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Polaris Sportsman 9922581 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Pantone 426 C
Sportsman 550 XP
Sportsman 850 XP
Sportsman 850 XP EPS
International
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.

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Summary of Contents for Polaris Sportsman 9922581

  • Page 1 Pantone 426 C Sportsman 550 XP Sportsman 850 XP Sportsman 850 XP EPS International Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • Page 2 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 3 Pantone 426 C For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No. 9922581 Rev 02 Printed in U.S.A.
  • Page 4 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ®...
  • Page 5 POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

  • Page 6: Table Of Contents

    Troubleshooting ..... . . 115 Polaris Products..... . . 119 Specifications .

  • Page 7: 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: 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 9: Safety

    Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.
  • Page 10 Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
  • Page 11 SAFETY Rider Safety Never carry a passenger on this vehicle. Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds.
  • Page 12 Never turn sharply at excessive speeds, which can lead to vehicle overturn. If the vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
  • Page 13 SAFETY Rider Safety Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving on hills. See page 52. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°.
  • Page 14 SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 53. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 15 SAFETY Rider Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this vehicle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached.
  • Page 16 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.

  • Page 17: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Gloves Sleeves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 18: Eye Protection

    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 19 Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.

  • Page 20: General Alert

    Safety Labels and Locations General Alert (Multi-Lingual) Before you operate this vehicle, read the owner’s manual. 7173025 Reverse Override Warning/4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.

  • Page 21: No Passenger" Warning

    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 Alert TIRE PRESSURE IN PSI (KPa): Front: 7.0 psi (48.3 kPa) Rear: 5.0 psi (34.5 kPa) MAXIMUM WEIGHT CAPACITY 575 lbs.

  • Page 22: Clutch Cover Alert

    Safety Labels and Locations Rack Warning Clutch Cover Alert 7175826 Rack Warning, Front and Rear WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. •...

  • Page 23: Features And Controls

    FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Engine Stop Switch Turn Signal Switch Headlight 4X4 Switch Switch Hazard Main Key Horn Switch 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 switch.

  • Page 24: Headlight Switch

    Switches Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position.

  • Page 25: Throttle Lever

    FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine.

  • Page 26: Foot Brake

    FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle.

  • Page 27: Parking Brake

    Brakes Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5.
  • Page 28 FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 33 for EPS Warning Indicator information. Automatic Transmission Gear Selector The transmission gear selector is Gear...

  • Page 29: Steering Lock

    FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. 1. Turn the handlebars to the full left position. Tip: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise. 3.

  • Page 30: Front Rack/Compartment

    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 31: 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 32: Engaging 4X

    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 33: 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 34: Instrument Cluster

    Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation. 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 35: Rider Information Center

    If this occurs, please see your Polaris dealer. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 36 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. 13. Directional Indicator - This indicator illuminates when the hazard switch or a turn signal switch is turned on.
  • Page 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override switch also acts as a MODE button when held down for approximately one half second.

  • Page 38: Standard/Metric Display

    Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override switch also acts as the SELECT button when pressed and released quickly.

  • Page 39: Information Display Area

    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 40 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 41 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 42 Instrument Cluster Rider Information Center SPORTSMAN 550 XP Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Gear Sensor Signal Injector 1 (MAG) Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control...
  • Page 43 Instrument Cluster Rider Information Center SPORTSMAN 850 XP / XP EPS Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Vehicle Speed Signal Gear Sensor Signal Injector 1 (MAG) (SDI Part Load) Injector 2 (PTO) (SDI Part Load) Ignition Coil Primary Driver 1 (MAG) Ignition Coil Primary Driver 2 (PTO)
  • Page 44 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 45: Operation

    Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.
  • Page 46 Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 67. Add oil if necessary to maintain the level between the safe and add marks. 3.

  • Page 47: Pre-Ride Checklist

    Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Hand brake/lever travel Foot brake Brake fluid...

  • Page 48: 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 49 OPERATION Driving Procedures 1. Wear protective riding gear. See page 14. 2. Perform the pre-ride inspection. See page 44. 3. Place the transmission in PARK. 4. Mount the vehicle from the left side. 5. Sit upright with both feet on the footrests. Keep both hands on the handlebars.

  • Page 50: Turning The Vehicle

    Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.

  • Page 51: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning.

  • Page 52: Driving Through Water

    Driving Through Water Follow these procedures when driving through water: 1. Check water depth and cur- rent before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the footrests.

  • Page 53: 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. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. Always follow the procedures outlined in this manual for operating over obstacles.

  • Page 54: Driving In Reverse

    Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the throttle suddenly. 6.
  • Page 55 OPERATION Driving Uphill 25° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Drive straight uphill. 3. Avoid steep hills (25° maximum). 4. Avoid hills with slippery or loose surfaces. 5.

  • Page 56: Driving Uphill

    OPERATION Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3.
  • Page 57 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Shift body weight uphill. 3. Keep your feet on the footrests. 4. Avoid hills with slippery or loose surfaces. 5.

  • Page 58: 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 2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down. 4.
  • Page 59 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 60 Turning Around on a Hill (K-Turn) 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. 11. Apply the foot brake. 12. With the transmission still in forward, start the engine. 13. Squeeze and release the brake lever to release the parking brake. 14.

  • Page 61: Hauling Cargo

    OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels.

  • Page 62: Towing Loads

    Use low forward gear when hauling or towing heavy cargo to extend belt life. Towing Loads Towing is approved OFF-ROAD ONLY. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. • Do not tow any trailer on a grade steeper than 15°.

  • Page 63: 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. Always block the rear wheels on the downhill side.

  • Page 64: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 65: 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 129.

  • Page 66: 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 67 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) Hours Calendar Miles (Km) Pre-Ride...
  • Page 68 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 69: Lubrication Guide

    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 70: Engine Oil

    2W-50 4-cycle oil or a similar oil for this engine. See the table on page 66 for fluid recommendations, capacities and plug torques. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.

  • Page 71: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change See the table on page 66 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil.
  • Page 72 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 73: Transmission Oil

    Transmission Oil Polaris recommends the use of Polaris Synthetic SPORTSMAN XP Transmission Fluid for this transmission. See the table on page 66 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62.

  • Page 74: Fluid Change

    Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 62. See page 119 for the part numbers of Polaris products. Use the recommended fluid. Use of other fluids may result in improper operation of components.

  • Page 75: Rear Gearcase Oil

    Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. See page 119 for the part numbers of Polaris products. The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.

  • Page 76: 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 77 ADC mode. We recommend the use of Polaris Demand Drive Plus Fluid. Maintain the fluid level between the minimum and maximum marks on the reser- voir. See page 119 for the part numbers of Polaris products.
  • Page 78 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 79: 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 119 for the part numbers of Polaris products.
  • Page 80 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 81: 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 82: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 119 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
  • Page 83 Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.

  • Page 84: Brake Inspections

    Brake Inspections The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Perform the following checks to keep the brake systems in good operat- ing condition.

  • Page 85: Toe Alignment

    0" to 1/8" (0-3 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for ser- vice. Stand...

  • Page 86: Steering Assembly

    Steering Assembly The steering assembly should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for ser- vice before operating the vehicle. Seat Removal 1. Grasp one side of the seat near the rear edge.

  • Page 87: Wheel Removal

    2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 4. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

  • Page 88: Wheel Installation

    Tires Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped). 3. Install the wheel nuts and finger-tighten them. 4.

  • Page 89: Air Filter

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

  • Page 90: 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 91: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 92 Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 93 MAINTENANCE Lights Rear Turn Signal Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the turn signal socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation.
  • Page 94 Lights Taillight/Brakelight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6.

  • Page 95: Throttle Cable Freeplay

    MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay 1. Remove the three cover screws from the right han- dlebar control and remove the cover.
  • Page 96 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 97: Camber And Caster

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

  • Page 98: Spark Plugs

    Refer to the specifications section beginning on page 120 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 99 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 100: Vehicle Immersion

    Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1.

  • Page 101: Spark Arrestor

    MAINTENANCE Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.

  • Page 102: 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 103 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 104: Pvt Drying

    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 105 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery electrolyte is poisonous.

  • Page 106: Battery Removal

    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 vehicle. Be careful not to tip a conven- tional battery sideways, which could spill electrolyte.

  • Page 107: 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 106 before installing the battery.

  • Page 108: 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 109 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 103. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 110 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 111: 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 112: 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 113 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 114: Storage Tips

    See page 108. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 115: Fluid Levels

    6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.

  • Page 116: Battery Maintenance

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

  • Page 117: Transporting The Vehicle

    Transporting the Vehicle 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks or handlebars.

  • Page 118: Troubleshooting

    Dry out the PVT. See page 101. 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 119 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 120 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 121: 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 122: 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 2859044 Polaris Battery Tender Engine Lubricant Coolant Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 123: Specifications

    1650 +/- 100 RPM 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 9.2" (23 cm) travel Progressive rate with 10.2" (26 cm) travel...
  • Page 124 Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Hand Lever Brakes, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) *EBS models require no helix/spring adjustment SPORTSMAN 550 XP...
  • Page 125 1200 +/- 100 RPM 6 +/- 5 BTDC @ 1200 RPM, Engine warm Champion REA6MC / .035 in. (0.9 mm) Wet Sump Automatic PVT (Polaris Variable Transmission) Dual a-arm with 9.2" (23 cm) travel Progressive rate with 10.2" (26 cm) travel...

  • Page 126: Specifications

    SPORTSMAN 850 XP / XP EPS Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Hand Lever Brakes, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching Altitude Meters 0-1800...

  • Page 127: 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 128: Warranty

    At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle- ment.
  • Page 129 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 vehicle that...
  • Page 130 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 131 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

  • Page 132: 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 133 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 134 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 135: Index

    INDEX 4X4 Switch ....20, 28 Access, Front Compartment ..27 Accessories ....113 Active Descent Control Fluid .
  • Page 136 Parking on an Incline ... . 60 Periodic Maintenance Chart ..62-65 Polaris Product List... . . 119 Polishing the Vehicle ... 109 Position Light Lamp .

  • Page 137: Specifications

    INDEX Rack/Compartment, Front ..27 Reverse Operation ....51 Reverse Override Switch ..20 Rider Information Center.

This manual is also suitable for:

2010 sportsman 550 xp2010 sportsman 850 xp2010 sportsman 850 xp eps

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