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Polaris Sportsman 550 EFI Owner's Manual

Polaris industries all-terrain vehicles owner's manual.

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  • Page 2

    WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342- 3764 for assistance.

  • Page 3

    The text is printed on 100% recycled with 40% post-consumer waste (PCW).

  • Page 4

    NEVER CARRY NEVER USE MORE THAN WITH DRUGS 1 PASSENGER OR ALCOHOL For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922051 Rev 03 Printed in USA...

  • Page 5

    • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

  • Page 6

    POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries 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...

  • Page 7: Table Of Contents

    Troubleshooting ..... . . 129 Polaris Products..... . . 133 Specifications .

  • Page 8

    The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols 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.

  • Page 9: Introduction

    Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

  • Page 10

    Record 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.

  • Page 11

    You should review this information on a regular basis. If you purchased a used Polaris ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

  • Page 12: Safety

    Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. A passenger (on approved models) should wear a hel- met that includes a rigid chin guard.

  • Page 13

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever 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.

  • Page 14

    SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

  • Page 15

    Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 16

    SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

  • Page 17

    SAFETY Safety Warnings Carrying a Passenger in the Cargo Box A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death. Never allow a passenger to ride in the cargo box.

  • Page 18

    SAFETY Safety Warnings Physical Control of the ATV Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.

  • Page 19

    SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 63. Never operate in TURF mode while operating on a hill or other irregular terrain.

  • Page 20

    SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

  • Page 21

    SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain.

  • Page 22

    SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

  • Page 23

    Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 68):...

  • Page 24

    SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water.

  • Page 25

    SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 26

    If an informational or graphic label becomes illegible or comes off, con- tact 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. General Warning...

  • Page 27

    Safety Labels and Locations General Warning Age 16 Warning Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger. NEVER operate this vehicle if you are under age 16. Reverse Override Warning/AWD Caution WARNING Improper use of override button can lead to loss of control resulting in severe...

  • Page 28

    Safety Labels and Locations Passenger Safety//Discretionary Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.

  • Page 29

    Safety Labels and Locations Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 7.0 psi (48.3 kPa) Rear: 5.0 psi (34.5 kPa) •...

  • Page 30

    SAFETY Safety Labels and Locations Rack Warning Rack Warning, Front 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. Maximum combined Front Rack and Container Load: 120 lbs. (54 kg) Clutch Cover Warning WARNING NO STEP...

  • Page 31

    SAFETY Safety Labels and Locations Box Warning WARNING Remove flammable material containers from box before filling. WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load - 400 lbs. (181 kg) 7173890...

  • Page 32

    FEATURES AND CONTROLS Switches Headlight Switch 4X4 Switch Mode/Reverse Override Button Engine Main Key Stop Switch Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, depress the override switch. WARNING! Activating the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.

  • Page 33: Features And Controls

    FEATURES AND CONTROLS Switches Main Key Switch Use the main key switch to start the engine. See page 57. 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 4X4, 2X4 or TURF mode. See page 38. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

  • Page 34

    This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 35

    FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes.

  • Page 36

    FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

  • Page 37

    Parking Brake Locking the 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.

  • Page 38

    FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.

  • Page 39

    Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehi- cle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

  • Page 40

    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, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

  • Page 41

    All Wheel Drive System 2X4 Mode When the switch is on 2X4, the ATV is in two-wheel drive at all times. TURF Mode When operating in TURF mode, the inside rear wheel will rotate inde- pendently from the outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage.

  • Page 42

    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. Engaging Active Descent Control The ADC system will automatically engage when all four of the follow- ing conditions occur:...

  • Page 43

    FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. 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.

  • Page 44

    Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when oper- ating without a passenger. Always return the seat to the 1-up position for single-rider operation.

  • Page 45

    If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. 8. To return the vehicle to single-rider operation, reverse all steps. Always lower the passenger backrest to the lowest position before folding it down into the cargo box.

  • Page 46

    FEATURES AND CONTROLS Front Rack/Compartment Release the front rack latches Latches and remove the rack to gain access to the front compart- ment. 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.

  • Page 47

    Instrument Cluster Your ATV 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. In addition to showing vehicle speed, the instrument cluster also dis- plays the following items: engine speed, odometer, resettable trip meters (2), total engine hours of operation, service interval timer and indicator, gear position, fuel level, AWD status, EPS status (if equipped), high...

  • Page 48

    If this occurs, take the ATV to your Polaris dealer for proper diagno- sis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.

  • Page 49

    13. EPS Warning Indicator - This indicator illuminates when the key is turned to the ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized Polaris dealer for service. FEATURES AND CONTROLS...

  • Page 50

    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 button also acts as a MODE button when held down for approximately one half second.

  • Page 51

    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 button also acts as the SELECT button when pressed and released quickly.

  • Page 52

    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.

  • Page 53

    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).

  • Page 54

    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.

  • Page 55

    Instrument Cluster Rider Information Center Sportsman X2 550 EFI 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...

  • Page 56

    Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.

  • Page 57: Operation

    Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 39. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 82. Add oil if necessary to maintain the level between the safe and add marks. 3.

  • Page 58

    Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...

  • Page 59

    Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle.

  • Page 60

    Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your Polaris dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

  • Page 61

    Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. OPERATION...

  • Page 62

    OPERATION Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 54. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.

  • Page 63

    Turning the Vehicle Both rear wheels drive equally at all times (except when operating in TURF mode). This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1.

  • Page 64

    Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfort- ably and safely reach the grab handles and footrests. 2.

  • Page 65

    Driving with a Passenger 12. Do not cross a hillside with a passenger on board. See page 64. 13. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passen- ger grab handles at all times.

  • Page 66

    Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.

  • Page 67

    Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Never operate in TURF mode while operating on a hill or other irregular terrain.

  • Page 68

    Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.

  • Page 69

    Driving Downhill When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

  • Page 70

    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. 8 ft. (2.4 m)

  • Page 71

    Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

  • Page 72

    OPERATION Driving Through Water Maximum Depth Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2.

  • Page 73

    Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3.

  • Page 74

    Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 75

    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. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

  • Page 76

    OPERATION Hauling Cargo WARNING 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: Never carry cargo in the rear box when operating the ATV in the 2-up mode with a passenger.

  • Page 77

    Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to main- tain stable driving condi- tions.

  • Page 78

    ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris-approved (or equivalent) accessories designed for ATV use. Maximum Towing Capacities Do not exceed the following maximum capacities when towing.

  • Page 79

    Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Dismount the vehicle. 5.

  • Page 80: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 81

    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 145.

  • Page 82: Maintenance

    Improperly performing the procedures marked with a 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 Perform these operations more often for vehicles subjected to severe use.

  • Page 83

    Periodic Maintenance Chart Item Hours Calendar Air filter, main element Engine oil change Brake pad wear Battery ADC fluid Rear gearcase oil Transmission oil Demand drive fluid General lubrication Shift linkage Steering Front suspension Rear suspension Throttle Cable/ ETC Switch E Throttle Body Intake Duct Drive belt...

  • Page 84

    Spark arrestor Valve clearance Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) 100 H...

  • Page 85

    Fluid (or GL5 80- 90 weight gear lube) Brake Fluid DOT 4 Only ADC Fluid Demand Drive Plus Fluid Front Prop Polaris Premium Shaft Yoke U-Joint Lube Front Prop Shaft Yoke Capacity Fill Plug at Fluid Torque Change 2 qt.

  • Page 86

    2W-50 4-cycle oil or a similar oil for this engine. See the table on page 81 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.

  • Page 87

    Engine Oil Oil Level Check the oil level when the engine is cold. Never check the oil with the engine running. 1. Position the vehicle on a level surface. 2. Access the oil dipstick and fill tube from the left side of the ATV. Remove the dipstick.

  • Page 88

    Engine Oil Oil and Filter Change See the table on page 81 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 77. Always change the oil filter whenever changing oil.

  • Page 89

    Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil fil- ter. Using an oil filter wrench (avail- able from your Polaris dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crank- case.

  • Page 90

    MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP Trans- mission Fluid for this transmission. See the table on page 81 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 77.

  • Page 91

    Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 77. See page 133 for the part numbers of Polaris products. Use the recommended fluid. Use of other fluids may result in improper operation of components.

  • Page 92

    Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77. See page 133 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.

  • Page 93

    Rear Gearcase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain hole. 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.

  • Page 94

    We recommend the use of Polaris Demand Drive Plus Fluid for the ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 133 for the part numbers of Polaris products. NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.

  • Page 95

    Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).

  • Page 96

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 133 for the part numbers of Polaris products.

  • Page 97

    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 com- partment. 1. View the fluid level in the bottle. 2. If the level is low, remove the front rack. 3.

  • Page 98

    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.

  • Page 99

    Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. 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.

  • Page 100

    6. If you discover improper alignment, see your Polaris dealer for ser- vice. Steering Assembly The steering assembly of the ATV 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. Stand String...

  • Page 101

    Seat Removal 1. Remove any cargo from the cargo box before removing the seat. 2. Stand on the right side of the vehicle. Pull the cargo box release lever upward. Lift the front of the cargo box. 3. Grasp edge of the seat near the left rear corner.

  • Page 102

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK.

  • Page 103

    Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. 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). 4.

  • Page 104

    Air Filter 1. Remove the seat. See page 97. 2. Remove the air box cover screws, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 105

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

  • Page 106

    Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fin- gers.

  • Page 107

    Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2.

  • Page 108

    Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw. Headlight Housing Replacement 1.

  • Page 109

    Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4.

  • Page 110

    Refer to the specifications section beginning on page 134 for the recom- mended 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 New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.

  • Page 111

    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 indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white.

  • Page 112

    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 ATV to a dealer before starting it, follow the steps outlined below.

  • Page 113

    Spark Arrestor WARNING 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.

  • Page 114

    • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 115

    PVT System When To Use Low Range and High Range The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the tempera- ture inside the clutch cover greatly extends the life of the PVT compo- nents (belt, cover, etc.).

  • Page 116

    Battery WARNING 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. WARNING Battery electrolyte is poisonous.

  • Page 117

    Battery Your ATV may have either a sealed battery, which requires little mainte- nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

  • Page 118

    Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 116 before installing the battery.

  • Page 119

    Tip: Power plug leads may need to be bent down so that the battery cover can be installed. Polaris recommends maintaining battery charge by using a Polaris Bat- tery Tender charger or by charging about once a month to make up for normal self-discharge.

  • Page 120

    MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 113. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

  • Page 121

    Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action specified on top of battery) None, check at 3 mos.

  • Page 122

    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 four cover screws from the right han- dlebar control and remove the cover.

  • Page 123

    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 ser- vice. 7. With the engine running, turn the handlebars fully to the left and right.

  • Page 124

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod.

  • Page 125

    The camber and caster are non-adjustable. Front and Rear Springs The front and rear shock absorber Adjuster springs are adjusted by rotating the adjuster either clockwise or counter- clockwise to increase or decrease spring tension. Accessory springs are available through your Polaris dealer.

  • Page 126

    Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always secure the seat in the 1-up position to prevent loss during transporting. 5. Secure the fuel cap and oil cap. 6.

  • Page 127

    Do not allow these types of products 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.

  • Page 128

    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 vehicle.

  • Page 129

    Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve 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.

  • Page 130

    123. 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. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 131

    5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protec- tive film of fresh oil. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.

  • Page 132

    Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated mate- rials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 133

    Dry out the PVT. See page 111. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).

  • Page 134: Troubleshooting

    Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark...

  • Page 135

    Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...

  • Page 136

    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 plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...

  • Page 137: Polaris Products

    Chain Lube, Aerosol (6.25 oz./185 ml) 2872348 Chain Lube, Aerosol (16 oz./473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender POLARIS PRODUCTS Engine Lubricant Coolant Additives / Miscellaneous Charger...

  • Page 138

    1750 +/- 50 13 +/- 3 BTDC @ 1350 RPM, Engine warm NGK BKR6E / .035 in. (0.9 mm) Wet Sump Automatic PVT (Polaris Variable Transmission) Dual A-Arm with 9" (22.9 cm) travel Progressive rate with 10" (25.4 cm) travel...

  • Page 139: Specifications

    Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) *EBS models require no helix/spring adjustment Sportsman X2 550 EFI H/L/N/R/P 5.034:1...

  • Page 140: 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)

  • Page 141

    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.

  • Page 142: 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. This warranty also does not cover any ATV that...

  • Page 143

    ATV. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or com- ponents or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY.

  • Page 144

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

  • Page 145

    How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.

  • Page 146

    How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.

  • Page 147

    This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.

  • Page 148

    Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 149

    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 ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 150: Maintenance Log

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 151

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 152: Index

    INDEX 4X4 Switch ....29 Access, Front Compartment ..42 Accessories ....128 Active Descent Control Fluid .

  • Page 153

    Fluid Level ADC ..... 90 Brake ....32-34 Coolant Bottle .

  • Page 154

    Passenger Seat ....40-41 Periodic Maintenance Chart ..77-80 Polaris Product List ... . 133 Polishing the Vehicle... 124 Pre-Ride Checklist .

  • Page 155

    Switches ....28-29 4X4 Switch ....29 Engine Stop Switch.

This manual also for:

Sportsman 550 x2, Sportsman 9922051

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