Instruction/ maintenance manual of the product Sportsman 550 Touring EPS Polaris
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A card cont aining import ant A TV safety information should be att ached to the owner' s manual on the ne xt page. If you cannot locate this card, or if it has been removed, pl ease call 1-8 00- 342-3764 for assistance .
The text is printed on 100% recycled with 40% post-consume r waste (PCW)..
For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922090 Rev 02 Printed in USA W ARNING Improper vehicle use can result in SEVERE INJUR Y or DEA TH.
1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e p roudly produce an ex citing line of utility and recreati onal products.
2 POLARIS, THE W A Y OUT and SPOR TSMAN ar e registered tra demarks of Polari s Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . .
4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potentia l personal injury haza rd.
5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions contained in thi s manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle handl es differently than other vehicles, such as motorcycles and cars.
6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n 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 yo ur key number) and mating it wi th one of your existing keys.
7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s 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 an d to reduce the chance of in jury . Helmet W earing a helmet can prevent a sever e 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. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.
10 SAFETY Safety W arnings Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual.
11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution whenever han dling gasoline. • Always refuel with the en gine stopped, and outdoors or in a well ventilated area.
12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e without wearing an approved helmet and protective eyewe ar increases the risk of a serious inj uries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield).
13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewal ks, paths, p arkin g lots and driveways) may adversely a ffect the handling of the A TV and could result in loss of control and accident or overturn.
14 SAFETY Safety W arnings Physical Control of the A TV Removing even one hand or foot can reduce ability to control the ve hicle or could cause loss of balance and ejecti on from the A TV .
15 SAFETY Safety W arnings Improper Hill Climbing Improper hill cl imbing could cau se loss of control or overturn. Always follow proper procedures for climbing hills as describ ed in the owner's manual. See p age 63. Always move the 4X 4 switch to ADC 4X4 before ascending or descending a hil l.
16 SAFETY Safety W arnings S talling While Clim bing a Hill S talling, rolling ba ckwards or improperly dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascendin g or descending a hill.
17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.
18 SAFETY Safety W arnings Improper T ire 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 float, causing loss of con trol or over turn.
20 SAFETY Safety W arnings Operating on Froz en Bodies of Wa t e r Operating on frozen bodies 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 da maged A TV can result in an accident. After any overturn or accident, have a qual ified service dealer in spect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems.
22 SAFETY Safety Labels and Locations W arning labels have b een placed on the ve hicle for your protectio n. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fe r from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle.
23 SAFETY Safety Labels and Locations General W arning W ARNING Improper A TV use can result in SEVERE INJURY or DEA TH AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND P ASSENGER N.
24 SAFETY Safety Labels and Locations Passenger W arning /Discretionary W arning W ARNING P ASSENGER SA FETY T o reduce the risk of SEVERE INJUR Y 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 Rack/Box W arn ing W ARNING • DO NOT T OW FROM RACK OR BUMPER. V ehicle dama ge or tipover may result causing severe injury or death. T ow only from tow hooks or hitch. • Maximum Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs.
26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse speed limi ter system.T o gain additional wheel speed while backin g, depress the override switch. W ARNING! Pressing the override button while the throttle is ope n can cause loss of control, wh ich may result in seri ous injury or death.
27 FEA TURES AND CONTROLS Switches Engine S top Switch Move the stop switch either left or right to the OFF position to stop the engine quickly . Move the stop switch to the RUN position before attempt- ing to start the engine. The engine will not start or run when the switch is off.
28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr o perly operating throttle controls could cause an accident. N ever start or oper ate an A TV that has a sticking or improperly operating th rottle. Always c ontact your deal er for service before operating the vehicle.
29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Neve r operat e the A TV with a spong y-feeling brake lever . Always contact your dealer for service before opera ting the vehicle.
30 FEA TURES AND CONTROLS Master Cylinde r/Br ake Fluid An over-full master cylinder may cause brake drag or b rake 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 br ake fluid.
31 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 .
32 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could result in seri ous injury or death. Ne ver back down a hill. Use caution when applying the a uxiliary brak e.
33 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the v ehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, bra ke to a complete stop. When the engine is idling, move the lever to the desired gear .
34 FEA TURES AND CONTROLS Electronic Power S teering (EPS) Electronic power steering (if equipped ) engages when the ignition key is turned to the ON positi on. EPS rema ins engaged whether the vehicle is moving or idle. S e e page 42 for EPS W arning Indicator information.
35 FEA TURES AND CONTROLS Fuel T a nk Always refuel with the engine stopped, and outdoo rs or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap and add fuel. Use eithe r leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M /2) octane.
36 FEA TURES AND CONTROLS Front S t orage 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 disengage the plungers.
37 FEA TURES AND CONTROLS All Wheel Drive System The Al l Wheel Driv e 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.
38 FEA TURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially , the vehicle's electronic sy stem will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 r emains enabled until the 4X4 switch is turned of f.
39 FEA TURES AND CONTROLS Active Descent Cont rol (ADC) System The ADC system allows engine brak ing to all four wheels when the vehicle descends a hill or incline.
40 FEA TURES AND CONTROLS Instrument Cluster Y our A TV is equipped with an instrument cluster that senses vehicle speed from a gear in the transmissi on.
41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for one second at start-up.
42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center 3. Speed Display - This area displ a ys vehicle groun d speed or engine rotational speed when the correspon ding display is selected. See page 43. 4. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.
43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center S peed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip : The re verse override button also acts as a MODE button when held down for approximately one half second.
44 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to togg le through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h).
45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Odometer Mode The odometer records and displays the distance traveled by the A TV . T rip Meter Mode The trip meters record the distance tr aveled by the A TV on each trip if reset before each trip.
46 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Pr ogrammable Service Interval When the ho urs of engine operation equal the p rogrammed service interval setting, the wr ench icon will flash for 5 seconds each time the engine is started.
47 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Diagnostic Display Mode The EFI diag nostic display mode is for informati onal purposes only .
48 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the cha rt (injector , fuel pump, etc.
49 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center *Assumes unipolar configuration of stepper motor SPORTSMAN 550 T ouring EPS Diagnostic Codes Component Condition SPN FMI Idle Air .
50 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 T ouring EPS Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor V oltage T oo High 51 3 V oltage .
51 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 T ouring EPS Diagnostic Codes Component Condition SPN FMI Chassis Relay Driver Circuit Open/Grounded 520208 5 Driver.
52 OPERA TION Failure to operate the A TV properly can re sul t 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.
53 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 35. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 81. Add oil if necessary to maintain the level betwee n the safe and add marks.
54 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A T V before each use to make sure it's in safe operating condition.
55 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle . Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicle.
56 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you r ide. Find out where the de signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or local officials.
57 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. Tip : The starter interlock will preven t the eng ine from starting if the transmis sion is in gear and the brake is not engaged.
58 OPERA TION Driving Procedures 1. W ear pro tective riding gear . See page 8. 2. Perform the pre-ride inspection. See page 54. 3. Place the transmission in P ARK. 4. Lock the parkin g brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on th e foo trests and both hands on the handlebars.
59 OPERA TION T urning the V ehicle Both rear wheels drive equally at all times. This means that the outside whee l must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly . 1. Slow down. 2. Never turn quickly when carrying a passenger or car go.
60 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 p assenger is tall enough to comfort- ably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you ha ve at least two hours of driving experience with this vehicle.
61 OPERA TION Driving with a Passenger 1 1. Ride to the ability of your passeng er , instead of to your own ability . A void unexpected or aggressive mane uvers that could cause a pa s- senger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board.
62 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas.
63 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure cou ld cause loss of c ontrol or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
64 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper pro cedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1.
65 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Always descend a hill with the tr ansmission in forward gear .
66 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.
67 OPERA TION T urning Around on a Hill (K-T urn) 1. S top and lock the parking brake wh ile keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Leave the transmission in forward and shut off the engine.
68 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 .
69 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 haz- ards such as logs, rocks and low hanging branches.
70 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or peop le behind the vehicle. Be aware that a passenger can obstruct your view . 2. Always avoid ba cking downhi ll. 3. Back slowly . 4.
71 OPERA TION Parking on an Incline A void parking on an in cline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. 4. Always block the rear wh eels on the downhil l side.
72 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly can al ter vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death.
73 OPERA TION Hauling Cargo Never exceed the weight capacitie s specified for your A TV on warning labels and in the specifications sec- tion of this manual. 1. Cargo weight should be evenly distributed (1/3 on th e front rack and 2/3 on the rear rack) and mounted as lo w as possible.
74 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 rack car go weight by the amount o f tongue weight. • The comb ination of rear rack cargo weig ht and tongue wei ght must not exceed the rear rack capacity .
75 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect 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.
76 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance chart .
77 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedure s marked with a Q coul d result in component failure and cause an accid ent, wh ich ma y result in seri ous injury or death. Always have an authorize d Pola ris dealer perform these services.
78 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - Weekly - Inspect; replace as needed X Engi.
79 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
80 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 76.
81 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. See the table on page 80 for fluid recommendatio ns, capacities and plug torques.
82 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 80 for flui d recommendations, capacities and plug torques. Always change th e oil and filter at t he intervals outlined in the Periodic Maintenance Chart beginning on page 76. Al ways change the oil filter whenever changing oil.
83 MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneat h the oil filter . Using an oil fil- ter 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.
84 MAINTENANCE T ransmission Oil Polaris recommends the use of Polaris Synthetic SPOR TSMAN XP T ra nsmission Fluid for this transmis sion. See the table on page 80 for fluid recommendations, capacities an d plug torques. Alwa ys check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 76.
85 MAINTENANCE T ransmission Oil Oil Change 1. Remove the footwell. 2. Place a drain pan under the ge arcase. 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.
86 MAINTENANCE Front Gearcase (Dem and Drive) Fluid See the table on page 80 for flui d recommendations, capacities and plug torques. Always check and change th e demand dri ve fluid at the inter- vals outlined in the Periodic Main tenance Ch art beginning on pa ge 76.
87 MAINTENANCE Rear Gearcase Oil See the table on page 80 for flui d recommendations, capacities and plug torques. Always check and change the rear gearca se oil at the intervals outlined in the Periodic Maintenan ce Chart beginning on page 76. See page 135 for th e part numbers of Polaris produ cts.
88 MAINTENANCE Active Descent Control (ADC) Fluid If your veh icle is equipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fluid and ADC fluid).
89 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).
90 MAINTENANCE Power S t eering 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 . S teering Assembly The steering assemb ly of the A TV should be checked period ically for loose nuts and bo lts.
91 MAINTENANCE Cooling System Recovery Bottle Coolan t The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the re covery bottle cap under the front box. See page 36. 1. V iew the fluid level in the bottle. 2. If the level is low , remove the bottle cap and add coolant as needed.
92 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s 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 coo ling system has been drained for maintenance or repair .
93 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handleba r . These brakes are self- adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drop s.
94 MAINTENANCE T oe 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). W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment.
95 MAINTENANCE Seat s Passenger Seat Removal 1. Pull the latch at the rear of the seat. 2. Pivot the rear of the sea t upward and remove the front legs of the seat base from the frame. 3. T o reinstall the seat, position the front legs of the seat base under the frame.
96 MAINTENANCE Seat s 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 faste ner . Remove the lower shock fastener .
97 MAINTENANCE Side Panel /Footwell Removal 1. Remove the seat be fore removing a side pa nel. 2. Remove the fasteners securing the side panel or fo otwell to remo ve it.
98 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly i nflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or dea th. Always follow all tire mainten ance procedures as outlined in this manua l a nd on the labels on the vehicle.
99 MAINTENANCE Ti r e s Front Wheel Hub T ightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operati ons. All service must be performed by your authorized Polaris dealer . Wheel Removal 1. S top the engine. 2. Place the transmission in P ARK.
100 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in P ARK. 2. Lock the parkin g brake. 3. Place the wheel on the hub with the valve stem toward the out side and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger -tighten them.
101 MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover screws, and remove the air box cover . 3. Remove the filter . 4. Remove the fabric type pre- filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry .
102 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short cir- cuits that may have caused the blown fuse , then replace the fuse. Spare fuses are provided in the fuse box.
103 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal opera tion. Clean head- lights frequently and replace burned out headlamps promptly . Always make sure lights are adjusted properly for best visibility .
104 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 su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall .
105 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 headla mp.
106 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the five (5) headlight pod screws. 2. Lift the pod cov er and disconnect the speedomete r harnesses from the sp eedometer . 3. Unplug the headlam p from the wiring harness. 4. Us e a small screw driver to remove the o-rings from the headlight mounting tabs.
107 MAINTENANCE Light s Lower Headlamp Replacement 1. T u rn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headla mp. 3. Reinstall the harness assembly into the headlight assembly .
108 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifi c ations section beginn ing on page 136 for the recom- mended spark plug type and gap fo r your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
109 MAINTENANCE Spar k P l ug s S p ark Plug Inspection Normal S p ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
110 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, majo r engine damag e can result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossi ble to take your A TV to a dealer before starting it, follow t h e steps outlined below .
111 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the area. Wear eye protection and leather work gloves.
112 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce i ts strength so that a failure ma y occur at a high speed. The PVT system ha s been precision balanced.
113 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt.
114 MAINTENANCE P VT System When T o Use Low Range and High Range P VT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface.
115 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t in an explosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last.
116 MAINTENANCE Battery Battery Removal 1. Remove the passenger seat and the seat pivot bolt. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable last. 4. Disconnect the battery hold-down strap. 5. On conventional batteries, re move the battery vent tube.
117 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery charging instructio ns on page 1 19 before installing the battery .
118 MAINTENANCE Battery Batter y Stor age 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 s torage and recha r ge as needed to mainta in a full charge.
119 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled ele ctrolyte during cha rging. See page 1 16. 2. Char ge the battery with a charging output no larger than 1/10 of the battery’ s amp/hr rating.
120 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top o f batter y) 100% 12.
121 MAINTENANCE Camber and Caster The camber and caster are non-adjust- able. Rear S pring 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 de aler .
122 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . 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 han- dlebar control and remove the cover .
123 MAINTENANCE Throttle Cable Freeplay 4. Place the transmission in P ARK. Lock the parking brake. 5. S ta rt 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 c orre ct gap.
124 MAINTENANCE Cleaning and S torage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various componen ts. NOTICE: High water pre ssure may damag e components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap.
125 MAINTENANCE Cleaning and S torage W ash ing the V ehicle If a high pressure water system is u sed for clea ning (n ot recommended), exercise extreme caution.
126 MAINTENANCE Cleaning and S torage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many ye ars. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
127 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S tarting the engin e during the storage period will disturb the protective film created by fogging and damage coul d occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as recommended.
128 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the flu id levels. Add or chan ge fluids as recommended in the Periodic Maintenance Char t beginni ng on page 76.
129 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 76. Battery S torage See pages 1 18-1 19 for storage and charging procedures.
130 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in P ARK. 3. Lock the parkin g brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the A TV to the transporti ng un it securely with suitable straps or rope.
131 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 66).
132 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.
133 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S talls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommen ded fuel Incorrect ignition ti.
134 TROUBLESHOOTING Engine S tops 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.
135 POLARIS PRODUCTS Part Number Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aeroso l) 2876244 PS-4 PLUS Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performan ce Synthetic 2 W-50 4-Cycle Oil (g al.) Gearcase / T ransmission Lu bricants 2877606 Synthetic SPOR T SMAN XP T ransmission Fluid (qt.
136 SPECIFICA TIONS * Based on EU Directive 76/432/EC **A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation. SPORTSMAN 550 T ourin g EPS Maximum W eight Capacity 735 lbs. ( 333 kg) (includes operator , passenger , cargo, accessories) Dry W eight 772 lbs.
137 SPECIFICA TIONS Clutching SPORTSMAN 550 T ourin g EPS Lubrication System Pressurized W et Sump T ransmission T ype Automatic PVT (Polaris V aria ble Tr ansmission) In-Line H-L-N-R-P Front Suspension Dual a-arm, 9" (22.9 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10" (25.
138 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN 850 T ourin g EPS Maximum W eight Capacity 735 lbs. ( 333 kg) (includes operator , passenger , cargo, accessories) Dry W eight 798 lbs. (362 kg) Front Rack/S torage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs.
139 SPECIFICA TIONS Clutching SPORTSMAN 850 T ourin g EPS Lubrication System Pressurized W et Sump T ransmission T ype Automatic PVT (Polaris V aria ble Tr ansmission) In-Line H-L-N-R-P Front Suspension Dual a-arm, 9" (22.9 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10" (25.
140 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles.
141 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all comp onents of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain (if equipped) for failure due to defects.
142 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND RE MEDIES The Polaris l imited warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling.
143 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND RE MEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfections caused.
144 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS AL L EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY .
145 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIF ICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA - TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries.
146 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied.
147 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited warranty is in addition to the Pola ris standard limited warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.
148 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts.
149 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
150 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMM ENTS.
151 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . . 26, 37 A Accessories . . . . . . . . . . . . . . . . . . . 129 Active Descent Control Fluid . . . 88-89 Active Desc ent Control System . . . . 39 ADC System . . . . . . . . . . . . . . . . . .
152 INDEX F Fluid Active Desce nt Control . . . . . . 88 ADC . . . . . . . . . . . . . . . . . . . 88-89 Brake . . . . . . . . . . . . . . . . . . . . 30 Demand Dri ve . . . . . . . . . . . . . 86 Engine Oil . . . . . . . . . . . . . . 81-83 Front Gear case .
153 INDEX O Oil Engine . . . . . . . . . . . . . . . . . 81-83 Rear Gearca se . . . . . . . . . . . . . . 87 Transmis sion . . . . . . . . . . . . 84-85 Oil Change Engine Oil and Filt er. . . . . . 82-83 Rear Gearca se . . . . . . . . . . . . . . 87 Transm ission .
154 INDEX S Safety Warnings . . . . . . . . . . . . . 10-21 Protective Apparel . . . . . . . . . . 12 Reverse Operati on . . . . . . . . . . 17 Skidding or Sli ding . . . . . . . . . 18 Slippery Terrain . . . . . . . . . . . . 17 Stalling While Climbing a Hill 16 Turning Improperly .
An important point after buying a device Polaris Sportsman 550 Touring 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 Sportsman 550 Touring 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 Sportsman 550 Touring EPS - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris Sportsman 550 Touring EPS you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris Sportsman 550 Touring EPS will certainly help you make a decision on the purchase.
If you already are a holder of Polaris Sportsman 550 Touring 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 Sportsman 550 Touring EPS.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris Sportsman 550 Touring EPS. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris Sportsman 550 Touring 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
