Polaris Sportsman 550 XP Owner's Manual

Polaris Sportsman 550 XP Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Summary of Contents for Polaris Sportsman 550 XP

  • Page 3 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 4 • 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.
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 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 6: Table Of Contents

    Troubleshooting ..... . . 121 Polaris Products..... . . 125 Specifications .
  • Page 7: Introduction

    INTRODUCTION 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 8 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 9: Vehicle Identification Numbers

    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 10: Safety

    Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly...
  • Page 11: Safe Riding Gear

    Boots 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. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 12: Equipment Modifications

    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 13: Safety Warnings

    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 14: Handling Gasoline

    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 refu- eling is performed or where gasoline is stored.
  • Page 15: Protective Apparel

    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. Always wear an approved helmet that fits properly and eye protection (goggles or face shield).
  • Page 16: Operating On Pavement

    SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use.
  • Page 17: Physical Control Of The Atv

    SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.
  • Page 18: Descending Hills Improperly

    Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill.
  • Page 19: Stalling While Climbing A Hill

    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. • Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 20: Operating On Slippery Terrain

    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.
  • Page 21: Improper Tire Maintenance

    SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 63. Before shifting into reverse gear, always check for obstacles or people behind the ATV.
  • Page 22: Skidding Or Sliding

    Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual.
  • Page 23: Improper Cargo Loading

    SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this ATV. • Cargo should be properly distributed and securely attached. •...
  • Page 24: Operating A Damaged Atv

    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 25: General Warning

    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 26: Discretionary Warning

    Safety Labels and Locations General Warning Age 16 Warning Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees vent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.
  • Page 27 SAFETY Safety Labels and Locations “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 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.
  • Page 28: Clutch Cover Warning

    Safety Labels and Locations Rack Warning Clutch Cover Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
  • Page 29: Features And Controls

    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, release the throttle and depress the override button.
  • Page 30 FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. Move the stop switch to the RUN position before attempt- ing to start the engine. The engine will not start or run when the switch is off.
  • Page 31: Throttle Lever

    Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Con- trol (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle...
  • Page 32: Brake Lever

    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 33 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 34: Parking Brake

    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 35 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 36: Fuel Tank

    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 39 for EPS Warning Indicator information. Automatic Transmission Gear Selector The transmission gear selector is Gear...
  • Page 37: All Wheel Drive System

    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 38 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.
  • Page 39: Engaging Active Descent Control

    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 40: Instrument Cluster

    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 41: Product View And Controls

    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 42 12. 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 43 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 44 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 45: Programmable Service Interval And Clock Mode

    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 46: Diagnostic Display Mode

    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 47 Short-to-Battery: The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage. Sportsman 550 XP / XP EPS Diagnostic Codes Component Throttle Position Sensor...
  • Page 48: Sportsman 550Xp/Xp Eps Diagnostic Codes

    Instrument Cluster Rider Information Center Sportsman 550 XP / XP EPS Diagnostic Codes Component Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Steering Over Current Shut Down Steering Excessive Current Error...
  • Page 49 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)
  • Page 50: Sportsman 850Xp/Xp Eps Diagnostic Codes

    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 Steering Over Current Shut Down Steering Excessive Current Error Steering Torque Sensor T1 Partial Failure Steering Torque Sensor T2 Partial...
  • Page 51 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 52: Operation

    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 53 OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Item Brake system/lever travel Brake fluid Auxiliary brake...
  • Page 54: Safe Operation Practices

    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 55: Trail Etiquette

    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 56: Starting The Engine

    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 57: Driving Procedures

    OPERATION Driving Procedures 1. Wear a helmet and eye protection. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.
  • Page 58: Turning The Vehicle

    OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.
  • Page 59: Driving On Slippery Surfaces

    OPERATION 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 60: Driving Uphill

    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. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 61 OPERATION 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 62: Driving Downhill

    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 36. 2. Avoid steep hills (25° maximum). 3. Shift body weight uphill. 4. Drive straight downhill. 5.
  • Page 63 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) 1. Stop and lock the parking brake while keeping body weight uphill. 2.
  • Page 64: Driving Through Water

    Driving Through Water Your ATV can operate through water with a maximum recom- mended depth equal to the bot- tom of the footrests. Follow these precautions when operat- ing through water: 1. Determine water depths and current before entering water. 2.
  • Page 65: Driving Over Obstacles

    OPERATION 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 66: Driving In Reverse

    Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.
  • Page 67: Hauling Cargo

    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, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 68: Towing Loads

    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. OPERATION Maximum...
  • Page 69: Parking On An Incline

    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 70: 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 USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
  • Page 71: Maintenance

    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 136.
  • Page 72: Periodic Maintenance Chart

    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 73 Demand drive fluid Rear gearcase oil Transmission oil General lubrication 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) Miles (Km) Pre-Ride Pre-Ride...
  • Page 74 Periodic Maintenance Chart Item Hours Calendar Throttle Cable/ ETC Switch E Throttle Body Intake Duct Drive belt Cooling system Radiator Cooling hoses Engine oil change Demand drive fluid 100 H Rear gearcase oil Transmission oil Fuel system Engine mounts Exhaust muffler/ pipe Spark plug Wiring...
  • Page 75: Lubrication Guide

    Rear ATV Angle Drive Gearcase Oil Fluid (or GL5 80- 90 weight gear lube) Brake Fluid DOT 4 Only ADC Fluid Polaris ADC Fluid Front Prop Polaris Premium Shaft Yoke U-Joint Lube Front Prop Shaft Yoke Capacity Fill Plug at Fluid...
  • Page 76: Engine Oil

    2W-50 4-cycle oil or a similar oil for this engine. See the table on page 72 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 77: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change See the table on page 72 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 68. Always change the oil filter whenever changing oil.
  • Page 78 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 counter- clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
  • Page 79: Transmission Oil

    MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP Trans- mission Fluid for this transmission. See the table on page 72 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 68.
  • Page 80: Fluid Change

    Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 for the part numbers of Polaris products. Use the recommended fluid. Use of other fluids may result in improper operation of components.
  • Page 81: Rear Gearcase Oil

    Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 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 82: Oil Change

    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 83 Periodic Maintenance Chart beginning on page 68. Maintain the fluid level between the minimum and maximum marks on the reservoir. We recommend the use of Polaris ADC Fluid. See page 125 for the part numbers of Polaris products. NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.
  • Page 84 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 85: Cooling System

    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 125 for the part numbers of Polaris products.
  • Page 86 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 87: Radiator Coolant

    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 88: Hand Brake

    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 89: Toe Alignment

    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 90: Seat Removal

    Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. Remove the seat. Side Panel/Footwell Removal Remove the seat before removing a side panel. Remove the screws and rivets securing the side panel or footwell (see illustration).
  • Page 91: Tire Tread Depth

    MAINTENANCE Tires WARNING Operating your ATV 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.
  • Page 92: Wheel Removal

    Tires 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 93: Wheel Installation

    MAINTENANCE 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).
  • Page 94: Air Filter

    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 pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5.
  • Page 95: Fuse Replacement

    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 96: Headlight Lamp Replacement

    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 97: High Beam Adjustment

    MAINTENANCE 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 98 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. MAINTENANCE Phillips Screw...
  • Page 99: Headlight Housing Replacement

    MAINTENANCE Lights Headlight Housing Replacement 1. Remove the five (5) headlight pod screws. 2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 3. Unplug the headlamp from the wiring harness. 4. Use a small screwdriver to remove the o-rings from the headlight mounting tabs.
  • Page 100 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 101: Spark Plugs

    Refer to the specifications section beginning on page 126 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...
  • Page 102 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 103: Vehicle Immersion

    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 104: Spark Arrestor

    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 105: Pvt System

    • 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 106 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.
  • Page 107: Pvt Drying

    MAINTENANCE PVT System When To Use Low Range and High Range Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) PVT Drying There may be some instances when water is accidently ingested into the PVT system.
  • Page 108 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 109: Battery Removal

    MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable last. 4. Disconnect the battery hold-down strap. 5. On conventional batteries, remove the battery vent tube. 6. Lift the battery out of the ATV. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
  • Page 110: Battery Installation

    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 109 before installing the battery.
  • Page 111: Battery Storage

    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 Bat- tery Tender charger or by charging about once a month to make up for normal self-discharge.
  • Page 112 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 106. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 113 MAINTENANCE 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 charger @ standard amps specified on top of battery)
  • Page 114: Cleaning And Storage

    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 115: Washing The Vehicle

    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 116 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 117: Storage Tips

    See page 111. 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 118 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
  • Page 119 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 120: Transporting The Atv

    Transporting the ATV 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.
  • Page 121: Throttle Cable Freeplay

    ADJUSTMENTS 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 han- dlebar control and remove the cover.
  • Page 122: Throttle Cable Freeplay

    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 123: Camber And Caster

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod.
  • Page 124: Troubleshooting

    Dry out the PVT. See page 104. 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.
  • Page 125 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 plugs...
  • Page 126 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 plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...
  • Page 127: Engine Overheating

    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...
  • Page 128: 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 129: Specifications

    SPECIFICATIONS Sportsman 550 XP / XP EPS 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...
  • Page 130 Sportsman 550 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, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching Altitude...
  • Page 131 1200 +/- 100 RPM 6 +/- 5 BTDC @ 1200 RPM, Engine warm Champion REA6MC / .035 in. (0.9 mm) Wet Sump Automatic PVT (Polaris Variable Transmis- sion) Dual a-arm with 9.2" (23 cm) travel Progressive rate with 10.2" (26 cm) travel...
  • Page 132 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, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching Altitude Meters 0-1800 (Feet)
  • Page 133: Warranty

    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 134 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 135 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 136 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 137 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
  • Page 138 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
  • Page 139: Maintenance Log

    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 140 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 141 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

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