Instruction/ maintenance manual of the product 550 EPS Polaris
Go to page of 166
PMS 419 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.
A card containi ng importan t A TV safety information should be attach ed to the owner's manua l on the next p age. If you cannot locate this car d, or if it has be en removed, plea se call 1-800- 342-3764 for assist ance.
1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
2 POLARIS® and SPOR TSMAN® are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 28 Operation . . . . . .
4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury haza rd.
5 INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS A TV is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicle s, such as motorcycles and cars.
6 INTRODUCTION V ehicle 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 POLARI S key blank (using your key number) and mating it with one of your existing keys.
7 SAFETY Safety T raining A TV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the A TV to take a training course.
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prevent a severe head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS veh icle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Prot ective Equipment (PPE) bearing markings such as VESC 8, V -8, Z8 7.
10 SAFETY Safety W arnings Failure to operate the A TV properly can resul t in a coll ision , loss of control, accident or overturn, which may result i n serious injury or d eath. Heed all safety warnings outlined in this section of the owner ’s manual.
11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme cau tion whenever handling gasol ine. • Always refuel wi th the engine stopped, and o utdoors or in a well ven tilated area.
12 SAFETY Safety W arnings Protective App arel Riding in this vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shie ld).
13 SAFETY Safety W arnings Carrying a Passenger in the Cargo Box A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death. N ever allow a passenger to ride in the cargo box.
14 SAFETY Safety W arnings Physical Control of the A TV Removing even one hand or foot can reduce ability to control the vehicle or co uld cause loss of balance and ejection from the A TV .
15 SAFETY Safety W arnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described i n the owner's manual. See page 65. Never operate in TURF mode while operating on a hill or other irre gular terrain.
16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed when climbing a hill. • Never operate in TURF mode while operating on a hill or other irregular terrain.
17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when operati ng on excessively rough, slipp ery or loose terrain could cause loss of traction, loss of control, accident or overturn.
18 SAFETY Safety W arnings Improper Tire Maintenance Operating this A TV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your A TV . Always maintain proper tire pressure as described in the owner's manual and on safety labels.
19 SAFETY Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast- flowing water could cause the tires to floa t, causing loss of control or overturn.
20 SAFETY Safety W arnings Operating on Frozen Bodies of Wa t e r Operating on frozen bodie s of water may result in serious injury or death if the A TV and/or riders fall through the ice.
21 SAFETY Safety W arnings Operating a Damaged A TV Operating a damaged A TV can result in a n accident. After any overturn or accident, have a qualifi ed service dealer inspect the entire ma chine for possible damage, including (but not limited to) brakes, th rottle and steering systems.
22 SAFETY Safety Labels and Locations W arning 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 dif fer from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
23 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if yo u are under the age of 16 increases the chances of severe injury or death to both operator and passenger .
24 SAFETY Safety Labels and Locations Passenger Safety//Discretionary Warning W ARNING P ASSENGER SAFETY T o reduce the risk of SEVERE INJURY or DEA TH NEVER CARR Y MORE THAN ONE P ASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.
25 SAFETY Safety Labels and Locations Tire Pressure/Load W arning W ARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pre ssure: Front: 7.0 psi (48.3 kPa) Rear: 7.
26 SAFETY Safety Labels and Locations Rack W a rning, Front W ARNING DO NOT TOW FROM RACK OR BUMPER. V ehicle damage or tipover ma y result causing severe injury or death. T ow only from tow hooks or hitch. Maximum combined Front Rack and Container Load: 120 lbs.
27 SAFETY Safety Labels and Locations Box W arning W ARNING Remove flammable material containers from box before filling. W ARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load - 400 lbs.
28 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limiter system.T o gain additional wheel speed while backing, depress the override swi tch. W ARNING! Pressing the override button whil e the throttle is open can cause loss of control, which may result in seri ous injury or death.
29 FEA TURES AND CONTROLS Switches Main Key Switch Use the main key switch to st art the engine. See page 59. 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 4X4, 2X4 or TURF mode. See pages 38-39. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.
30 FEA TURES AND CONTROLS Throttle Lever Operating an A TV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an A TV that has a sticking or improperly operating throttle . Always c ontact your dealer for service before operating the vehicle.
31 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spon gy brake lever can result in loss of braking, whi ch could cause an accident. Never operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for service before opera ting the vehicle.
32 FEA TURES AND CONTROLS Master Cylinder/Brake Fluid An over-full master cyl inder 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.
33 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PA R K . 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 .
34 FEA TURES AND CONTROLS Auxiliary Foot Brake Never back down a hill. Applying the auxi liary brake when backing down a hill may cause rear tipover, which could result in serious inj ury or death. Use caution when ap plying the auxiliary brake. Do not aggressivel y apply the auxiliary brake when going forward.
35 FEA TURES AND CONTROLS Auxiliary Foot Brake 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 43. Maintain the fluid level between the maximum and minimum marks.
36 FEA TURES AND CONTROLS Automatic T ransmission 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 T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear .
37 FEA TURES AND CONTROLS Fuel T ank Cap Remove the fuel tank cap to add fuel to the fuel tank. 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 gr eater than 10 per cent, such as E-85 fuel .
38 FEA TURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.
39 FEA TURES AND CONTROLS All Wheel Drive System 2X4 Mode When the switch is on 2X4, the A TV is in two-wheel drive at all times. TURF Mode When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns.
40 FEA TURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.
41 FEA TURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger . Do not operate the vehicle with the seat in the 2-up position when operating without a passenger . Al ways return the seat to the 1-up position for single-rider operation.
42 FEA TURES AND CONTROLS Passenger Seat Seat Conversion 5. Lift the adjustment latch at the top of the passenger backrest. Raise the backrest to the desired position.
43 FEA TURES AND CONTROLS Front Box/Comp artment Release the front box anchor latches and remove the box as sembly to gain access to the front compartment. T o reinstall the box, hold the box as shown in the rack illustration. Position the front edge in the tabs, then push the box downward and secure the latches.
44 FEA TURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may d amage A TV components. Wash the A TV by hand or with a garden ho se using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer len s and other plasti c surfaces.
45 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Indicator Lamp s Lamp Indicates Condition V ehicle S p eed When standard mode is selected, speed displays in miles per hour . When metric mode is selected, speed displays in kilometers per hour .
46 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center The rider information center is located in the instrument cluster .
47 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center 1. Gear Display - This area displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2.
48 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly . The transmission cannot be in reverse when using the override button as a MODE button.
49 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center Clock Mode Tip : The clock must be reset any time the battery has been disconn ected or discharged. 1. T urn the key to the ON position. Use the MODE button to toggle to the odometer display .
50 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center Programmable Service Interval When the hours of engine oper ation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started.
51 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center 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.
52 FEA TURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector , fuel pump, etc.), or the item has failed. Short-to-Gr ound: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
53 FEA TURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions *Assumes unipolar configuration of ste ppe r motor Sport sman X2 550 EPS Diagnostic Codes Component Condition SPN FMI T.
54 FEA TURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Sport sman X2 550 EPS Diagnostic Codes EPS Models Only S teering Over Current Shut Down Current Above Norma l or Ground.
55 OPERA TION Failure to operate the A TV properly can result in a collision, loss of co ntrol, 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.
56 OPERA TION Pre-Ride Checklist Failure to inspect and verify that the A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition.
57 OPERA TION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 year s of age to operate this vehicle. Do not allow anyone with cognitive or physical di sabilities to operate this vehicle.
58 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer , a local riding club or local officials.
59 OPERA TION S t arting the Engine 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Place the transmission in P ARK. 3. Lock the parking brake. Tip : The starter interlock will prevent the engine from starting if the brake is not engaged.
60 OPERA TION Driving Procedures 1. W ear protective riding gear . See page 8. 2. Perform the pre-ride inspection. See page 56. 3. Place the transmission in P ARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the foo trests and both hands on the handlebars.
61 OPERA TION T urning the V ehicle Both rear wheels drive equally at all times (except when operating in TURF mode). This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly .
62 OPERA TION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up A TV . 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.
63 OPERA TION Driving with a Passenger 12. Do not cross a hillside with a passenger on board. See page 66. 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.
64 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces su ch as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas.
65 OPERA TION Driving Uphill Braking and handling are greatly af fected when operating in hilly terrain. Improper procedure could ca use loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Never operate in TURF mode while operating on a hill or other irregular terrain.
66 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not r ecommended. Improper procedure could cause loss of control or overturn. A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1.
67 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
68 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.
69 OPERA TION T urning Around on a Hill (K-T urn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
70 OPERA TION Driving Through W ater Y our A TV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water .
71 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.
72 OPERA TION 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. Back slowly . 4. Apply the brakes lightly for stopping.
73 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
74 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or tow ing cargo improperl y can alter vehicl e handling and may cause loss of control or brake instability . Always follow these precautions when hauling cargo : Never carry cargo in the rear box when operating the A TV in the 2-up mode with a passenger .
75 OPERA TION Hauling Cargo 1. Never exceed the weight capacities specified for your A TV on warning labels and in the specifications section of this manual. 2. Cargo weight should be mounted as low as possible. 3. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.
76 OPERA TION Hauling Cargo T owing Loads Always attach a towed load to the hitch point. Remove the hitch from the A TV when not towing a trailer . If towing a load, reduce rear box cargo weight by the amount of tongue weight. • The combination of rear box car go weight and tongue weight must not exceed the rear box capacity .
77 OPERA TION Hauling Cargo Dumping Cargo 1. Select a level site to dump the car go box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Dismount the vehicle. 5.
78 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. Improper winch use can result in SEVERE INJURY or DEA TH. Always follow all winch instructions and warnings in this manual.
79 WINCH GUIDE Winch Safety Precautions 1 1. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. A void winching with the winch cable at an ang le to the winching vehicle’ s centerline whenever possible.
80 WINCH GUIDE Winch Safety Precautions 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water . T ake your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use.
81 WINCH GUIDE Winch Operation Read the W inch Safety Precautions in the preceding pages before using your winch. Tip : Consider practicing the operation a nd use of your winch before you a ctually need to use it in the field. Improper winch use can result in SEVERE INJURY or DEA TH.
82 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. W ARNING! Never put your fi nge rs into the hook. This could lead to SEVERE INJURY . A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
83 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’ s pulling capacity . Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
84 WINCH GUIDE Winch Operation 1 1. The ONL Y time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle.
85 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’ s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use.
86 WINCH GUIDE Winch Cable Care For your safety , always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer . W ARNING! Use of worn or damaged ca ble could lead to sudden failure and SEVERE INJUR Y .
87 WINCH GUIDE Shock Loading W ARNING! Y our winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to brea k. The end of a broke n winch cable under such hig h loading can cause SEVERE INJUR Y or DEA TH to you and other bystanders.
88 WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store ener gy . This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous.
89 WINCH GUIDE Winch Maintenance and Service Safety W ARNING! Improper or lack of winch ma inten ance and service could lead to SEVERE INJUR Y or DEA TH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use.
90 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.
91 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will he lp 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 .
92 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key W ARNING! Improperly perf or ming th e procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
93 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź E Air filter , main element - Weekly - Inspect; replace as needed Ź D .
94 MAINTENANCE Periodic Maintenance Chart Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
95 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 91. Items not listed in the chart should be lubricated at the General Lubr ication interval. The a-arms and upper control arms are lubricated at the factory , and no additional lubrication will be needed.
96 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W - 50 4-cycle oil or a similar oil for this engi ne. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W - 50 oil.
97 MAINTENANCE Engine Oil Oil Level Check the oil level when the engine is cold. Never check the oil with the engine running. 1. Position the vehicle on a level surface. 2. Access the oil dipstick and fill tube from the left side of the A TV . Remove the dipstick.
98 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 95 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the int ervals outlined in the Periodic Maintenance Chart beginning on page 91. Al ways change the oil filter whenever changing oil.
99 MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filte r . 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.
100 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 91. See the table on page 95 for fluid recommendations , capacities and plug torques. See page 147 for the part nu mbers of POLARIS products.
101 MAINTENANCE T ransmission 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. T orque to specification. 4. Remove the fill plug.
102 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 91. See the table on page 95 for fluid r ecommendations, capacities and plug torques.
103 MAINTENANCE Front Gearcase (Demand Drive) Fluid 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. 3.
104 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Level Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 91. W e recommend the use of POLARIS Demand Drive Fluid for the ADC unit.
105 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 dif ferential).
106 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 91. See the table on page 95 for fluid recommendations , capacities and plug torques. See page 147 for the part nu mbers of POLARIS products.
107 MAINTENANCE Rear Gearcase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain hole. 3. Remove the drain plug. Allow the oil to drain completely . 4. Clean and reinstall the drain plug with a new sealing washer .
108 MAINTENANCE Cooling System The engine coolant le vel is controlled, or maintai ned, by the recovery system. The recovery system components are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
109 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front storage compartment. 1. V iew the fluid level in the bottle. 2.
110 MAINTENANCE Cooling System Radiator Coolant T o 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 .
111 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar . These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops.
112 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/4-1/2 inch (6-12 mm). W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attempt to adjust ti e rod alignment.
113 MAINTENANCE Seat Removal 1. Remove any cargo from the cargo box before removing the seat. 2. Stand beside the vehicle. Pull the cargo box release strap upward. Lift the front of the carg o box . 3. Grasp edge of the seat near the opposite rear corner .
114 MAINTENANCE Ti r es Operating your A TV with worn tires, impr operly inflated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follo w all tire maintenance procedures as outlined in this manual and on the labels on the vehicle.
115 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t oward forward rotation (if equipped).
116 MAINTENANCE Air Filter 1. Remove the seat. See page 11 3 . 2. Remove the air box cover strap, and remove the air box cover . 3. Remove the filter . 4. Remove the fabric type pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry .
117 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.
118 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility .
119 MAINTENANCE Light s 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.
120 MAINTENANCE Light s 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. T ilt the headlamp upward or downward. 3. T ighten the screw . Headlight Housing Replacement 1.
121 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn 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 .
122 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications section beginning on page 148 for the recommended spark plug type and gap for your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
123 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection Normal Sp ark Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes ar e not burned or eroded. This indicates the proper type and heat range for the engine and the service.
124 MAINTENANCE V ehicle Immersion If your vehicle becomes immersed, major engine damage ca n result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below .
125 MAINTENANCE S p ark Arrester Failure to heed the following warnings whil e servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protec tion and leather work gloves.
126 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 occu r at a high speed. The PVT system has be en precision balanced.
127 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.
128 MAINTENANCE PVT System When T o Use Low Range and High Range The air temperature in th e clutch cover is substan tially 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.
129 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an e xplosion 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.
130 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 132 before installing the battery .
131 MAINTENANCE Battery Battery S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full char ge.
132 MAINTENANCE Battery Battery Charging The following battery char ging 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 w ith electrolyte and has been sealed and fully char ged at the factory .
133 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. St ate of Charge V oltage Action Charge Time (Using constant current charger @ standa rd amps specified on to p o f batt ery) 100% 12.
134 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 .
135 MAINTENANCE Throttle Cable Freeplay 4. Place the transmission in P ARK. Lock the parking brake. 5. Star t 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.
136 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. W ARNING! Improper adj ustment of the handlebars or incorrect torqui ng of the adjuster block tightening bolts can cause limi ted steering or loosenin g of the handlebars, resulting in loss of co ntrol and serious inju ry or death.
137 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counter - clockwise to increase or decrease spring tension.
138 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in P ARK. 3. Lock the parking brake. 4. Always secure the seat in the 1-up position to prevent loss during transporting.
139 MAINTENANCE Cleaning and St orage W ash ing the V ehicle 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 dama ge components. POLARIS recommends washing the vehicle by han d or with a garden hose, using mild soap.
140 MAINTENANCE Cleaning and St orage W ashing th e V ehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution.
141 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S t arting the engine durin g the storage period w ill disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended.
142 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fog the Engine 1. After stabilizing the fuel, remove the spark plugs and add 2-3 tablespoons of engine oil. T o acc ess the plug holes, use a section of clear 1/4" hose and a small plastic squeeze bottle filled with the pre- measured amount of oil.
143 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. S tarting out going up a steep incline Use low range or turn around using the K-turn (see page 68).
144 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery volt age Recharge the battery to 12.
145 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly , St alls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing.
146 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fu.
147 POLARIS PRODUCTS Part Number Description Engine Lub ricant 2870791 Fogging Oi l (12 oz. Aeroso l) 2876244 PS-4 Full Synthe tic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Fu ll Synt hetic 5W -50 4-Cyc le Oil (gal./3. 8 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt.
148 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sport sman X2 550 EPS Maximum W eight Capacity 735 lbs. (333 kg) (includes operator , passenger , cargo, accessories) Dry W eight 813 lbs. (368.8 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts.
149 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment Sport sman X2 550 EPS T ransmission H/L/N/R/P Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.693:1 Drive Ratio, Front 3.818:1 T i res/Pressure, Front Maxxis A T 26 x 8 - 14 / 7 psi (48.
150 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship.
151 W ARRANTY LIMIT A TIONS OF W ARRANT IES AND REMEDIES This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship .
152 W ARRANTY LIMIT A TIONS OF W ARRANT IES AND REMEDIES THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FOR TH IN THIS W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF THIS W ARRANTY .
153 W ARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration From to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
154 W ARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER V ICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS.
155 W ARRANTY U.S.A. EP A Emissions Limited W arranty This emissions limi ted warranty is in addition to t he POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehi cle is designed, built and equipped so it conforms with applicable U.
156 W ARRANTY U.S.A. EP A Emissions Limited W arranty The following parts are considered emission-related components for evaporative emissions: *As related to the evaporative emission cont rol sy stem.
157 W ARRANTY U.S.A. EP A Emissions Limited W arranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual.
158 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.
159 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TEC HNICIAN SERVICE PERFORMED / COMMENTS.
160 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . . . . 29 A Accessories . . . . . . . . . . . . . . . . . . 138 Active Descent Control Fluid . 104-105 Active Descen t Control System . . . . 40 ADC System . . . . . . . . . . . . . . . . . . 40 Air Filte r .
161 INDEX F Fluid ADC . . . . . . . . . . . . . . . . . . 104-105 Brake . . . . . . . . . . . . . . . . . . . . . . 32 Coolant . . . . . . . . . . . . . . . . . . . . 108 Demand Drive . . . . . . . . . . 102-103 Engine Oil . . . . . . . . . . . . . . .
162 INDEX N Noise Emission Control System . . . 90 O Oil Engine . . . . . . . . . . . . . . . . . . . 96-99 Rear Gearcase . . . . . . . . . . . 106-107 Transmission . . . . . . . . . . . . 100-101 Oil and Filter Change. . . . . . . . . . 98-99 Oil Change Rear Gearcase .
163 INDEX T Toe Alignme nt . . . . . . . . . . . . . . . . 112 Towing Capacities . . . . . . . . . . . . . . 76 Towing Loads . . . . . . . . . . . . . . . . . . 76 Trail Etiquet te . . . . . . . . . . . . . . . . . . 58 Training . . . . . . . . . . . .
Improper vehicle use can result in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS. AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND P ASSE.
An important point after buying a device Polaris 550 EPS (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 550 EPS yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 550 EPS - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 550 EPS you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 550 EPS will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 550 EPS, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 550 EPS.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 550 EPS. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 550 EPS along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
