Polaris Sportsman 550 2014 Owner's Manual
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Polaris Sportsman 550 2014 Owner's Manual

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2014
Sportsman 550 Touring International
Sportsman 850 Touring 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 550 2014

  • Page 1 2014 Sportsman 550 Touring International Sportsman 850 Touring 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 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 3 POLARIS® and SPORTSMAN® are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 4: Table Of Contents

    Troubleshooting ..... . . 133 POLARIS Products..... 137 Specifications .

  • Page 5: Introduction

    INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 6 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 7: 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 8 SAFETY Restrictions Towing is approved OFF-ROAD ONLY. Towing a trailer with this vehicle on public roads is prohibited. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road. Equipment Modifications The warranty on your POLARIS vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.
  • Page 9 SAFETY Rider Safety Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Never permit others to operate the vehicle unless they have read and understand this manual and all product...
  • Page 10 SAFETY Rider Safety Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your...
  • Page 11 SAFETY Rider Safety Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 50. Keep both hands on the handlebars. Keep both feet on the footrests. A passenger should always be seated in the passenger seat with both feet on the footrests and both...
  • Page 12 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. Always follow the procedures outlined in this manual for driving on hills.
  • Page 13 SAFETY Rider Safety Always follow the procedures outlined in this manual for crossing the side of a hill. See page 58. Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.
  • Page 14 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page Always follow the procedures outlined in this manual for driving in reverse. See page 64. Always use the size and type of tires specified for your vehicle.
  • Page 15 SAFETY Rider Safety Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. See pages 66-68. Allow a greater distance for braking.
  • 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. Downloaded from ManualsNet.com...
  • Page 17 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Sleeves Gloves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 18 Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 19 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Hill...
  • Page 20 SAFETY Safety Labels and Locations General Alert (Multi-Lingual) PASSENGER UNDER Before you operate or ride this vehicle, read the owner’s manual. 7174362 Reverse Override Warning/4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death.
  • Page 21 SAFETY Safety Labels and Locations Rack/Box Rack/Box Warning Warning Hitch Capacity Label Clutch Cover Alert (under seat) Rack/Box Warning 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 22: Features And Controls

    FEATURES AND CONTROLS Switches Main Key Switch Use the main key switch to start the engine. See page 52. End all electrical power to the vehicle. Main Key Switch LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position.
  • Page 23 FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. Headlight Switch Engine Stop Switch Push the stop switch down to stop the engine quickly. Pull the stop switch up to the Override RUN position before Switch...
  • Page 24 FEATURES AND CONTROLS Switches Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch. Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.
  • Page 25 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. 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 FEATURES AND CONTROLS Brake Lever Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle 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 27 FEATURES AND CONTROLS Master Cylinder/Brake Fluid 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 28 FEATURES AND CONTROLS 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.
  • Page 29 FEATURES AND CONTROLS Auxiliary Foot Brake 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 30 If your factory-installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, please see your POLARIS dealer to purchase a 30 AH battery. 1. Fully charge the new battery before installing it. See page 123.
  • Page 31 Test the seat latch by attempting to pull the seat upward. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your POLARIS dealer for service. See pages 101-102 for passenger seat adjustment procedures.
  • Page 32 FEATURES AND CONTROLS Fuel Tank Always refuel with the engine Fuel Tank stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap and add fuel. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.
  • Page 33 FEATURES AND CONTROLS Front Storage Box Open the front storage box to access the under-compartment area. 1. Release the front box cover latches and lift the cover. 2. Release the plunger latches that secure the box to the frame. 3. Close the cover and Cover Latches Plunger Latches lift the unlatched...
  • Page 34 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 35 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off.
  • Page 36 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 following conditions occur:...
  • Page 37 FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.
  • Page 38 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. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
  • Page 39 If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 40 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. Gear Display - This area displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2.
  • Page 41 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.
  • Page 42 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 43 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 44 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See pages 44-47 for code definitions and failure descriptions. Please see your POLARIS dealer for all major repairs. Downloaded from ManualsNet.com...
  • Page 45 FEATURES AND CONTROLS Instrument Cluster 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 46 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 550 Touring Diagnostic Codes Component Condition Idle Air Control Driver Circuit Grounded 520193 Shorted Load* 520193 Starter Enable Circuit Driver Circuit Short to B+ 1321 All Wheel Drive Control Driver Circuit Short to B+ 520207 System Power Voltage Too High...
  • Page 47 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 850 Touring Diagnostic Codes Component Condition Throttle Position Sensor Voltage Too High Voltage Too Low Engine Temperature Sensor Voltage Too High Voltage Too Low Temperature Too High Engine Overheat Shutdown Intake Air Temperature Sensor Voltage Too High Voltage Too Low...
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 850 Touring Diagnostic Codes Component Condition Chassis Relay Driver Circuit Open/Grounded 520208 Driver Circuit Short to B+ 520208 Driver Circuit Grounded 520208 All Wheel Drive Control Driver Circuit Open/Grounded 520207 Driver Circuit Short to B+ 520207 Driver Circuit Grounded...

  • Page 49: Operation

    Break-In Period The break-in period for your new POLARIS vehicle is the first 20 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
  • Page 50 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 87. Add oil if necessary to maintain the level between the safe and add marks. 3.
  • Page 51 OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Passenger seat latch...
  • Page 52 OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 6. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
  • Page 53 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.
  • Page 54 OPERATION Driving Procedures 1. Wear protective riding gear. See page 16. 2. Perform the pre-ride inspection. See page 50. 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 55 OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your...
  • Page 56 OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. 2.
  • Page 57 OPERATION Driving on Slippery Surfaces Turn in Sideways direction of skid skid Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2.
  • Page 58 OPERATION Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 2. Drive straight uphill. 3. Avoid steep hills (15° maximum). 4. Always check the terrain carefully before ascending any hill. 5.
  • Page 59 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. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle.
  • Page 60 OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 2. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.
  • Page 61 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) Downloaded from ManualsNet.com search engine...
  • Page 62 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 3. Leave the transmission in forward and shut off the engine. 4.
  • Page 63 OPERATION Driving Through Water Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in Maximum Depth water deeper than the bottom of the footrests.
  • Page 64 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. 5.
  • Page 65 OPERATION 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. Drive slowly. Apply the brakes lightly for stopping. 4.
  • Page 66 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. Downloaded from ManualsNet.com search engine...
  • Page 67 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 68 OPERATION Hauling Cargo Never exceed the weight capacities specified for your vehicle on warning labels and in the specifications section of this manual. 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
  • Page 69 OPERATION Hauling Cargo 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°. • Always attach a towed load to the hitch point. Remove the hitch from the vehicle when not towing a trailer.

  • Page 70: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 71 WINCH GUIDE Winch Safety Precautions 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.
  • Page 72 WINCH GUIDE Winch Safety Precautions 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23.
  • Page 73 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 74 WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 75 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
  • Page 76 WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 78.
  • Page 77 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 78 WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 79 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 80 WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.
  • Page 81 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 82: Emission Control Systems

    Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your POLARIS vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 83: 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 146.
  • Page 84 Symbol Description ► Perform these operations more often for vehicles subjected to severe use. Emission-related service. Have an authorized POLARIS dealer perform these services. Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first)
  • Page 85 ► Cooling hoses 50 H 1000 (1600) Inspect for leaks ► Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Downloaded from ManualsNet.com search engine...
  • Page 86 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) ► Oil lines and 100 H 1000 (1600) Inspect for leaks and loose fasteners fittings ► Engine oil change 100 H 1000 (1600) Change the oil and filter ►...
  • Page 87 Grease fittings (3 pumps maximum) every 500 miles, Shaft Yoke before long periods of storage, or after pressure washing or submerging. A-Arms, Front POLARIS All Grease fittings after extreme use or if suspension and Rear Season Grease becomes squeaky. Front...
  • Page 88 POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W- 50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W- 50 oil. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 89 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 86 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 82. Always change the oil filter whenever changing oil.
  • Page 90 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 91 Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 82. See page 137 for the part numbers of POLARIS products. Maintain the oil level at the bottom of the fill plug hole. The...
  • Page 92 MAINTENANCE Transmission Oil Oil Change 1. Remove the footwell. 2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. 3. Clean and reinstall the drain plug. Torque to specification. 4. Remove the fill plug. Add the proper amount of the recommended oil.
  • Page 93 Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 82. See page 137 for the part numbers of POLARIS products. Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
  • Page 94 We recommend the use of POLARIS Demand Drive Fluid for the ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 137 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 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level Bleeder surface. Before performing the Screw fluid change, allow the vehicle to sit for at least 30 minutes. Bleeder 2. Thoroughly clean the areas Valve Screw around and on the ADC reservoir and bleeder valves...
  • Page 96 Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 82. See page 137 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 97 Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. POLARIS Antifreeze is already premixed and ready to use.
  • Page 98 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. See page 1. View the fluid level in the bottle. 2.
  • Page 99 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 100 MAINTENANCE 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 101 1/4-1/2 inch (6-12 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 service. Downloaded from ManualsNet.com...
  • Page 102 MAINTENANCE Seats Passenger Seat Removal 1. Pull the latch at the rear of the seat. 2. Pivot the rear of the seat upward and remove the front legs of the seat base from the frame. 3. To reinstall the seat, position the front legs of the seat base under the frame.
  • Page 103 MAINTENANCE Seats Passenger Seat Suspension 1. Remove the passenger seat. 2. Remove the fastener retaining the passenger seat shock to the passenger seat support. 3. Pivot the seat support upward to access the lower shock fastener. Remove the lower shock fastener. 4.
  • Page 104 MAINTENANCE Side Panel/Footwell Removal 1. Remove the seat before removing a side panel. 2. To remove a side panel or footwell, remove the fasteners securing it to the frame. Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Hex Head Screw Plastic Rivet...
  • Page 105 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.
  • Page 106 3. Lock the parking brake. 4. Loosen the wheel nuts slightly. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 5. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.
  • Page 107 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. 4. Install the wheel nuts and finger-tighten them. 5.
  • Page 108 MAINTENANCE Air Filter 1. Remove the seat. Strap 2. Remove the air box cover strap, 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 109 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.
  • Page 110 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and replace burned out headlamps 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 fingers.
  • Page 111 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 approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.
  • Page 112 MAINTENANCE Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.
  • Page 113 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 114 MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly. Taillight/Brakelight Lamp Replacement 1. Remove the harness connector Connector from the back of the light Lamp assembly.
  • Page 115 Refer to the specifications section beginning on page 138 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Torque Specification Plug Condition New Spark Plug 9-11 ft.
  • Page 116 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white.
  • Page 117 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1.
  • Page 118 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 119 • 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 120 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 121 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use 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) High PVT Drying There may be some instances when water is accidently ingested into the...
  • Page 122 (black) cable last. Your vehicle is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.
  • Page 123 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 124 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 125 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
  • Page 126 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.
  • Page 127 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 handlebar control and remove the cover.
  • Page 128 6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your POLARIS dealer for service. 7. With the engine running, turn the handlebars fully to the left and right.
  • Page 129 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 130 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 131 128. 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 132 5. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
  • Page 133 Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your vehicle. Always install accessories that are approved by POLARIS for your vehicle. Please see your POLARIS dealer. Transporting the Vehicle Follow these procedures when transporting the vehicle.

  • Page 134: Troubleshooting

    PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to...
  • Page 135 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
  • Page 136 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug(s)
  • Page 137 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs...

  • Page 138: Polaris Products

    2877923 Demand Drive Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug Coolant 2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l) 2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l) Grease / Specialized Lubricants 2871312 Grease Gun Kit, All Season Grease 2871322 All Season Grease (3 oz./89 ml cartridge)

  • Page 139: Specifications

    SPECIFICATIONS SPORTSMAN 550 Touring Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 765 lbs. (347 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weight 150 lbs.
  • Page 140 SPECIFICATIONS SPORTSMAN 550 Touring Lubrication System Pressurized Wet Sump Transmission Type Automatic PVT (POLARIS Variable Transmis- sion) In-Line H-L-N-R-P Front Suspension Dual a-arm, 9" (22.9 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10" (25.4 cm) travel Gear Reduction, Low 5.034:1...
  • Page 141 SPECIFICATIONS SPORTSMAN 850 Touring Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 798 lbs. (362 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weight 150 lbs.
  • Page 142 SPECIFICATIONS SPORTSMAN 850 Touring Lubrication System Pressurized Wet Sump Transmission Type Automatic PVT (POLARIS Variable Transmis- sion) In-Line H-L-N-R-P Front Suspension Dual a-arm, 9" (22.9 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10" (25.4 cm) travel Gear Reduction, Low 5.034:1...

  • Page 143: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 144 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 145 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied.
  • Page 146 SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.

  • Page 147: 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 services performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS Downloaded from ManualsNet.com...
  • Page 148 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS Downloaded from ManualsNet.com search engine...
  • Page 149 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS Downloaded from ManualsNet.com search engine...

  • Page 150: Index

    INDEX 4X4 Switch ....21, 33 Demand Drive Fluid ... . . 92 Diagnostic Codes, 550 XP EPS . 44-45 Diagnostic Codes, 850 XP EPS .
  • Page 151 INDEX Fluid Change Helmet ......16 ADC ..... . 94 High Beam Adjustment .
  • Page 152 Spark Plugs ....114-115 Polaris Product List... . . 137 Specifications ... . . 138-141 Polishing the Vehicle .
  • Page 153 INDEX Taillight Lamp Replacement ..113 Vehicle Identification Numbers..5 Throttle Body Adjustment ..126 Vehicle Immersion ... . . 116 Throttle Cable Freeplay Adjustment .
  • Page 154 Antes de utilizar ou andar neste veículo, leia o Manual do proprietário. Innan du hanterar eller kör detta fordon, läs Handboken. For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 USA Part No. 9924611 Rev 02 Printed in USA *9924611...

This manual is also suitable for:

Sportsman 850 2014

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