ATV or Youth Sportsman 550 Touring International / 850 Touring International 2011 Owner's Manual

PMS 419

Sportsman

550 Touring International

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.

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

PMS 419

PASSENGER

UNDER

12

GB

D

I

FI

E

F

P

S

Before you operate or ride this vehicle, read the owner’s manual.

Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahren.

Antes de operar o conducir este vehículo, lea el

Manual del propietario.

Lire le Manuel d’utilisation avant d’utiliser ou de conduire ce véhicule.

Prima di usare o guidare il veícolo, leggere il

Manuale di istruzioni.

Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista.

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.polarisindustries.com

Polaris Sales Inc., 2100 Hwy 55

Medina, MN 55340 USA

Part No. 9922825 Rev 01

Printed in USA

*9922825 *

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER ® utility vehicles

• Victory Motorcycles ®

• Low emission vehicles (LEVs)

Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service

Dealer ® (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period.

For more information about POLARIS, visit us online at www.polarisindustries.com.

1

POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS

Industries Inc.

Copyright 2010 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. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in U.S.A.

2011 SPORTSMAN 550/850 Touring International Owner’s Manual

P/N 9922825

2

TABLE OF CONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . 21

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Emission Control Systems . . . . . . . . . . . . . . . . . . . . 69

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

POLARIS Products . . . . . . . . . . . . . . . . . . . . . . . . 125

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Declaration of Conformity . . . . . . . . . . . . . . . . . . . 130

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3

4

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.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

INTRODUCTION

As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Ride responsibly.

Know all laws and regulations concerning the operation of this vehicle in your area.

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.

The ignition switch must be replaced if all keys are lost.

Engine Serial Number

VIN

Key

Number

####

550 850

Vehicle Model Number: ___________________________________________________________

Frame VIN: ____________________________________________________________________

Engine Serial Number: ____________________________________________________________

Key Number: ___________________________________________________________________

5

6

SAFETY

WARNING

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.

Read and understand your owner's manual and all warnings before operating this POLARIS vehicle.

Safety Training

When you purchased your new POLARIS vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used POLARIS vehicle from a party other than a

POLARIS dealer, please request free safety training from any authorized POLARIS dealer.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Never allow anyone under 16 years of age to operate this vehicle.

Never allow anyone under 12 years of age to ride as a passenger on this

2-up vehicle.

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.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only

Polaris-approved accessories. Know their function and effect on the vehicle.

7

8

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.

Contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com.

Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Never allow anyone under 12 years of age to ride as a passenger on this

2-up vehicle.

Never carry more than one passenger on this 2-up vehicle.

Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

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 experience.

Never attempt jumps or other stunts.

SAFETY

9

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 hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

10

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for turning.

See page 54.

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.

Always follow the procedures outlined in this manual for driving on hills. See page 57. Always move the

4X4 switch to ADC 4X4 before ascending or descending a hill. See page 35. 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 15



.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 59.

Always move the 4X4 switch to ADC

4X4 before ascending or descending a hill. See page 35. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

>15



11

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.

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 60.

Always follow the procedures outlined in this manual for operating over obstacles. See page 63.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 56.

12

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

62.

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. Maintain the proper tire pressure.

Never modify the vehicle through improper installation or use of accessories.

13

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.

Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

14

SAFETY

Rider Safety

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Always unlock the steering before starting the engine. See page 31.

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

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.

15

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Long

Sleeves

Eye Protection

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.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

E 4

051039

0006.31

16

SAFETY

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. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

17

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection.

Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

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.

2x4

H

E

Trip 1

88 km

88 mi

F

RPM

H

H

General

Alert

Reverse

Override

Warning

Age 16

Alert

H

Hill

Operation

Alert

18

SAFETY


General Alert

(Multi-Lingual)

Before you operate or ride this vehicle, read the owner’s manual.

7174362

PASSENGER

UNDER

12

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.

CAUTION

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

7175512

Hill Operation Alert

• Never operate this vehicle on HILLS steeper than 15 degrees 15



.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

7174361

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (KPa):

Front: 7.0 psi (48.3 kPa)

Rear: 5.0 psi (34.5 kPa)

MAXIMUM WEIGHT CAPACITY 735 lbs. (333 kg)

INCLUDES WEIGHT OF OPERATOR,

PASSENGER, CARGO AND ACCESSORIES.

Read Owner’s Manual for more detailed loading information.

7176783

Tire Pressure/Load

Alert

19

SAFETY


Rack/Box

Warning

H

H

H

Rack/Box

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.

• Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg)

7175448

Clutch Cover Alert

Hitch Capacity Label

TRAILER MAX WEIGHT:

1500 LBS. (682 KG) ON LEVEL GROUND

850 LBS. (386 KG) UP TO 15



GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

7170509

20

FEATURES AND CONTROLS

Switches

Main Key Switch

Use the main key switch to start the engine. See page 52.

E

Trip 1

88 88 mi

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.

Main Key

Switch

After starting the engine, release the key switch to the POSITION

LIGHTS ON position.

4X4 Switch

Use the 4X4 switch to engage ADC

4X4, 4X4 or 2X4. See page 35. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

4X4

Switch

21


Switches

Engine Stop Switch

The engine will not start or run when the switch is in the

OFF position.

Trip 1 RPM

88 88 km mi

2x4

OFF

RUN

Push the stop switch down to stop the engine quickly. Pull the stop switch up to the

RUN position before attempting to start the engine.

Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Hazard Switch

Headlight

Switch

Override

Switch

Horn

Switch

Momentary High Beam Switch

Press this switch with your left forefinger to activate the headlight high beam.

The lights will return to low beam when the switch is released.

Engine

Stop

Switch

Hazard

Switch

Turn Signal

Switch

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

Turn Signal Switch

Push the toggle switch either left or right to activate the corresponding turn signal light. Return the toggle to the center position to end the signal.

Horn Switch

Press the horn switch to sound the horn.

Momentary High-Beam

Switch

22


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. Always release the throttle before pressing the override switch.

The reverse override button also acts as a MODE button when held down for approximately one half second. See the instrument cluster information beginning on page 36.

Tip: The override button will not function as a MODE button if the transmission is in reverse.

Headlight Switch

The main key switch must be on and the engine stop switch must be in the RUN position to operate the headlight switch.

High Beam

Low Beam

23


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. Check occasionally during operation.

Do not start or operate the vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Press the throttle lever to increase engine speed and vehicle movement.

Release the lever to reduce engine speed and vehicle movement.

Electronic Throttle Control

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

24


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. These brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

25


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. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.

Check the brake fluid in the master cylinder before each ride.

1. Position the vehicle on a level surface.

Master Cylinder

2. Position the handlebars so the master cylinder is level.

3. View the brake fluid level through the indicator window on the top of the master cylinder. The eye will appear dark when the fluid level is full.

When fluid is low, the eye will be clear.

Indicator

Window

4. If the fluid level is low, remove the cover screws and add fluid to the fill line. Do not overfill. Use DOT 4 brake fluid only.

5. Reinstall the cover. Torque screws to 7 in. lbs. (.8 Nm).

26


Parking Brake

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake lever two or three times, then squeeze and hold.

3. Push the parking brake lock forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Operating the vehicle while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill. Another option is to park the vehicle in a sidehill position. Never depend on the parking brake alone if the vehicle is parked on a hill. Always block the wheels to prevent rolling.

27


Auxiliary Foot Brake

Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake.

The auxiliary foot brake is located on the inside of the right footrest.

Operate this brake with your right foot.

If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the front storage box. See page 32.

Maintain the fluid level between the maximum and minimum marks.

Use DOT 4 brake fluid only.

NOTICE: Do not use ADC fluid in the brake fluid reservoir. ADC fluid will damage the rubber components of the brake system.

Auxiliary

Foot Brake

Brake Fluid

Reservoir

28


Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

P: Park

Gear

Selector

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

Whenever the vehicle is left unattended, always place the transmission in PARK and lock the parking brake.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed.

29


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 37 for EPS Warning Indicator information.

Passenger Seat

Always make sure the passenger seat is installed and securely latched before operating with a passenger. 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 89-90 for passenger seat adjustment procedures.

See page 89 for passenger seat removal and installation procedures.

Beverage Holders

This vehicle is equipped with beverage holders on each side of the passenger seat. To secure a beverage or other container, remove the rubber retainer strap from one side of the holder. Place the container into the recess and reinstall the strap over the top of the container. Place one of the rubber cylinders through one of the holes to secure a strap.

When trailering the vehicle, and whenever a holder is not in use, always secure the rubber straps in one of the tighter positions to prevent loss of the retainer.

Tight Position

Less Tight Position

30


Fuel Tank

Always refuel with the engine 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. Do not use fuel with ethanol content greater than 10%, such as

E-85 fuel.

The fuel tank is designed to allow for the normal expansion of fuel. Do not overfill. Do not fill the tank neck.

Fuel Tank

Cap

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full right position.

Tip: The handlebars may also be locked in the full left position.

2. Insert the steering lock key and turn it clockwise.

3. Remove the key. Place the steering lock keys in a safe place.

The lock must be replaced if the keys are lost.

4. Reverse the procedure to unlock the steering.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

31


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 lift the unlatched edge of the box to

Cover Latches disengage the plungers. Pivot the box forward.

Plunger Latches

4. To remove the box completely, disengage the plungers and slide the box rearward and upward.

5. Always secure the plunger latches and the cover latches before operating the vehicle.

Access the following components under the front box:

• Radiator cap

• Brake fluid reservoir

• ADC fluid reservoir

• Coolant recovery bottle cap

• Electrical/fuse/relay components

• Battery

Battery

Brake Fluid

Reservoir

ADC Fluid

Reservoir

Coolant

Bottle Cap

Radiator

Cap

Electrical/Fuse/Relay

32


All Wheel Drive System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4

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. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

See page 35.

4X4 Mode

When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator icon in the instrument cluster display will be visible.

When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

4X4

Switch

There is no limit to the length of time the vehicle may remain in 4X4.

The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

2X4 Mode

When the switch is on 2X4, the vehicle is in two-wheel drive at all times.

33


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. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the 4X4 switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to

4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

34


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:

• The 4X4 switch must be in the ADC 4X4 position

• Vehicle speed must be 15 mph (24 km/h) or less

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the following conditions occur:

• The 4X4 switch is moved out of the ADC 4X4 position

• Vehicle speed exceeds 15 mph (24 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

35


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. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

Digital/Analog Gauge

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).

Indicator Lamps

Speedometer

E

Trip 1

88 : 88 mi

F

RPM

Rider

Information

Center

36




Indicator Lamps

Lamp Indicates

Vehicle

Speed

Over

Temperature

Condition

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

This lamp flashes to indicate an overheated engine. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will automatically reduce engine power.

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

Neutral

High Beam

This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

This lamp illuminates when the headlamp switch is set to high beam.

Direction

Indicators

A direction indicator flashes when a turn signal is active. Both indicators flash when the hazard signal is active.

Check Engine This indicator appears if an EFI-related fault occurs.

Do not operate the vehicle if this warning appears.

Serious engine damage could result. See your dealer.

37




Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 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. To change to metric and/or a 24-hour clock, see page 41.

2

E

Trip 1

1

3

7 6

88 :

km mi

88

5

4

38





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.

Fuel Gauge Display - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See your dealer.

3.

Information Display - This area displays odometer, trip meter, engine hour meter, engine speed and programmable service hour interval.

4.

Active Descent Control Display This icon displays when ADC is active. See page 35.

5.

Clock Display - The clock displays time in a 12-hour or 24-hour format. If the engine is turned off, press the MODE button. The time will display for 5-10 seconds. See page 41 for resetting instructions.

6.

Service Reminder Display - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 41 for resetting instructions.

7.

4X4 Display - This icon displays when the 4X4 system is engaged

(switch is on either ADC 4X4 or 4X4).

39





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.

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement.

Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to the odometer display.

Distance

Fuel

Temperature

Time

Standard Display

Miles

U.S. Gallons

Fahrenheit

12-Hour Clock

Metric Display

Kilometers

Liters, Imperial Gallons

Celsius

24-Hour Clock

1. Turn the key to the OFF position.

2. Place the transmission in neutral.

3. Press and hold the MODE button while turning the key to the ON position.

4. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.

5. Press and hold the MODE button to save the setting and advance to the next display option.

6. Repeat the procedure to change remaining display settings.

40





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.

2. Press and hold the MODE button until the hour segment flashes.

Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes.

Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.

After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

41





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. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval.

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.

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).

The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

42





Engine Error Codes

The error screen displays only when the CHECK

ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored in the gauge when the key is turned off.

The code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

Error Code

Number (0-9)

Suspect Parameter

Number (SPN)

If the CHECK ENGINE light illuminates, retrieve the error codes from the display. Please see your

POLARIS dealer for all major repairs.

Failure Mode Indicator (FMI)

1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code menu.

3. Record the numbers displayed in the gear position (if any), clock and odometer displays.

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.

43



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.

Shorted Load: The wires leading to the item listed in the chart are shorted together, or the item has shorted internally.

Short-to-Battery: The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage.

SPORTSMAN 550 Touring Diagnostic Codes

Component

Throttle Position Sensor

Engine Temperature Sensor

Intake Air Temperature Sensor

Condition

Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Voltage Too High

Voltage Too Low

Manifold Absolute Pressure Sensor

Crankshaft Position Sensor

Gear Sensor Signal

Fan Relay Driver Circuit

Voltage Too High

Voltage Too Low

Circuit Fault

Voltage Too Low (to Calibrate)

Voltage Too High

Injector 1 (MAG)

Signal Fault

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded


Fuel Pump Driver Circuit Driver Circuit Open/Grounded




102

102

636

523

523

523

651

651

1268

1268

SPN

51

51

110

110

110

110

105

105

1347

1347

1071

1071

3

5

2

5

3

8

4

3

4

3

5

3

5

3

4

16

0

3

4

FMI

3

4

3

44





Component

Idle Air Control

Starter Enable Circuit

All Wheel Drive Control

System Power

Throttle Safety Signal

Active Descent Control System

Condition

Driver Circuit Grounded

Shorted Load*



Voltage Too High

Voltage Too low

Voltage Too High

Voltage Too Low

Signal Out of Range

Throttle Stuck


SPN

520193

FMI

5

520193 11

1321 3

520207 3

168

168

520194

520194

520194

520194

520203

7

3

3

4

3

4

2

EPS Models Only

Steering Over Current Shut Down

Steering Excessive Current Error

Steering Torque Sensor T1 Partial

Failure

Current Above Normal or

Grounded

Current Above Normal or

Grounded

T1 Shorted to Ground

T1 Shorted to Bus

Steering Torque Sensor T2 Partial

Failure


T2 Shorted to Bus

Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground

T1 and T2 Shorted to Bus

T1 Shorted to Ground & T2

Shorted to Bus

T2 Shorted to Ground & T1

Shorted to Bus

T1 and T2 are Shorted

520221

520222

520223

520223

520224

520224

520225

520225

4

3

4

3

4

3

520225 16

520225

6

6

17

Steering Position Sensor P1 Partial

Failure

Steering Position Sensor P2 Partial

Failure

P1 Shorted to Ground

P1 Shorted to Bus


P2 Shorted to Bus

Steering Position Sensor Full Failure P1 and P2 Shorted to Ground

EPAS Inverter Temperature

EPAS CAN Communications

Receive Error

EPAS CAN Communications

Transmit Error

No TX Message for 2 Seconds

520225

520226

520226

520227

520227

520228

P1 and P2 Shorted to bus

Greater than 110 Degrees C

520228 3

520229 16

Greater than 120 Degrees C 520229

No RX Message for 2 Seconds 520230

0

9

520231

2

4

3

4

3

4

9

*Assumes unipolar configuration of stepper motor

45





Component Condition

Throttle Position Sensor Voltage Too High

Engine Temperature Sensor

Intake Air Temperature Sensor Voltage Too High

Voltage Too Low

Manifold Absolute Pressure Sensor Voltage Too High

Voltage Too Low

Signal Out of Range

Crankshaft Position Sensor

Voltage Too Low

Voltage Too High

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Vehicle Speed Signal

Gear Sensor Signal

Circuit Fault

Plausibility Fault

Speed Too High

Plausibility Fault

Voltage Too Low

Injector 1 (MAG) (SDI Part Load)

Injector 2 (PTO) (SDI Part Load) Driver Circuit Open/Grounded



Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+

Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+

Fuel Pump Driver Circuit

Voltage too high

Signal fault




Fan Relay Driver Circuit






Idle Air Control

Starter Enable Circuit





Position Out of Range




3

4

4

5

7

4

5

5

3

3

5

3

4

4

3

5

3

3

5

3

3

2

4

8

2

8

2

4

3

4

3

4

2

FMI

3

4

3

4

16

0

1347

1347

1347

1071

1071

1071

634

634

634

634

523

523

651

651

651

652

652

652

1268

1269

1321

1321

1321

636

636

84

84

523

105

105

102

102

102

SPN

51

51

110

110

110

110

46




Component

Chassis Relay


Condition


All Wheel Drive Control

System Power

Throttle Safety Signal






Voltage Too High

Voltage Too low

Voltage Too High

Voltage Too Low

Signal Out of Range

Throttle Stuck

Active Descent Control System Driver Circuit Open/Grounded

Idle Speed



Speed Too High

Speed Too Low

EPS Models Only

Steering Over Current Shutdown Current Above Normal/Grounded

Steering Excessive Current Error Current Above Normal/Grounded

Steering Torque Sensor T1 Partial Failure


T1 Shorted to Bus

Steering Torque Sensor T2 Partial Failure

Steering Torque Sensor Full

Failure


T2 Shorted to Bus

T1 and T2 Shorted to Ground

T1 and T2 Shorted to Bus

520221

520222

520223

520223

520224

520224

520225

520225

6

6

4

3

4

3

4

3

T1 Short to Ground & T2 Short to Bus 520225 16

Steering Position Sensor P1

Partial Failure

Steering Position Sensor P2

Partial Failure

Steering Position Sensor Full

Failure

EPAS Inverter Temperature

T2 Short to Ground & T1 Short to Bus 520225 17

T1 and T2 are Shorted 520225 2


P1 Shorted to Bus


520226

520226

520227

4

3

4

P2 Shorted to Bus

P1 and P2 Shorted to Ground

P1 and P2 Shorted to bus



520227

520228

520228

520229

520229

3

4

3

16

0

EPAS CAN Comm. Receive Err No RX Message for 2 Seconds

EPAS CAN Comm. Transmit Err No TX Message for 2 Seconds

IC CAN Comm. w/EPAS EPAS Offline

520230 9

520231 9

520230 31

SPN FMI

520208 5

520208 3

520208 4

520207 5

520207 3

520207 4

168

168

520194 3

520194 4

3

4

520194 2

520194 7

520203 5

520203 3

520203 4

520211 3

520211 4

47

OPERATION

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Break-In Period

The break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the 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.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

48

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 75. Add oil if necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 50.

6. Pull only light loads.

7. Change both the oil and the filter at 20 hours, one month or 500 miles (800 km), whichever comes first.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

49

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

Passenger seat latch

Brake system/lever travel

Remarks

Ensure latch is secure

Ensure proper operation

Brake fluid

Auxiliary brake

Front suspension

Rear suspension

Steering/steering lock

Ensure proper level


Inspect, lubricate if necessary

Inspect, lubricate if necessary

Unlock the steering; ensure free operation

Steering

Tires

Ensure free operation

Inspect condition and pressure

Wheels/fasteners Inspect, ensure fastener tightness

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil Ensure proper levels

Coolant level

Coolant hoses

Throttle

Switches

Engine stop switch

Mirrors

Turn signals, indicators

Air filter, pre-filter

Headlamp

Brake light/taillight

Riding gear

ADC Fluid

Ensure proper level

Inspect for leaks


Ensure operation


Adjust for best side/rear vision

Ensure operation

Inspect, clean

Check operation

Check operation

Wear approved helmet, goggles, and protective clothing

Ensure proper level

24

114

21

22

24

22

95

23

97

101

16

-

92

94

-

31

75

85

86

-

Page

30

25

87

26

28

74

74

31

81

50

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.

3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.

4. Before operating, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable).

5. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

6. Drive in a manner appropriate for your skills, your passenger’s skills and operating conditions. Never operate at excessive speeds.

Never attempt wheelies, jumps or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

7. Never consume alcohol or drugs before or while operating this vehicle.

8. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

9. Never operate a damaged vehicle. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.

10. Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

11. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

12. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

51

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.

4. Sit on the vehicle and move the engine stop switch to RUN.

5. Do not press the throttle while starting the engine.

6. Turn the ignition key past the POSITION

LIGHTS ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

7. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

Cold Weather Operation

If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

52

Driving Procedures

OPERATION

1. Wear protective riding gear. See page 16.

2. Perform the pre-ride inspection. See page 50.



5. Mount the vehicle from the left side.

6. Sit upright with both feet on the footrests and both hands on the handlebars.

7. Start the engine and allow it to warm up.

8. Shift the transmission into gear.

9. Check your surroundings and determine your path of travel.

10. Release the parking brake.

11. Slowly depress the throttle with your right thumb and begin driving.

12. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

53

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 weight on the outer footrest.

Use the same leaning technique for turning in reverse.

3. Practice making turns at slow speeds before attempting to turn at faster speeds.

Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

54

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. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

3. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 16.

4. Perform the pre-ride inspection. See page 50.

5. Always make sure the passenger seat is installed and securely latched before operating with a passenger.


7. Mount the vehicle from the left side. After the operator is seated, the passenger should mount the vehicle from the left side. Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts.

8. Allow a passenger to ride only in the approved passenger seat.

9. Do not carry more than one passenger.

10. Slow down. Control may be more difficult with a passenger on board. Allow more time and distance for braking.

11. Ride to the ability of your passenger, instead of to your own ability.

Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle.

12. Do not cross a hillside with a passenger on board. See page 58.

13. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

14. Make sure the passenger understands the importance of "active riding." When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.

55

OPERATION

Driving on Slippery Surfaces

Sideways skid

Turn in direction of 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. Slow down when entering slippery areas.

3. 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. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.

4. Be alert. Watch the trail. Avoid quick, sharp turns.

5. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

56

Driving Uphill

OPERATION

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. Avoid hills with slippery or loose surfaces.

6. Keep both feet on the footrests.

7. Shift body weight uphill. A passenger should also shift body weight uphill.

8. Proceed at a steady rate of speed to avoid stalling.

9. Never open the throttle suddenly or make sudden gear changes.

10. Be alert. Be prepared to take emergency action. This may include dismounting quickly.

57

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle.

3. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

4. If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately !

58

Driving Downhill

OPERATION

15



Maximum

When driving downhill, follow these precautions:


2. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

3. Slow down. Never travel down a hill at high speed.

4. Drive straight downhill. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.

5. Shift body weight uphill. A passenger should also shift body weight uphill.

6. Apply the brakes slightly to aid in slowing. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control.

59

OPERATION

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill!

Use the K-turn to turn around.

8 ft. (2.4 m)

60

OPERATION

Turning Around on a Hill (K-Turn)

1. Stop and lock the parking brake while keeping body weight uphill.


3. Leave the transmission in forward and shut off the engine.

4. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. A passenger should not remount until the vehicle returns to firm, level ground.

5. Staying uphill of the vehicle, turn the handlebars full left.

6. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

7. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill. A passenger should not remount until the vehicle returns to firm, level ground.

8. Start the engine with the transmission still in forward.

9. Release the parking brake and proceed slowly , controlling speed with the brake lever, until the vehicle is on more level ground.

61

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 water deeper than the bottom of the footrests.

Maximum Depth

If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 70. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings .

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 104, then see your dealer for service at the first opportunity.

5. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

62

Driving Over Obstacles

OPERATION

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. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.

63

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. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use with caution.

NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

64

Parking on an Incline

OPERATION

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Stop the engine.



4. Always block the rear wheels on the downhill side.

65

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.

• Never carry cargo on the rear rack when operating the vehicle in the 2-up mode with a passenger.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

• Never exceed the stated load capacity for this vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

• CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack increases the possibility of vehicle overturn.

• CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

• HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

• USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

• TOWING is approved OFF-ROAD ONLY.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

66

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.

2/3

2. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.

3. Do not obstruct the headlight beam with cargo.

1/3

4. Slow down.

5. Use low forward gear when hauling or towing heavy cargo to extend belt life.

6. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling, and control may be affected.

67

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.

• If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.

• The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your POLARIS warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARISapproved (or equivalent) accessories designed for use on this vehicle.

Maximum

10 cm

Maximum Towing Capacities

Do not exceed maximum towing capacities. Avoid towing on inclines.

Maximum Towed Load (Level Ground)

Maximum Vertical Hitch Weight

550

1500 lbs. (680 kg)

150 lbs. (68 kg)

850

1500 lbs. (680 kg)

150 lbs. (68 kg)

68

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

Electromagnetic Interference

This spark ignition system complies with Canadian standard ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices

(such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

69

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in safe, reliable condition. 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.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

70

MAINTENANCE


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

E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) n Have an authorized POLARIS dealer perform these services.

71

MAINTENANCE


Perform all services at whichever maintenance interval is reached first.

Item



E

Steering

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Passenger seat latch

Wheels/fasteners

Frame fasteners

Engine oil level

Air filter, pre-filter

Coolant

Maintenance Interval

(whichever comes first)

Hours Calendar

-

-

-

-

-

-

-

-

-

-

-

-

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Daily

Miles

(Km)

-

-

-

-

-

-

-

-

-

-

-

-

Remarks

Make adjustments as needed. See Pre-Ride

Checklist on page 50.



ADC fluid

 Power steering unit

Headlight/taillight



E

Air filter, main element



Engine oil change

 n



 Transmission oil



Demand drive fluid 25 H

 Demand drive fluid

(extreme use)



General lubrication

Shift linkage n

Brake pad wear

Battery

Rear gearcase oil

Steering

 Front suspension



Rear suspension

-

-

-

-

-

20 H

10 H

20 H

25 H

25 H

25 H

50 H

50 H

50 H

50 H

50 H

Daily

Daily

Daily

Daily

Weekly

1 Month

Monthly

Monthly

Monthly

Monthly

Monthly

1 M

3 M

6 M

6 M

6 M

6 M

-

-

-

-

-

Inspect; clean often; replace as needed

Check level daily, change coolant every 2 years

Check level, add as needed

Inspect daily; clean often

Check operation

Inspect; replace as needed

500 (800) Perform break-in oil and filter change (see page 48)

100 (160) Inspect periodically

200 (320) Check terminals; clean; test

250 (400) Inspect level



250 (400) Change fluid every 25 hours if ADC is subjected to extreme use. See page 80.

500 (800) Lubricate all fittings, pivots,

500 (800)

500 (800)

500 (800)

500 (800) cables, etc.

Inspect, lubricate

Lubricate

Lubricate

Lubricate

 Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service n Have an authorized POLARIS dealer perform these services.

72

MAINTENANCE


Item n E Throttle Cable/

ETC Switch

E Throttle Body

Intake Duct

Drive belt

Cooling system



Radiator

 Cooling hoses 50 H



Engine oil change 100 H

 Rear gearcase oil 100 H



Transmission oil 100 H

 Demand drive fluid

(normal use)

100 H

Fuel system 100 H

 Engine mounts

Exhaust muffler/ pipe n E Spark plug



Wiring

Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

50 H 6 M

50 H

50 H

50 H

50 H

100 H

100 H

100 H

100 H

6 M

6 M

6 M

6 M

6 M

6 M

12 M

12 M

12 M

12 M

12 M

12 M

12 M

12 M

Remarks

500 (800) Inspect; adjust; lubricate; replace if necessary

500 (800) Inspect duct for proper sealing/air leaks

500 (800) Inspect; adjust; replace as needed

1000 (1600) Inspect coolant strength seasonally; pressure test system yearly

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect for leaks

1000 (1600) Change the oil and filter

1000 (1600) Change fluid



1000 (1600) Check for leaks at tank cap, lines, filter, pump; replace lines every two years

1000 (1600) Inspect

1000 (1600) Inspect n Clutches (drive and driven) n Front wheel bearings

Brake fluid n

 n

ADC fluid

Spark arrestor n E Valve clearance n Toe adjustment

Headlight aim

100 H

100 H

200 H

200 H

300 H

1000 H

12 M

12 M

24 M

24 M

36 M

-

-

-

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

2000 (3200) Change every two years

2000 (3200) Change every two years

3000 (4800) Clean out

10000

(16000)

Inspect; adjust

Inspect periodically; adjust when parts are replaced

Adjust as needed

73

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Recommended

Lubricant

550 Engine Oil PS-4 PLUS

Performance

Synthetic 2W-50

850 Engine Oil PS-4 PLUS

Performance

Synthetic 2W-50

Transmission

Oil

AGL PLUS

Transmission

Fluid

Demand Drive

Fluid (Front

Gearcase)

Demand Drive

PLUS Fluid

Rear

Gearcase Oil

ATV Angle Drive

Fluid (or GL5 80-

90 weight gear lube)

Brake Fluid

ADC Fluid

DOT 4 Only

Demand Drive

PLUS Fluid

Front Prop

Shaft Yoke

A-Arms, Front and Rear

Capacity at Fluid

Change

2 qt.

(1.9 l)

2 qt.

(1.9 l)

32 oz.

(946 ml)

9.3 oz.

(275 ml)

7.1 oz.

(210 ml)

---

---

Fill Plug

Torque

---

---

10-14 ft. lbs.

(14-19 Nm)

8-10 ft. lbs.

(11-14 Nm)

10-14 ft. lbs.

(14-19 Nm)

---

---

Drain Plug

Torque

15-17 ft. lbs.

(20-23 Nm)

12 ft. lbs.

(16 Nm)

10-14 ft. lbs.

(14-19 Nm)

11 ft. lbs.

(15 Nm)

10-14 ft. lbs.

(14-19 Nm)

---

---

Inspection

Procedure

Page 75.

Page 75.

Page 78.

Page 80.

Page 83.

Page 26.

Page 81.

POLARIS

Premium U-Joint

Lube

Grease fittings (3 pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.

POLARIS

Premium All-

Season Grease

Grease fittings after extreme use or if suspension becomes squeaky.

Front

Front Prop Shaft

Yoke

74

MAINTENANCE

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 PLUS Performance

Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 74 for fluid recommendations, capacities and plug torques.

Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 125 for the part numbers of POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Oil Level

Check the oil level when the engine is cold. Never check the oil with the engine running.


2. Access the oil dipstick and fill tube from the left side of the vehicle. Remove the dipstick. Wipe it dry with a clean cloth.

3. Reinstall and tighten the dipstick.

4. Remove the dipstick and check the oil level.

5. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.

6. Reinstall and tighten the dipstick.

Full

Full

850

Dipstick

Add

Add

550

75

MAINTENANCE

Engine Oil

Oil and Filter Change

See the table on page 74 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 70. Always change the oil filter whenever changing oil.

550 Drain

Plug to front 850 Drain

Plug

Filter Access


2. Start the engine. Allow it to warm up at idle for two to three minutes.

3. Stop the engine.

4. Clean the area around the drain plug.

5. Place a drain pan under the crankcase.

6. Remove the drain plug. Allow the oil to drain completely.

Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

7. Install a new sealing washer on the drain plug. The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

8. Reinstall the drain plug. Torque to specification.

76

MAINTENANCE

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.

550 850

11. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

Oil Filter

12. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn.

13. Remove the dipstick. Add the proper amount of the recommended oil. Do not overfill.

14. Reinstall the dipstick.



17. Start the engine. Allow it to idle for one to two minutes.

18. Stop the engine.

19. Check for leaks.

20. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.

21. Dispose of used filter and oil properly.

77

MAINTENANCE

Transmission Oil

POLARIS recommends the use of POLARIS AGL PLUS Transmission

Fluid for this transmission. See the table on page 74 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 70. See page 125 for the part numbers of

POLARIS products.

Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the vehicle behind the footwell.

The drain plug is located on the bottom rear side of the gearcase.

Fill

Level

Oil Check

1. Remove the footwell (see page 91).

2. Remove the fill plug. Check the oil level.

Drain Plug

3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to specification.

5. Reinstall the footwell.

Fill Plug

78

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.


6. Check for leaks.

7. Reinstall the footwell.

8. Dispose of used oil properly.

79

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

See the table on page 74 for fluid recommendations, capacities and plug torques. Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 70.

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. Extreme use includes any of the following:

• operation in ADC mode for prolonged periods

• constant ADC operation on hilly or mountainous terrain

• ADC is the primary mode of all-wheel-drive operation

Tip: If the front gearcase is makes excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your

POLARIS dealer for service.

Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.

Fluid Check

1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level.

2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.


Fill

Level

Fill

Plug

Fluid Change

Drain Plug

1. Position the vehicle on a level surface. Remove the fill plug.

2. Place a drain pan under the demand drive unit. Remove the drain plug. Allow the fluid to drain completely.

3. Clean and reinstall the drain plug. Torque to specification.

4. Add the proper amount of the recommended fluid.


6. Check for leaks. Dispose of used fluid properly.

80

MAINTENANCE

Active Descent Control (ADC) Fluid

Check and change the ADC fluid at the intervals outlined in the Periodic

Maintenance Chart beginning on page 70.

We recommend the use of POLARIS Demand Drive Plus Fluid for the

ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 125 for the part numbers of POLARIS products.

NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.

Fluid Check

1. Access the reservoir under the front box. See page 32.

2. View the fluid level in the reservoir.

3. If the level is below the minimum mark, remove the cap and add the recommended fluid.

4. Reinstall the cap.

5. Close and secure the front box and cover.

ADC Fluid Reservoir

81

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves

(one on each side of the differential).

3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir. Debris in the reservoir may result in inadequate bleeding and reduced performance of the system.

4. Fill the reservoir to the maximum line with fresh fluid.

Bleeder

Screw

Cap

Bleeder

Valve

Screw

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the bleeder valve screws (turn counter-clockwise) and allow fluid and trapped air to flow from the fitting.

Tighten the screw when clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT: Close the bleeder valve screws before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the bleeder valve screws to 80 in. lbs. (9 Nm). Reinstall the bleeder valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks. Make sure the reservoir is free of debris.

9. Reinstall the cap securely. Clean up any drips or spills.

82

MAINTENANCE

Rear Gearcase Oil

See the table on page 74 for fluid recommendations, capacities and plug torques. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. 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.

Fill

Level Maintain the fluid level at the bottom of the fill hole threads.

Do not overfill.

Oil Check


2. Remove the fill plug.

Check the oil level.

Fill Plug

3. Add the recommended oil as needed to bring the level to the bottom of the fill hole threads. Do not overfill .


Drain Plug

Oil Change


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.

5. Remove the fill plug. Add the proper amount of the recommended oil. Do not overfill .


7. Check for leaks.

8. Dispose of used oil properly.

83

MAINTENANCE

Power Steering Unit

If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly.

Clean

Often

Steering Assembly

The steering assembly of the vehicle 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.

Cooling System

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.

POLARIS recommends the use of POLARIS Premium 60/40 antifreeze/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. Do not dilute with water. See page

125 for the part numbers of POLARIS products.

Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

84

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

32.

1. View the fluid level in the bottle.

2. If the level is low, remove the bottle cap and add coolant as needed.

Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

3. Reinstall the cap.


Recovery

Bottle Cap

Maximum

Mark

Minimum

Mark

85

MAINTENANCE

Cooling System

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. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.

Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

1. Access the pressure cap under the front box. See page 32.

2. Remove the pressure cap.

3. Using a funnel, slowly add coolant through the radiator filler neck.

4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.


Radiator

Cap

86

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 selfadjusting.

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. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level.

Do not overfill.

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level. See page 26.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness. Replace brake pads when they are worn to 3/64" (1 mm).

5. Check the security and surface condition of the disc.

3/64" (1 mm)

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. See page 28.

87

MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 0” to 1/8” (0-3 mm).

Severe injury or death can result from improper toe alignment and adjustment.

Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.


2. Place the handlebars in a straight-ahead position.

Stand

3. Tie a length of string between two stands as shown in the illustration.

Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straightedge instead of string.

String

2

4. Measure the distance from the string to the rim at the front (1) and

1 rear (2) of the front rim.

The rear measurement should be 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.

88

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. Pivot the rear of the seat downward onto the latch. Press down firmly on the seat pad until the latch clicks. Test the seat latch by attempting to pull the seat upward.

Passenger Seat Backrest Adjustments

The passenger backrest can be adjusted horizontally and vertically.

1. Unzip the two zippers at the bottom of the backrest pad. Lift the pad upward to remove it from the backrest frame.

2. To adjust the backrest forward or rearward, loosen the top adjuster bolt. Pivot the adjuster forward or rearward to one of the three adjustment positions and tighten the bolt.

3. To adjust the backrest upward or downward, loosen the four vertical adjustment screws on the front side of the backrest frame. Slide the backrest upward or downward to the desired position and tighten the screws.

4. Reinstall the backrest pad.

89

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. Remove the shock from the vehicle.

If adjustment is necessary, use a suitable pliers or spanner wrench. Adjust the shock to the desired spring preload. Rotate the adjustment cam to the left to increase preload.

5. Reinstall the shock.

6. Torque the upper and lower shock fasteners to 38 ft. lbs. (51 Nm).

7. Reinstall the passenger seat.

Operator Seat Removal

1. Remove the passenger seat. See page 89.

2. Grasp one side of the operator’s seat near the rear edge.

3. Pull upward abruptly to disengage the under-seat fasteners.

4. Remove the seat.

90

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

91

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.

Refer to the specifications section beginning on page 126 for recommended tire type, size and pressure.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8” (3 mm) or less.

1/8" (3 mm)

92

MAINTENANCE

Tires

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized

POLARIS dealer.

Wheel Removal

1. Stop the engine.



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.

6. Remove the wheel nuts.

7. Remove the wheel.

93

MAINTENANCE

Tires

Wheel Installation



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. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.

Cast Aluminum

75 ft. lbs.

(102 Nm)

45 ft. lbs.

(61 Nm)

Steel

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for service.

Wheel Type

Aluminum

Steel

Nut Type

Lug Nut

Lug Nut

Nut Torque

75 ft. lbs. (102 Nm)

45 ft. lbs. (61 Nm)

94

MAINTENANCE

Air Filter

1. Remove the seat.

2. Remove the air box cover screws, and remove the air box cover.

3. Remove the filter.

4. Remove the fabric type prefilter from the main filter.

Wash the pre-filter in soapy water, then rinse and let dry.

5. Reinstall the pre-filter over the main filter. Install a new main filter if needed.

6. Reinstall the filter into the air box.

7. Reinstall the air box cover and the seat.

Pre-Filter

Main

Filter

Screws

95

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.

1. Access the fuses under the front box. See page 32.

2. Remove the fuse box cover.

3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating.

4. Reinstall the fuse box cover.


96

550

Fuse Box

850

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.

Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.

1. Remove the five (5) headlight pod screws.

2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.

Hot components can cause burns to skin. Allow lamps to cool before servicing.

3. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.

4. Turn the lamp counter-clockwise to remove it.

5. Install the new lamp. Make sure the tab on the lamp locates properly in the housing.

6. Reassemble the pod.

97

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.

25 ft. (7.6 m)

Lamp Center Height

2 " (5 cm)

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Start the engine.Turn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5 cm) below the mark on the wall. Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight pod. Adjust the beam to the desired position by turning the knob either clockwise or counter-clockwise.

Adjustment

Screw

98

Lights

Low Beam Adjustment

The low beam can be adjusted slightly upward or downward.

1. Loosen the phillips screw located at the rear of the headlamp.

2. Tilt the headlamp upward or downward.

3. Tighten the screw.

MAINTENANCE

Phillips Screw

99

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.

5. Pull the headlight housing up to release it from the locking tabs.

6. Carefully pull the assembly up and out of the pod.

7. Reverse the steps to install the new housing and reassemble the pod.

100

MAINTENANCE

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly.

2. Remove the headlamp and install the new headlamp.

3. Reinstall the harness assembly into the headlight assembly.

4. Turn the headlight harness clockwise to secure the headlamp.

Harness

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 from the back of the light assembly.

2. Turn the lamp counter-clockwise to remove it.

3. Install the new lamp.

4. Reinstall the harness connector.

5. Test the light for proper operation.

Connector Lamp

101

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 126 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.

Plug Condition

New Spark Plug

Previously Installed

Spark Plug

Torque Specification

550

9-11 ft. lbs.

(12-15 Nm)

17-20 ft. lbs.

(23-27 Nm)

850

18-20 ft. lbs.

(24-27 Nm)

18-20 ft. lbs.

(24-27 Nm)

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 103.

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Rotate the spark plug counter-clockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to specification.

102

MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil or incorrect throttle body adjustments.

103

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. Move the vehicle to dry land or at the very least, to water below the footrests.

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter.

3. Remove the spark plug.

4. Turn the engine over several times using the electric start.

5. Dry the spark plugs. Reinstall the plugs or install new plugs.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

NOTICE: Serious damage can occur after immersion if fluids are not changed promptly. See your dealer as recommended .

7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

8. If water has been ingested into the PVT, follow the procedure on page 108 for drying out the PVT.

104

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. Do not stand behind or in front of the vehicle while purging.

Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.

1. Remove the arrestor cleanout plug from the bottom of the muffler.

2. Place the transmission in

PARK.

3. Start the engine.

4. Quickly squeeze and release the throttle lever several times to purge carbon from the system.

5. If carbon comes out of the exhaust, cover or plug the exhaust outlet(s). Wear protective gloves.

Clean-Out Plug

6. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4.

7. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot (30 cm) higher than the front. Block the wheels.

8. Repeat steps 4 to 6 until no more particles are expelled.

9. Stop the engine. Allow the arrestor to cool.

10. Reinstall the arrestor plug and remove the exhaust outlet cover or plug.

105

MAINTENANCE

PVT System

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual.

• This PVT system is intended for use on POLARIS products only. Do not install it in any other product.

• Always make sure the PVT housing is securely in place during operation.

106

MAINTENANCE

PVT System

The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.

The approximate gear ratio difference between high and low range is

1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the system's dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 km/h) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1600 - 1800 RPM. However, in high range at 3 MPH (5 km/h), the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.

The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).

107

MAINTENANCE

PVT System

When To Use Low Range and High Range

Condition

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)

Range to Use

Low

Low

Low

High

PVT Drying

There may be some instances when water is accidently ingested into the

PVT system. Use the following instructions to dry it out before operating.


2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.

3. Start the engine. Place the transmission in PARK.

4. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 5 seconds.

5. Allow the engine RPM to settle to idle speed, then shift the transmission to low range.

6. Test for belt slippage. If the belt slips, repeat the process.

7. Take the vehicle to your dealer for service as soon as possible.

108

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.

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.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

Battery Removal

1. Access the battery under the front box. See page 32.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Disconnect the battery hold-down strap.

5. Lift the battery out of the vehicle.

109

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 111 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Secure the battery hold-down strap.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.


Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

POLARIS recommends maintaining battery charge by using a

POLARIS 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. See page 125 for the part numbers of POLARIS products.

110

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. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register

12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging.

111

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

100%

75%-100%

50%-75%

25%-50%

0%-25%

Voltage

12.8-13.0 volts

12.5-12.8 volts

12.0-12.5 volts

11.5-12.0 volts

11.5 volts or less

Action

Charge Time

(Using constant current charger @ standard amps specified on top of battery)

None required None, check at 3 mos. from date of manufacture

May need slight charge, if no charge given, check in 3 months

Needs charge

Needs charge

Needs charge with desulfating charger

3-6 hours

5-11 hours

At least 13 hours, verify state of charge

At least 20 hours

112

MAINTENANCE

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension.

Accessory springs are available through your POLARIS dealer.

Handlebars

The handlebars can be adjusted for rider preference.

Adjuster

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.

1. Remove the upper headlight pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. Torque the front two bolts to

10-12 ft. lbs. (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8” (3 mm) will remain at the rear of the clamp blocks.

Handlebar

Bolts

113

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.

2. With the handlebars straight ahead, place very light pressure on the throttle lever. A gap of 2-3 mm should be visible between the throttle arm stop pin and the throttle arm.

If adjustment is needed:

1. Locate the throttle cable adjuster. Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut.

2. Loosen the adjuster lock nut.

3. Rotate the boot to turn the adjuster until 2-3 mm of freeplay is achieved between the stop pin and the throttle arm. While adjusting freeplay, flip the throttle lever back and forth repeatedly .

(continued on next page)

Arm Stop Pin

Cable

Adjuster

Boot

Throttle

Arm

2-3 mm Gap

Lock Nut

Adjuster

114

MAINTENANCE

Throttle Cable Freeplay

4. Place the transmission in PARK. Lock the parking brake.

5. Start the engine and allow the idle to stabilize. If necessary, tap the throttle lever to ensure the idle speed settles.

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. Tap the throttle lever at each turn, verifying that idle RPM returns to the recommended setting. If idle speed increases, it may be necessary to increase the gap between the stop pin and throttle arm, but do not exceed the recommended 2-3 mm gap.

8. When adjustments are complete, tighten the locknut.

9. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.

10. Ensure the control cover seal is in place, then reinstall the cover and screws.

115

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. 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.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

116

MAINTENANCE


Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items:

• Wheel bearings

• Radiator

• Transmission seals

• Cab and body panels

• Electrical components

• Switches and controls

• Fuel system components

• Labels and decals

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.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

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.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

117

MAINTENANCE


Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 116.

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.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 76.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter. See page

95.

2. Clean the air box.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the

Periodic Maintenance Chart beginning on page 70.

• Demand drive unit (front gearcase)

• ADC fluid (ADC models) (change every two years)

• Rear gearcase

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

118

MAINTENANCE


Storage Tips

Fog the Engine

1. After stabilizing the fuel, remove the spark plug and add 2-3 tablespoons of engine oil. To access the plug hole, use a section of clear

1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

2. Reinstall the spark plug. Torque to specification.

3. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs.

4. Turn the engine over several times using electric start. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

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

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 70.

Battery Storage

See pages 110-111 for storage and charging procedures. Store the battery in a cool, dry place.

Storage Area/Covers

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 condensation, and may promote corrosion and oxidation.

119

MAINTENANCE


Accessories

Auxiliary power outlets provide 12-volt power for operating accessories. 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.

1. Stop the engine.



4. Secure the fuel cap, oil cap and seats.

5. 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 Aarm bolt pockets, racks or handlebars.

6. Remove the key to prevent loss during transporting.

120

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall trailer in high range

Starting out going up a steep incline

Driving at low RPM or ground speed (3-7 MPH)

Insufficient warm-up at low ambient temperatures

Use low range during loading.

Use low range or turn around using the K-turn (see page

60).

Drive at a higher speed or use low range more frequently.

See page 108.

Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.

Use the throttle quickly and effectively.

Slow/easy clutch engagement

Towing/pushing at low

RPM/low ground speed

Utility use/plowing

Stuck in mud or snow

Use low range only.

Use low range only.

Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch.

WARNING!

Excessive throttle may cause loss of control and vehicle overturn.

Climbing over large objects from a stopped position

Wrong or missing belt

Improper break-in

Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch.

WARNING!

Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the

PVT system

Clutch malfunction

Dry out the PVT. See page 108. Inspect clutch seals for damage if repeated leaking occurs.

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 warm up belt

Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).

Install the recommended belt.

Always break in a new belt and/or clutch. See page 49.

121

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Low battery voltage

Loose battery connections

Loose solenoid connections

Solution

Recharge the battery to 12.8 VDC

Check all connections and tighten


Engine Turns Over, Fails to Start

Possible Cause

Out of fuel

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Mechanical failure

Solution

Refuel, cycle key to ON position three times for 5 seconds each, then start

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Immediately see your POLARIS dealer


See your dealer

Engine Backfires

Possible Cause

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Mechanical failure

Loose ignition connections

Water present in fuel

Leaking exhaust components

Solution

Inspect, clean and/or replace spark plug(s)

Set gap to specs or replace plugs


See your dealer

See your dealer

See your dealer



See your dealer

122

TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Poor quality or low octane fuel

Incorrect ignition timing


Solution

Replace with recommended fuel

See your dealer


Engine Runs Irregularly, Stalls or Misfires

Possible Cause


Worn or defective spark plug wires



Water present in fuel

Low battery voltage

Kinked or plugged fuel tank vent line

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Possible Lean Fuel Cause

Low or contaminated fuel

Kinked or plugged fuel tank vent line

Low octane fuel

Incorrect fuel

Possible Rich Fuel Cause

Fuel is very high octane

Stopping/starting without adequate warm-up

Incorrect fuel

Clogged air filter

Solution

Inspect, clean and/or replace spark plugs

See your dealer



Replace with new fuel

Recharge battery to 12.8 VDC

Inspect and replace


Inspect and clean or replace

See your dealer

See your dealer

See your dealer

Solution

Add or change fuel, clean the fuel system

Inspect and replace



Solution

Replace with lower octane fuel

Allow engine to warm up before operating and/or stopping



123

TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Out of fuel

Kinked or plugged fuel vent line

Water is present in fuel


Worn or defective spark plug wires



Low battery voltage

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

Solution

Refuel, cycle key to ON position three times for 5 seconds each, then start

Inspect and replace

Replace with new fuel

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plug





See your dealer

See your dealer

See your dealer

Clean radiator screen and core, clean engine exterior, see your dealer

Engine Overheating

Possible Cause

Debris lodged in screen

Plugged Radiator

Solution

Clean the screen.

Use a garden hose to flush any debris from the radiator fins. NOTICE: High pressure washers can deform the radiator fins and reduce cooling efficiency.

124

POLARIS PRODUCTS

Part

Number

Description

Engine Lubricant

2870791 Fogging Oil (12 oz./355 ml Aerosol)

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068 AGL PLUS Transmission Fluid (qt./.95 l)

2878069 AGL PLUS Transmission Fluid (gal./3.8 l)

2877922 Demand Drive Plus Fluid (qt./.95 l)

2877923 Demand Drive Plus Fluid (gal./3.8 l)

2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)

2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

2870465 Pump for Gallon (3.8 l) Jug

Coolant

2871323 60/40 Coolant (gal./3.8 l)

2871534 60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season

2871322 Premium All Season Grease (3 oz./89 ml cartridge)

2871423 Premium All Season Grease (14 oz./414 ml cartridge)

2871460 Starter Drive Grease

2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)

2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)

2871329 Dielectric Grease (Nyogel TM )

Additives / Miscellaneous

2871326 Carbon Clean Plus

2870652 Fuel Stabilizer

2872189 DOT 4 Brake Fluid

2871956 Loctite TM 565 Thread Sealant

2859044 POLARIS Battery Tender TM Charger

125

SPECIFICATIONS

SPORTSMAN 550 Touring

Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories)

765 lbs. (347 kg) Dry Weight

Front Rack/Storage Box Capacity 120 lbs. (54 kg)

Rear Rack Capacity 240 lbs. (109 kg)

Hitch Tongue Weight 150 lbs. (68 kg) (Rear rack capacity and tongue weight not to exceed 240 lbs./109 kg)

Hitch Towing Rating

Unbraked Trailer Towing

Capacity*

1500 lbs. (680 kg) on level ground

1995 lbs. (905 kg)

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Fuel Capacity

Engine Oil Capacity

86.5 in. (219.7 cm)

47.6 in. (121 cm)

58.25 in. (148 cm)

57 in. (145 cm)

11.6 in. (29.5 cm)

96 in. (244 cm) unloaded

5.25 gal. (20 l)

2 qts. (1.9 l)

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Fluid Capacity

Rear Gearcase Fluid Capacity

Fuel System

Fuel Delivery

Engine

Displacement

Bore x Stroke

Alternator Output

Compression Ratio

Starting System

Ignition System

Ignition Timing

Idle RPM**

Throttle Body/Size

Spark Plug / Gap

2 qts. (1.9 l)

9.3 oz. (275 ml)

32 oz. (946 ml)

7.1 oz. (210 ml)

Visteon Electronic Fuel Injection

Electronic Fuel Pump (in tank)

ES550PLE011

549 cc

96.6 x 75 mm

490w @ 1350 RPM/Peak 630w

9.6:1

Electric

Visteon EFI (ECU Controlled)

13



+/- 3



BTDC @ 1650 RPM

1750 +/- 50

Mikuni/42 mm

NGK BKR6E / .035 in. (0.9 mm)

* Based on EU Directive 76/432/EC

**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.

126

SPECIFICATIONS

Lubrication System

Transmission Type

Front Suspension

Rear Suspension

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Drive Ratio, Rear

Tire Size/Pressure, Front

Tire Size/Pressure, Rear

Brakes, Front/Rear

Brake, Auxiliary

Brake, Parking

Headlight

Taillight

Brake Light

Instrumentation


Pressurized Wet Sump

Automatic PVT (POLARIS Variable Transmission)

In-Line H-L-N-R-P

Dual a-arm, 9" (22.9 cm) travel

Dual a-arm with Rolled IRS, 10" (25.4 cm) travel

5.034:1

4.508:1

2.693:1

3.818:1

3.7:1

26 x 8 - 14 / 7 psi (48.3 kPa)

26 x 10 - 14 / 5 psi (34.5 kPa)

Single-Control Hydraulic Disc, All-Wheel

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

12v/7 watts

12v/27 watts

Digital/Analog

Clutching

Altitude Shift

Weight

Drive Clutch

Spring

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

23-58

PN 1322911

23-54

PN 1322914

Red/Black

PN 7043500

Red/Black

PN 7043500

*EBS models require no helix/spring adjustment

Driven

Clutch

Spring

Red/White

PN 3235088

Red/White

PN 3235088

Helix*

105-165 BA3

PN 3235092

105-165 BA3

PN 3235092

127

SPECIFICATIONS


Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories)

798 lbs. (362 kg) Dry Weight

Front Rack/Storage Box Capacity 120 lbs. (54 kg)

Rear Rack Capacity 240 lbs. (109 kg)

Hitch Tongue Weight 150 lbs. (55 kg) (Rear rack capacity and tongue weight not to exceed 240 lbs./55 kg)

Hitch Towing Rating

Unbraked Trailer Towing

Capacity*

1500 lbs. (680 kg) on level ground

1995 lbs. (905 kg)

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Fuel Capacity

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Fluid Capacity

Rear Gearcase Fluid Capacity

Fuel System

Fuel Delivery

Engine

Displacement

Bore x Stroke

Alternator Output

Compression Ratio

Starting System

Ignition System

Ignition Timing

Idle RPM

Throttle Body/Size

Spark Plug / Gap

86.5 in. (219.7 cm)

47.6 in. (121 cm)

58.25 in. (148 cm)

57 in. (145 cm)

11.6 in. (29.5 cm)

96 in. (244 cm) unloaded

5.25 gal. (20 l)

2 qts. (1.9 l)

2 qts. (1.9 l)

9.3 oz. (275 ml)

32 oz. (946 ml)

7.1 oz. (210 ml)

Bosch Multi-Port Sequential Electronic Fuel

Injection

Electronic Fuel Pump (in tank)

EH085OLE013

850 cc

87 x 71.5 mm

475w @ 1200 RPM/Peak 630w

11.0:1

Electric

Bosch EFI (ECU Controlled)

6



+/- 5



BTDC @ 1200 RPM

1200 +/- 50

Mikuni Dual Bore/40 mm

REA8MCX / .035 in. (0.9 mm)

* Based on EU Directive 76/432/EC

128

SPECIFICATIONS

Lubrication System

Transmission Type

Front Suspension

Rear Suspension

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Drive Ratio, Rear

Tire Size/Pressure, Front

Tire Size/Pressure, Rear

Brakes, Front/Rear

Brake, Auxiliary

Brake, Parking

Headlight

Taillight

Brake Light

Instrumentation


Pressurized Wet Sump

Automatic PVT (POLARIS Variable Transmission)

In-Line H-L-N-R-P

Dual a-arm, 9" (22.9 cm) travel

Dual a-arm with Rolled IRS, 10" (25.4 cm) travel

5.034:1

4.508:1

2.367:1

3.818:1

3.7:1

26 x 8 - 14 / 7 psi (48 kPa)

26 x 10 - 14 / 5 psi (34.5 kPa)

Single-Control Hydraulic Disc, All-Wheel

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

12v/7 watts

12v/27 watts

Digital/Analog

Clutching

Altitude Shift

Weight

Drive Clutch

Spring

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

24-68

PN5632418

24-63

PN 5632215

Red/Green

PN 7043382

Red/White

PN 7043349

*EBS models require no helix/spring adjustment

Driven

Clutch

Spring

Red/White

PN 3235088

Red/White

PN 3235088

Helix*

105-165 BA3

PN 3235092

105-165 BA3

PN 3235092

129

DECLARATION OF CONFORMITY

POLARIS Industries Inc.,

2100 Hwy 55, Medina, MN 55340 U.S.A.

Telephone 763-542-0500

April 22, 2010

We, POLARIS Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES

2006/42/EC as amended (Machinery Directive)

2004/108/EC as amended (EMC Directive)

TEST / EVALUATION METHODS

EN 1050 hazard analysis prEN 15997 driver-perceived noise level prEN 15997 vibration

CISPR 12:2009

CAN/CSA-C108.4-M92

EN 55012:2007

EN 61000-6-2:2005

___KA05__ / ___KA09__

___FA09__

___VA17__

___PB20__

___BA32__, ___NA32__

___CA32__, ___EA32__

___BA50__, ___BG50__

___GJ45__

___GJ52__, ___GP52__

___LH46__

___MH50__

___DH50__

___ZN55__ ___ZX55__

___TN55__, ___TX55__

___DN55__, ___DX55__

___MN76__

___CL76__, ___CF76__

___ZN85__, ___ZX85__

___TN85__, ___TX85__

___DN85__, ___DX85__

___RH45__

___RH50__

___TH76__

___WH50__

___WH76__

___HR76__

___HY76__, ___TY76__

___TH90__

___WH90__

___VH76__, ___VY76__

___XH76__

PRODUCT IDENTIFICATION

VEHICLE SERIES TRADE NAME

OUTLAW 50 / 90

SPORTSMAN 90

RZR 170

PHOENIX 200

TRAIL BLAZER 330

TRAIL BOSS 330

SCRAMBLER 500

OUTLAW 450

OUTLAW 525 / 525 S

SPORTSMAN 400

SPORTSMAN 500 HO

SPORTSMAN 500 HO TOURING

SPORTSMAN 550 EFI

SPORTSMAN 550 X2

SPORTSMAN 550 TOURING

SPORTSMAN 800

SPORTSMAN 800 6X6

SPORTSMAN 850 EFI

SPORTSMAN 850 X2

SPORTSMAN 850 TOURING

RANGER 400 / 450

RANGER 500 4X4

RANGER 800 EFI 4X4

RANGER 500 CREW

RANGER 800 EFI CREW

RANGER 800 6X6

RANGER HD 800 4X4

RANGER DIESEL

RANGER DIESEL CREW

RANGER RZR / RZR S

RANGER RZR 4

European Community Person

Authorized to Compile the Technical File:

Ross Clifford, General Manager

POLARIS Britain Ltd

Forge Mills Park, Station Road

Coleshill, Warwickshire B46 1HT

MODEL YEARS

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2008, 2009, 2010, 2011

2010, 2011

2009, 2010, 2011

2010, 2011

2010, 2011

2008, 2009, 2010, 2011

2009, 2010, 2011

2009, 2010, 2011

2010, 2011

2010, 2011

2010, 2011

2010, 2011

2010, 2011

2011

2010, 2011

2010, 2011

2010, 2011

2011

2011

2008, 2009, 2010, 2011

2011

Authorized Manufacturer Signatory

Empowered to Draw up the EC Declaration of

Conformity:

Lawrence E. Keller, Product Compliance Manager

7290 East Viking Blvd.

Wyoming, MN 55092

130

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. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a POLARIS dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

131

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause beyond

POLARIS' control.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

• Wheels and tires

• Suspension components

• Brake components

• Seat components

• Clutches and components

• Steering components

• Batteries

• Light bulbs/Sealed beam lamps

• Finished and unfinished surfaces

• Carburetor/Throttle body components

• Engine components

• Drive belts

• Hydraulic components

• Circuit breakers/Fuses

• Electronic components

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:

• Spark Plugs

• Filters

• Fuel

• Sealants

• Hotel fees

• Towing charges

• Mileage

• Rentals/Loss of product use

• Lubricants such as oil, grease, etc.

• Batteries (unless defective)

• Cosmetic damage/repair

• Coolants

• Meals

• Shipping/ handling fees

• Product pick-up/delivery

• Loss of vacation/personal time

132

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes. Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY

ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF

THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON

FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR

OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND

SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR-

POSE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

133

WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX

MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-

PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

POLARIS suggests that you use your original selling dealer; however, you may use any

POLARIS Servicing Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

134

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)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

135

MAINTENANCE LOG

DATE MILES

(KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

136

0-9

4X4 Switch . . . . . . . . . . . . . . . . . 21, 33

A

Accessories . . . . . . . . . . . . . . . . . . . 120

Active Descent Control Fluid . . . 81-82

Active Descent Control System . . . . 35

ADC System . . . . . . . . . . . . . . . . . . . 35

Age Restrictions . . . . . . . . . . . . . . . . . 6

Air Filter . . . . . . . . . . . . . . . . . . . . . . 95

All Wheel Drive System . . . . . . . 33-34

Auxiliary Foot Brake . . . . . . . . . . . . 87

B

Battery . . . . . . . . . . . . . . . . . . 109-112

Charging . . . . . . . . . . . . . 111-112

Installation . . . . . . . . . . . . . . . 110

Removal . . . . . . . . . . . . . . . . . 109

Storage . . . . . . . . . . . . . . . . . . 110

Belt Life . . . . . . . . . . . . . . . . . . . . . . 29

Beverage Holders . . . . . . . . . . . . . . . 30

Boots . . . . . . . . . . . . . . . . . . . . . . . . . 17

Box, Front . . . . . . . . . . . . . . . . . . . . . 32

Brake Fluid, Auxiliary Foot Brake . . 28

Brake Fluid, Main Brake System . . . 26

Brake Lever. . . . . . . . . . . . . . . . . . . . 25

Brake, Foot . . . . . . . . . . . . . . . . . 28, 87

Brake, Hand Lever . . . . . . . . . . . . . . 87

Brake, Parking . . . . . . . . . . . . . . . . . 27

Brakelight Lamp Replacement . . . . 101

Brakes . . . . . . . . . . . . . . . . . . . . . . . . 87

Break-In Period. . . . . . . . . . . . . . 48-49

C

Camber Adjustment . . . . . . . . . . . . 113

Cargo. . . . . . . . . . . . . . . . . . . . . . 67-68

Cargo Loading . . . . . . . . . . . . . . . . . 66

Caster Adjustment. . . . . . . . . . . . . . 113

Check Engine Indicator . . . . . . . . . . 43

Cleaning and Storage . . . . . . . 116-120

Clothing . . . . . . . . . . . . . . . . . . . . . . 17

Clutching (550) . . . . . . . . . . . . . . . . 127

Clutching (850) . . . . . . . . . . . . . . . . 129

INDEX

C

Cold Weather Operation . . . . . . . . . . 52

Coolant Bottle. . . . . . . . . . . . . . . . . . 85

Coolant, Radiator . . . . . . . . . . . . . . . 86

Cooling System. . . . . . . . . . . . . . 84-86

D

Demand Drive Fluid . . . . . . . . . . . . . 80

Diagnostic Codes (550) . . . . . . . 44-45

Diagnostic Codes (850) . . . . . . . 46-47

Disengaging Active Descent Control 35

Display Units, Standard/Metric . . . . 40

Drink Holders . . . . . . . . . . . . . . . . . . 30

Drive Belt Wear/Burn. . . . . . . . . . . 121

Drivetrain Break-In. . . . . . . . . . . . . . 49

Driving Downhill . . . . . . . . . . . . . . . 59

Driving in Reverse . . . . . . . . . . . . . . 64

Driving on a Sidehill. . . . . . . . . . . . . 58

Driving on Slippery Surfaces . . . . . . 56

Driving Over Obstacles . . . . . . . . . . 63

Driving Procedures . . . . . . . . . . . . . . 53

Driving Through Water . . . . . . . . . . 62

Driving Uphill. . . . . . . . . . . . . . . . . . 57

Driving with a Passenger . . . . . . . . . 55

E

Electromagnetic Interference . . . . . . 69

Electronic Power Steering . . . . . . . . 30

Electronic Throttle Control. . . . . . . . 24

Engaging 4X4 . . . . . . . . . . . . . . . . . . 34

Engaging Active Descent Control . . 35

Engine Break-In . . . . . . . . . . . . . . . . 49

Engine Fogging. . . . . . . . . . . . . . . . 119

Engine Oil. . . . . . . . . . . . . . . . . . 75-77

Engine Stop Switch. . . . . . . . . . . . . . 22

EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Equipment Modifications . . . . . . . . . . 7

Error Codes, Engine . . . . . . . . . . . . . 43

Exhaust Emission Control System . . 69

Eye Protection. . . . . . . . . . . . . . . . . . 17

137

INDEX

F

Fluid

Active Descent Control . . . . 81-82

Brake . . . . . . . . . . . . . . . . . . . . 26

Demand Drive . . . . . . . . . . . . . 80

Engine Oil . . . . . . . . . . . . . . 75-77

Front Gearcase . . . . . . . . . . . . . 80

Rear Gearcase Oil . . . . . . . . . . 83

Transmission . . . . . . . . . . . . 78-79

Fluid Change

Active Descent Control . . . . . . 82

Demand Drive . . . . . . . . . . . . . 80

Engine Oil . . . . . . . . . . . . . . 76-77

Rear Gearcase . . . . . . . . . . . . . 83

Transmission . . . . . . . . . . . . . . 79

Fluid Level

Active Descent Control . . . . . . 81

Brake . . . . . . . . . . . . . . . . . . . . 26

Brake (Auxiliary). . . . . . . . . . . 28

Brake Fluid . . . . . . . . . . . . . . . 26

Coolant (Bottle) . . . . . . . . . . . . 85

Coolant (Radiator) . . . . . . . . . . 86

Demand Drive . . . . . . . . . . . . . 80

Engine Oil . . . . . . . . . . . . . . . . 75

Rear Gearcase . . . . . . . . . . . . . 83

Transmission . . . . . . . . . . . . . . 78

Foot Brake, Auxiliary . . . . . . . . . . . 28

Footwell Removal . . . . . . . . . . . . . . 91

Front Box. . . . . . . . . . . . . . . . . . . . . 32

Front Gearcase Fluid . . . . . . . . . . . . 80

Fuel Recommendations . . . . . . . . . . 31

Fuel Safety . . . . . . . . . . . . . . . . . . . . 15

Fuel Tank Cap . . . . . . . . . . . . . . . . . 31

Fuse Replacement . . . . . . . . . . . . . . 96

G

Gasoline Handling . . . . . . . . . . . . . . 15

Gauge, Code Definitions . . . . . . . 44-47

Gauge, Digital/Analog. . . . . . . . . 36-43

Gear Selector . . . . . . . . . . . . . . . . . . 29

Gearcase Oil, Front . . . . . . . . . . . . . 80

Gearcase Oil, Rear . . . . . . . . . . . . . . 83

Gloves . . . . . . . . . . . . . . . . . . . . . . . 17

H

Hand Brake . . . . . . . . . . . . . . . . . . . . 87

Handlebar Adjustment. . . . . . . . . . . 113

Hauling Cargo . . . . . . . . . . . . . . . 66-68

Hazard Switch . . . . . . . . . . . . . . . . . . 22

Headlight Housing Replacement . . . 100

Headlight Lamp Replacement . . . . . . 97

Headlight Switch . . . . . . . . . . . . . . . . 23

Helmet . . . . . . . . . . . . . . . . . . . . . . . . 16

High Beam Adjustment . . . . . . . . . . . 98

High Range Use. . . . . . . . . . . . . . . . 108

Horn Switch. . . . . . . . . . . . . . . . . . . . 22

Hub Tightening . . . . . . . . . . . . . . . . . 93

I

Idle RPM Adjustment . . . . . . . . . . . 114

Immersion Maintenance . . . . . . . . . 104

Indicator Lamps. . . . . . . . . . . . . . . . . 37

Instrument Cluster . . . . . . . . . . . . 36-47

K

Key Switch . . . . . . . . . . . . . . . . . . . . 21

K-Turn . . . . . . . . . . . . . . . . . . . . . 60-61

L

Lights . . . . . . . . . . . . . . . . . . . . 97-101

Headlight Housing. . . . . . . . . . 100

Headlight Lamp . . . . . . . . . . . . . 97

High Beam Adjustment . . . . . . . 98

Low Beam Adjustment . . . . . . . 99

Lower Headlamp Replacement 101

Taillight/Brakelight/Worklight 101

Turn Signal Replacement . . . . 101

Low Beam Adjustment . . . . . . . . . . . 99

Low Range Use . . . . . . . . . . . . . . . . 108

Lower Headlamp Replacement . . . . 101

Lubrication Guide . . . . . . . . . . . . . . . 74

M

Maintenance Chart. . . . . . . . . . . . 70-73

Master Cylinder . . . . . . . . . . . . . . . . . 26

Metric Display . . . . . . . . . . . . . . . . . . 40

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . 24

Modifications. . . . . . . . . . . . . . . . . . . . 7

Momentary High-Beam Switch . . . . 22

138

N

Noise Emission Control System . . . . 69

O

Oil

Engine . . . . . . . . . . . . . . . . . 75-77

Rear Gearcase . . . . . . . . . . . . . . 83

Transmission. . . . . . . . . . . . 78-79

Oil and Filter Change . . . . . . . . . 76-77

Oil Change

Rear Gearcase . . . . . . . . . . . . . . 83

Transmission. . . . . . . . . . . . . . . 79

Oil Level

Engine . . . . . . . . . . . . . . . . . . . . 75

Rear Gearcase . . . . . . . . . . . . . . 83

Transmission. . . . . . . . . . . . . . . 78

Oil Recommendations. . . . . . . . . . . . 75

Override Switch . . . . . . . . . . . . . . . . 23

P

Parking Brake . . . . . . . . . . . . . . . . . . 27

Parking on an Incline . . . . . . . . . . . . 65

Passenger Seat. . . . . . . . . . . . . . . . . . 30

Periodic Maintenance Chart . . . . 70-73

Polaris Product List. . . . . . . . . . . . . 125

Polishing the Vehicle . . . . . . . . . . . 117

Power Steering . . . . . . . . . . . . . . . . . 30

Power Steering Unit (Cleaning) . . . . 84

Pre-Ride Checklist . . . . . . . . . . . . . . 50

PVT Break-In . . . . . . . . . . . . . . . . . . 49

PVT Drying. . . . . . . . . . . . . . . . . . . 108

PVT System . . . . . . . . . . . . . . 106-108

R

Rear Gearcase Oil . . . . . . . . . . . . . . . 83

Reverse Operation. . . . . . . . . . . . . . . 64

Rider Information Center . . . . . . 38-43

Rider Safety . . . . . . . . . . . . . . . . . 8-15

Riding Gear. . . . . . . . . . . . . . . . . 16-17

INDEX

S

Safe Operation Practices. . . . . . . . . . 51

Safety Labels . . . . . . . . . . . . . . . 18-20

Safety Training . . . . . . . . . . . . . . . . . . 6

Seat Backrest, Passenger . . . . . . . . . 89

Seat Removal, Operator . . . . . . . . . . 90

Seat Removal, Passenger . . . . . . . . . 89

Seat Suspension, Passenger . . . . . . . 90

Seats . . . . . . . . . . . . . . . . . . . . . . 89-90

Severe Use . . . . . . . . . . . . . . . . . . . . 70

Side Panel Removal . . . . . . . . . . . . . 91

Sidehilling. . . . . . . . . . . . . . . . . . . . . 58

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor. . . . . . . . . . . . . . . . . 105

Spark Arrestor Requirements . . . . . . 69

Spark Plug Inspection . . . . . . . 102-103

Spark Plug Recommendations . . . . 102

Spark Plug Torque Specification . . 102

Spark Plugs . . . . . . . . . . . . . . . 102-103

Specifications . . . . . . . . . . . . . 126-129

Speedometer . . . . . . . . . . . . . . . . . . . 36

Spring Adjustment, Rear Shock . . . 113

Starting the Engine . . . . . . . . . . . . . . 52

Steering Assembly . . . . . . . . . . . . . . 84

Steering Lock . . . . . . . . . . . . . . . . . . 31

Stop Switch. . . . . . . . . . . . . . . . . . . . 22

Storage . . . . . . . . . . . . . . . . . . 116-120

Storage Box, Front . . . . . . . . . . . . . . 32

Storage Tips . . . . . . . . . . . . . . 118-119

Suspension, Passenger Seat . . . . . . . 90

Switches

4X4 Switch . . . . . . . . . . . . . 21, 33

Engine Stop Switch. . . . . . . . . . 22

Hazard Switch. . . . . . . . . . . . . . 22

Headlight Switch . . . . . . . . . . . 23

Horn Switch . . . . . . . . . . . . . . . 22

Main Key Switch . . . . . . . . . . . 21

MODE Button. . . . . . . . . . . . . . 23

Momentary High-Beam Switch 22

Override Switch . . . . . . . . . . . . 23

Turn Signal Switch . . . . . . . . . . 22

139

INDEX

T

Taillight Lamp Replacement . . . . . 101

Throttle Body Adjustment . . . . . . . 114

Throttle Cable Freeplay . . . . . . 114-115

Throttle Lever . . . . . . . . . . . . . . . . . 24

Tire Tread Depth . . . . . . . . . . . . . . . 92

Tires . . . . . . . . . . . . . . . . . . . . . . 92-94

Wheel Installation . . . . . . . . . . 94

Wheel Nut Torque . . . . . . . . . . 94

Wheel Removal . . . . . . . . . . . . 93

Toe Alignment . . . . . . . . . . . . . . . . . 88

Towing Capacities . . . . . . . . . . . . . . 68

Towing Loads . . . . . . . . . . . . . . . . . 68

Training, Safety . . . . . . . . . . . . . . . . . 6

Transmission . . . . . . . . . . . . . . . . . . 29

Transmission Oil . . . . . . . . . . . . . 78-79

Transporting the Vehicle . . . . . . . . 120

Turn Signal Replacement . . . . . . . 101

Turn Signal Switch . . . . . . . . . . . . . 22

Turning Around on a Hill . . . . . . 60-61

Turning the Vehicle . . . . . . . . . . . . . 54

V

Vehicle Identification Numbers. . . . . . 5

Vehicle Immersion . . . . . . . . . . . . . 104

VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

W

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . 116-117

Wheel Installation . . . . . . . . . . . . . . . 94

Wheel Nut Torque Specifications . . . 94

Wheel Removal . . . . . . . . . . . . . . . . . 93

140

No results