 Headlight Switch Horn Switch 4X4 Switch Hazard Switch Main Key Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch. Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.
FEATURES AND CONTROLS Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. See page 45 for starting procedures. Engine Stop Switch The engine will not start or run when the switch is in the OFF position.
FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation. Do not start or operate the vehicle with sticking or improperly operating throttle controls.
FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes. Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes.
FEATURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then 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.
FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 33 for EPS Warning Indicator information. Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle.
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. 1. Turn the handlebars to the full left position. Tip: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 4. Reverse the procedure to unlock the steering.
FEATURES AND CONTROLS Front Rack/Compartment Release the front rack latches and remove the rack to gain access to the front compartment. To reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches.
FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is ADC 4X4 controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, 2x4 the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 4X4 Mode When the switch is on 4X4, the 4X4 vehicle is in 4X4, and the 4X4 Switch indicator icon in the instrument cluster display will be visible.
FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, please see your Polaris dealer.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately. Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See your dealer. 5. High Beam Indicator - This indicator appears when the lights are set to high beam. 6.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override switch also acts as a MODE button when held down for approximately one half second. The transmission cannot be in reverse when using the override switch as a MODE button.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override switch also acts as the SELECT button when pressed and released quickly. The transmission cannot be in reverse when using the override switch as a SELECT button.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your Polaris dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart. Shorted Load: The wires leading to the item listed in the chart are shorted together, or the item has shorted internally.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 550 XP Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Gear Sensor Signal Injector 1 (MAG) Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Con
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 XP / XP EPS Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Vehicle Speed Signal Gear Sensor Signal Injector 1 (MAG) (SDI Part Load) Injector 2 (PTO) (SDI Part Load) Ignition Coil Primary Driver 1 (MAG) Ignition Coil Primary Driver 2 (PTO) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Contr
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 XP / XP EPS Diagnostic Codes Component Chassis Relay All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed Condition Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Voltage Too High Voltage Too low Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Dr
OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 67. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. 5.
OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
OPERATION Starting the Engine 1. Position the vehicle on a level surface 2. Place the transmission in PARK. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. 3. Sit on the vehicle. Move the engine stop switch to RUN. 4. Do not press the throttle while starting the engine. 5. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter.
OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 46 Wear protective riding gear. See page 14. Perform the pre-ride inspection. See page 44. Place the transmission in PARK. Mount the vehicle from the left side. Sit upright with both feet on the footrests. Keep both hands on the handlebars. Start the engine and allow it to warm up. Apply the brakes. Shift the transmission into gear. Check your surroundings and determine your path of travel. Release the brakes.
OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 3. Practice making turns at slow speeds before attempting to turn at faster speeds.
OPERATION Driving on Slippery Surfaces Sideways Skid Turn in direction of skid Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction. 3.
OPERATION Driving Through Water Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of Maximum the footrests. If it's unavoidDepth able, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 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.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 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.
OPERATION Driving Uphill 25° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Drive straight uphill. 3. 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.
OPERATION Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. 4. Use the K-turn to turn around. See page 56. Always follow the procedures outlined in this manual for driving on hills.
OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Shift body weight uphill. 3. Keep your feet on the footrests. 4. Avoid hills with slippery or loose surfaces. 5. Avoid crossing the sides of steep hills. 6.
OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down. 4. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. 5. Shift your weight rearward. 6. Apply the brakes slightly to aid in slowing.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. 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.
OPERATION Turning Around on a Hill (K-Turn) 9. 10. 11. 12. 13. 14. Lock the hydraulic parking brake. Remount from the uphill side. Keep your weight uphill. Apply the foot brake. With the transmission still in forward, start the engine. Squeeze and release the brake lever to release the parking brake. Release the foot brake and drive slowly downhill. Control speed with either the hand or foot brake until the vehicle is on level ground.
OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels. • Never exceed the stated load capacity for this vehicle.
OPERATION Hauling Cargo Never exceed the weight capacities specified for your vehicle on warning labels and 2/3 in the specifications section of 1/3 this manual. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Use low forward gear when hauling or towing heavy cargo to extend belt life.
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Always block the rear wheels on the downhill side.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated. Exhaust Emission Control System Exhaust emissions are controlled by engine design.
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 129.
MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Remarks Miles (Km) Steering - Pre-Ride - Front suspension - Pre-Ride - Rear suspension - Pre-Ride - Tires - Pre-Ride - Brake fluid level - Pre-Ride - Brake lever travel - Pre-Ride - Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - See Pre-Ride Checklist on page 44.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Q Throttle Cable/ E ETC Switch 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary E Throttle Body Intake Duct 50 H 6M 500 (800) Inspect duct for proper sealing/air leaks 500 (800) Inspect; replace as needed Drive belt 50 H 6M Cooling system 50 H 6M 1000 (1600) Inspect coolant strength seasonally; pressure test system yearly 50 H 6M 1000 (1600)
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 66 for fluid recommendations, capacities and plug torques. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 119 for the part numbers of Polaris products.
MAINTENANCE Engine Oil Oil and Filter Change See the table on page 66 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil. 550 Drain Plug 850 Drain Plug to front Filter Access 1. Position the vehicle on a level surface. Place the transmission in PARK. 2. Start the engine. Allow it to warm up at idle for two to three minutes. 3.
MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. Oil Filter 12.
MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic SPORTSMAN XP Transmission Fluid for this transmission. See the table on page 66 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. See page 119 for the part numbers of Polaris products. Maintain the oil level at the bottom of the fill plug hole.
MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 66 for fluid recommendations, capacities and plug torques. Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. See page 119 for the part numbers of Polaris products. Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. See below for capacity.
MAINTENANCE Rear Gearcase Oil See the table on page 66 for fluid recommendations, capacities and plug torques. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. See page 119 for the part numbers of Polaris products. The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase. Fill Maintain the fluid level at the Level bottom of the fill hole threads. Do not overfill. Oil Check 1.
MAINTENANCE Rear Gearcase Oil Oil Change 1. 2. 3. 4. 5. 6. 7. 8. Position the vehicle on a level surface. Place a drain pan under the drain hole. Remove the drain plug. Allow the oil to drain completely. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. Remove the fill plug. Add the proper amount of the recommended oil. Do not overfill. Reinstall the fill plug. Torque to specification. Check for leaks. Dispose of used oil properly.
MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 71 for demand drive fluid maintenance. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to extreme use.
MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level Bleeder surface. Before performing the Screw fluid change, allow the vehicle Cap to sit for at least 30 minutes. Bleeder 2. Thoroughly clean the areas Valve Screw around and on the ADC reservoir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir.
MAINTENANCE Power Steering Unit If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly. Clean Often Cooling System The engine coolant level is controlled by the recovery system. Recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle 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.
MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed. Escaping steam can cause burns.
Brake Fluid MAINTENANCE Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.
MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the indicator window (eye) on the top of the master cylinder. Master Cylinder Full Tip: The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. Low 3.
Brake Inspections MAINTENANCE The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Perform the following checks to keep the brake systems in good operating 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 for fluid leaks. 3.
MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 0" to 1/8" (0-3 mm) toe out. Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3.
MAINTENANCE Steering Assembly The steering assembly should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. Remove the seat. Side Panel/Footwell Removal Remove the seat before removing a side panel.
MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Refer to the specifications section beginning on page 120 for recommended tire type, size and pressure.
MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped). 3. Install the wheel nuts and finger-tighten them. 4. Lower the vehicle to the ground. 5. Torque the wheel nuts to specification. Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn.
MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover screws, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type prefilter 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.
MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short 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.
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 7.6 m X NOTE: 5 cm Include rider weight on the seat when measuring. 4. Start the engine.Turn the headlight switch to high beam. 5.
Lights MAINTENANCE Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
MAINTENANCE Lights Rear Turn Signal Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the turn signal socket counterclockwise to remove it. 3. Remove the lamp. 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.
MAINTENANCE Lights Taillight/Brakelight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. Reinstall all components in reverse order.
MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay 1. Remove the three cover screws from the right handlebar control and remove the cover. 2. With the handlebars straight ahead, place very light pressure on the throttle lever. A gap of 2-3 mm should be visible between the throttle arm stop pin and the throttle arm. If adjustment is needed: 1.
MAINTENANCE Throttle Cable Freeplay 4. Place the transmission in PARK. 5. Start the engine and allow the idle to stabilize. If necessary, tap the throttle lever to ensure the idle speed settles. 6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your Polaris dealer for service. 7. With the engine running, turn the handlebars fully to the left and right.
MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Accessory springs are available through your Polaris dealer. Adjuster Handlebars The handlebars can be adjusted for rider preference.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 120 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Plug Condition Torque Specification 550 XP 850 XP/XP EPS New Spark Plug 9-11 ft. lbs. (12-15 Nm) 18-20 ft. lbs. (24-27 Nm) Previously Installed Spark Plug 17-20 ft. lbs.
MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine 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.
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land or at the very least, to water below the footrests. 2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. 3.
MAINTENANCE Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot.
MAINTENANCE PVT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components.
MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch. The approximate gear ratio difference between high and low range is 1:2.25.
MAINTENANCE PVT System When To Use Low Range and High Range Condition Operating at speeds less than 7 MPH (11 km/h) Range to Use Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 7 MPH (11 km/h) High PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug.
MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk.
MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. Remove the seat. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Disconnect the battery hold-down strap. On conventional batteries, remove the battery vent tube. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 106 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Polaris recommends maintaining battery charge by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 103. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 104. Make sure the positive terminal polarity is properly connected.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended. See page 108. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 62. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength) Fog the Engine 1.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 62. Battery Maintenance Remove the battery and recharge it as outlined on page 106. Store the battery in a cool, dry place. Storage Area/Covers Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated.
MAINTENANCE Transporting the Vehicle 1. 2. 3. 4. Stop the engine. Place the transmission in PARK. Secure the fuel cap, oil cap and seat. 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 Aarm bolt pockets, racks or handlebars. 5. Remove the key to prevent loss during transporting.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures Solution Use low range during loading. Use low range or turn around using the K-turn (see page 56). Drive at a higher speed or use low range more frequently. See page 101. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent lin
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to ON position three times for 5 seconds each, then
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2877606 2873602 2873603 2877922 2877923 2871653 2872276 2870465 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.
SPECIFICATIONS SPORTSMAN 550 XP Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting Syst
SPECIFICATIONS SPORTSMAN 550 XP Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Hand Lever Brakes, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster H/L/N/R/P 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 26x8-14 AT / 7 psi (48.3 kPa) 26x10-14 AT / 5 psi (34.
SPECIFICATIONS SPORTSMAN 850 XP / XP EPS Maximum Weight Capacity Dry Weight 575 lbs. (261 kg) 784 lbs. (356 kg) (XP) 796 lbs. (361 kg) (XP EPS) Fuel Capacity 5.25 gal. (20 l) (XP) 4.5 gal. (17 l) (XP EPS) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 7.1 oz. (210 ml) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 32 oz. (950 ml) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs.
SPECIFICATIONS SPORTSMAN 850 XP / XP EPS Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Hand Lever Brakes, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster H/L/N/R/P 5.034:1 4.508:1 2.367:1 3.818:1 3.7:1 26x8-14 AT / 7 psi (48.3 kPa) 26x10-14 AT / 5 psi (34.
DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive) TEST / EVALUATION METHODS EN 1050 hazard analysis CD 77/311/EEC driver-perceived noise level CISPR 12:2001 EN 55012:2002 CAN/CSA-C108.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a Polaris dealer.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in f
WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
MAINTENANCE LOG Present this 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.
MAINTENANCE LOG DATE 130 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 131
INDEX 0-9 C 4X4 Switch . . . . . . . . . . . . . . . . 20, 28 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 A Access, Front Compartment . . . . . . 27 Accessories . . . . . . . . . . . . . . . . . .
INDEX F L Fluid ADC Fluid. . . . . . . . . . . . . . 74-75 Brake Fluid . . . . . . . . . . . . . 79-80 Demand Drive Fluid . . . . . . . . . 71 Engine Oil . . . . . . . . . . . . . . . . 67 Fluid Change ADC Fluid. . . . . . . . . . . . . . . . . 75 Demand Drive Fluid . . . . . . . . . 71 Engine Oil . . . . . . . . . . . . . . 68-69 Foot Brake, Auxiliary . . . . . . . . . . . . 23 Footwell Removal. . . . . . . . . . . . . . . 83 Front Compartment. . . . . . . . . . . . . . 27 Front Gearcase (Demand Drive).
INDEX R S Rack/Compartment, Front . . . . . . . . 27 Reverse Operation . . . . . . . . . . . . . . 51 Reverse Override Switch . . . . . . . . . 20 Rider Information Center. . . . . . . 32-41 Rider Safety . . . . . . . . . . . . . . . . . . 7-13 Riding Gear . . . . . . . . . . . . . . . . . 14-15 Switches 4X4 Switch . . . . . . . . . . . . . 20, 28 Engine Stop Switch . . . . . . . . . . 21 Hazard Warning. . . . . . . . . . . . . 20 Headlight Switch . . . . . . . . . . . . 21 Horn . . . . . . . . . . . . .
