Polaris Sportsman Forest 550 Owner's Manual For Maintenance And Safety
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Polaris Sportsman Forest 550 Owner's Manual For Maintenance And Safety

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Sportsman Forest 550
Sportsman Forest 850
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 Forest 550

  • Page 1 Sportsman Forest 550 Sportsman Forest 850 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 Before you operate this vehicle, read the owner’s manual For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923562 Rev 01 Printed in USA *9923562...
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit- ing line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ®...
  • Page 4 POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc. MAXXIS is a registered trademark of Maxxis International. ® Copyright 2011 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 5: Table Of Contents

    Troubleshooting ..... . . 121 POLARIS Products..... 125 Specifications .

  • Page 6: 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. DANGER A DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 7: 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 8: 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 9 SAFETY Rider Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. See the OPERATION section of the owner’s manual for proper operating procedures. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.
  • Page 10 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 11 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 12 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 13 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 14 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 15 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 16: 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 17: 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 18 POLARIS dealer to pur- chase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. The following pages repeat the information found on each label.

  • Page 19: General Alert

    SAFETY Safety Labels and Locations General Alert (Multi-Lingual) Before you operate this vehicle, read the owner’s manual. 7173025 Reverse Override Warning/4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.
  • Page 20 SAFETY Safety Labels and Locations “No Passenger” Warning Tire Pressure/Load Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT: 7.0 (48.3) REAR: 7.0 (48.3) MAXIMUM WEIGHT CAPACITY 575 lbs.

  • Page 21: Clutch Cover Alert

    SAFETY Safety Labels and Locations Rack Rack Warning Warning    Clutch Cover Warning (under seat) Clutch Cover Alert 7175826 Rack Warning, Front and Rear WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death.

  • Page 22: Features And Controls

    FEATURES AND CONTROLS Switches Momentary High-Beam Switch Mode/Reverse 4X4 Switch Override Switch Winch Main Key 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 23: Turn Signal Switch

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

  • Page 24: 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 25: 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 26: Parking Brake

    FEATURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock for- ward to engage the lock. 4. Release the brake lever. 5.
  • Page 27 FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering 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 located on the right side of the...

  • Page 28: Steering Lock

    If your factory-installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso- ries, please see your POLARIS dealer to purchase a 30 AH battery. 1. Fully charge the new battery before installing it. See page 112.

  • Page 29: 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 30: 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 31: Engaging 4X

    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 32: 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 33: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation. 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, high beam status, bat-...

  • Page 34: 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 35 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...
  • Page 36 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 37: Standard/Metric Display

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

  • Page 38: 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 39 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 40 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 Forest 550 Diagnostic Codes Component Condition Throttle Position Sensor...
  • Page 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 550 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+...
  • Page 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 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 Manifold Absolute Pressure Sensor...
  • Page 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 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 520207...

  • Page 44: 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 lon- ger life for these components.
  • Page 45 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 73. Add oil if necessary to maintain the level between the safe and add marks. 3.

  • Page 46: Pre-Ride Checklist

    OPERATION 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 Remarks Page...

  • Page 47: 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.
  • Page 48 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 49: Turning The Vehicle

    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 50: Driving On Slippery Surfaces

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

  • Page 51: Driving Through Water

    OPERATION 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 Maximum the footrests.

  • Page 52: 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 53: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5.
  • Page 54 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 55: 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 56 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 57: Driving Downhill

    OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed.
  • Page 58 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 59 OPERATION 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 60: 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 61 OPERATION Hauling Cargo 1. Never exceed the weight capaci- ties specified for your vehicle on warning labels and in the speci- fications section of this manual. 2. 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 62: Parking On An Incline

    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 63: Winch Guide

    WINCH GUIDE The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and oper- ating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people. Winch Safety Precautions 1.

  • Page 64: Winch Cable Care

    WINCH GUIDE Winch Cable Care 1. The life of a cable is directly related to the care it receives. The wire cable on a new winch (and any replacement cables) must be re- spooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage.

  • Page 65: Winch Preparation And Inspection

    WINCH GUIDE Winch Preparation and Inspection DANGER Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.

  • Page 66: Winch Rigging

    WINCH GUIDE Winch Rigging WARNING Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch. 1.

  • Page 67: Winch Operation

    WINCH GUIDE Winch Operation NOTICE: This winch is designed for intermittent use. Prolonged use may result in damage due to overheating. 1. Use common sense. 2. Take your time. 3. Think through the situation. 4. Pay attention to what is going on when you are winching. 5.
  • Page 68 WINCH GUIDE Winch Operation 13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.

  • Page 69: Emission Control Systems

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

  • Page 70: 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 135.

  • Page 71: Periodic Maintenance Chart

    Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key  Perform these operations more often for vehicles subjected to severe use.
  • Page 72 250 (400) Inspect level  General 50 H 500 (800) Lubricate all fittings, pivots, lubrication cables, etc.  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services. ...
  • Page 73 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Throttle Cable/ 50 H 500 (800) Inspect; adjust; lubricate;  ETC Switch replace if necessary E Throttle Body 50 H 500 (800) Inspect duct for proper seal- Intake Duct ing/air leaks Drive belt...

  • Page 74: Lubrication Guide

    DOT 4 Only Page 85. ADC Fluid Demand Drive Page 78. Plus Fluid Front Prop POLARIS Grease fittings (3 pumps maximum) every 500 miles, Shaft Yoke Premium U-Joint before long periods of storage, or after pressure Lube washing or submerging.

  • Page 75: Engine Oil

    Synthetic 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 recommenda- tions for ambient temperature operation.

  • Page 76: 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 77 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 78: Transmission Oil

    MAINTENANCE Transmission Oil POLARIS recommends the use of POLARIS Synthetic SPORTSMAN XP Transmission 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 79: 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. Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
  • Page 80 ADC mode. We recommend the use of POLARIS Demand Drive Plus Fluid. Main- tain the fluid level between the minimum and maximum marks on the reservoir. See page 125 for the part numbers of POLARIS products.
  • Page 81 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 around and on the ADC Screw reservoir and bleeder valves...

  • Page 82: 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 83: Oil Change

    MAINTENANCE 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 84: Cooling System

    Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Premium 60/40 anti- freeze/coolant 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.
  • Page 85 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front storage com- partment. 1. View the fluid level in the bottle. 2.

  • Page 86: 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 87: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 125 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 88 MAINTENANCE Brake Fluid Hand Brake Indicator Master Window The master cylinder is located on Cylinder 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.

  • Page 89: Brake Inspections

    MAINTENANCE 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 90: Toe Alignment

    1.5 mm more than the front measurement on each side of the vehicle to obtain the recommended 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 service.

  • Page 91: Steering Assembly

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

  • Page 92: 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 93: Wheel Installation

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

  • Page 94: Air Filter

    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 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 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 97 MAINTENANCE 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 98 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. Rear Turn Signal Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the turn signal socket counterclockwise to remove it.
  • Page 99 MAINTENANCE 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 100: 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 101 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 102: Camber And Caster

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

  • Page 103: 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. Torque Specification Plug Condition New Spark Plug 9-11 ft.
  • Page 104 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 105: 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 vehicle to a dealer before starting it, follow the steps outlined below. 1.

  • Page 106: Spark Arrester

    MAINTENANCE Spark Arrester Failure to heed the following warnings while servicing the spark arrester 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 107: Pvt System

    • 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 108 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 fly- weights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

  • Page 109: Pvt Drying

    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 110 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 111: 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 vehicle. Be careful not to tip a conven- tional battery sideways, which could spill electrolyte.

  • Page 112: Battery Installation

    If your factory-installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso- ries, please see your POLARIS dealer to purchase a 30 AH battery. Before installing the 30 AH battery, remove the plastic spacer at the bot- tom of the battery compartment.

  • Page 113: Battery Storage

    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 114 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 109. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 115 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 116: 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 gar- den 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 117: 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 118 MAINTENANCE 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 119: Storage Tips

    See page 114. 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 recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 120: 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 121: 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 materials. They do not allow enough ventilation to prevent condensa- tion, and may promote corrosion and oxidation.

  • Page 122: Transporting The Vehicle

    MAINTENANCE 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 123: 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 124 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 125 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 plugs...

  • Page 126: Engine Overheating

    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 plugs Inspect, clean and/or replace spark plug...

  • Page 127: Polaris Products

    Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger...

  • Page 128: Specifications

    Steering System Akerman Principle, with handlebar controls Transmission Power System Shaft drive on all wheels Driving System Type Automatic PVT (POLARIS Variable Transmis- sion) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm) travel...
  • Page 129 SPECIFICATIONS SPORTSMAN Forest 550 Transmission and Gears High/Low/Neutral/Reverse/Parking Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.693:1 Drive Ratio, Front 3.818:1 Drive Ratio, Rear 3.7:1 Tires Type Front Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure...
  • Page 130 Steering System Akerman Principle, with handlebar controls Transmission Power System Shaft drive on all wheels Driving System Type Automatic PVT (POLARIS Variable Transmis- sion) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm) travel...
  • Page 131 SPECIFICATIONS SPORTSMAN Forest 850 Transmission and Gears High/Low/Neutral/Reverse/Parking Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.367:1 Drive Ratio, Front 3.818:1 Drive Ratio, Rear 3.7:1 Tires Type Front Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Tires Type Rear Off Road Style, Deep Tread Design, size 26x10- 14 AT / 7 psi (48.3 kPa) Pressure...

  • Page 132: Warranty

    WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 133 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 134 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim: •...
  • Page 135 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 materi- als, 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 136 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS dealer autho- rized to repair POLARIS vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 137: 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 138 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 139 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 140: Index

    INDEX 4X4 Switch ....20, 28 Coolant, Radiator....84 Cooling System ....82-84 Corrosion Removal, Chrome.
  • Page 141 Periodic Maintenance Chart ..68-71 Polaris Product List... . . 125 Key Switch ....21 Polishing the Vehicle .
  • Page 142 INDEX Rack/Compartment, Front ..27 Taillight ..... . . 97 Reverse Operation ....51 Throttle Body Adjustment .

This manual is also suitable for:

Sportsman forest 850

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