Owners Manual
Page 28
... experience any shifting problems. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is left unattended, always place the transmission in PARK. EPS remains engaged whether the vehicle is moving or idle. Whenever the vehicle is turned to the desired gear. Automatic Transmission Gear Selector The transmission gear selector is locked when...
... experience any shifting problems. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is left unattended, always place the transmission in PARK. EPS remains engaged whether the vehicle is moving or idle. Whenever the vehicle is turned to the desired gear. Automatic Transmission Gear Selector The transmission gear selector is locked when...
Owners Manual
Page 31
... limit to ADC 4X4 before ascending or descending a hill. When the rear wheels regain traction, the demand drive unit will automatically engage any time the rear wheels lose traction. Always move the 4X4 switch to the length of time the vehicle may remain in the instrument cluster display will be visible. FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is ADC 4X4 controlled by the 4X4...
... limit to ADC 4X4 before ascending or descending a hill. When the rear wheels regain traction, the demand drive unit will automatically engage any time the rear wheels lose traction. Always move the 4X4 switch to the length of time the vehicle may remain in the instrument cluster display will be visible. FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is ADC 4X4 controlled by the 4X4...
Owners Manual
Page 33
... allows engine braking to ADC 4X4 before ascending or descending a hill. Always move the 4X4 switch to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (25 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
... allows engine braking to ADC 4X4 before ascending or descending a hill. Always move the 4X4 switch to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (25 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
Owners Manual
Page 36
... occurred in the fuel sensor circuit. Clock - Engine Overheat Warning - Drive at idle and high electrical load (lights, cooling fan, accessories) is inoperative. Do not operate the vehicle if this warning appears. This indicator illuminates when the hazard switch or a turn signal switch is turned on after starting the engine, the EPS system is applied. FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4. Refuel immediately. The vehicle should be brought to keep the battery charged. If the...
... occurred in the fuel sensor circuit. Clock - Engine Overheat Warning - Drive at idle and high electrical load (lights, cooling fan, accessories) is inoperative. Do not operate the vehicle if this warning appears. This indicator illuminates when the hazard switch or a turn signal switch is turned on after starting the engine, the EPS system is applied. FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4. Refuel immediately. The vehicle should be brought to keep the battery charged. If the...
Owners Manual
Page 42
... 523 523 523 651 651 1268 1268 1347 1347 1071 1071 520193 520193 1321 520207 168 168 520194 520194 520194 520194 520203 FMI 3 4 3 4 16 0 3 4 3 4 8 4 3 2 5 3 5 3 5 3 5 3 5 11 3 3 3 4 3 4 2 7 3 Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Gear Sensor Signal Injector 1 (MAG) Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System *Assumes unipolar configuration of stepper motor 39
... 523 523 523 651 651 1268 1268 1347 1347 1071 1071 520193 520193 1321 520207 168 168 520194 520194 520194 520194 520203 FMI 3 4 3 4 16 0 3 4 3 4 8 4 3 2 5 3 5 3 5 3 5 3 5 11 3 3 3 4 3 4 2 7 3 Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Gear Sensor Signal Injector 1 (MAG) Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System *Assumes unipolar configuration of stepper motor 39
Owners Manual
Page 43
... 523 523 651 651 651 652 652 652 1268 1269 1347 1347 1347 1071 1071 1071 634 634 634 634 1321 1321 1321 FMI 3 4 3 4 16 0 3 4 3 4 2 8 2 8 2 4 3 2 5 3 4 5 3 4 3 3 5 3 4 5 3 4 5 3 4 7 5 3 4 Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Vehicle Speed Signal Gear Sensor Signal Injector 1 (MAG) (SDI Part Load) Injector 2 (PTO) (SDI Part Load) Ignition Coil Primary Driver 1 (MAG) Ignition Coil Primary Driver 2 (PTO) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control Starter Enable Circuit 40
... 523 523 651 651 651 652 652 652 1268 1269 1347 1347 1347 1071 1071 1071 634 634 634 634 1321 1321 1321 FMI 3 4 3 4 16 0 3 4 3 4 2 8 2 8 2 4 3 2 5 3 4 5 3 4 3 3 5 3 4 5 3 4 5 3 4 7 5 3 4 Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Vehicle Speed Signal Gear Sensor Signal Injector 1 (MAG) (SDI Part Load) Injector 2 (PTO) (SDI Part Load) Ignition Coil Primary Driver 1 (MAG) Ignition Coil Primary Driver 2 (PTO) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control Starter Enable Circuit 40
Owners Manual
Page 44
.... FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 XP / XP EPS Diagnostic Codes Component Chassis Relay Condition Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Voltage Too High Voltage Too low Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Speed Too High Speed Too Low EPS Models Only Steering Over...
.... FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 XP / XP EPS Diagnostic Codes Component Chassis Relay Condition Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Voltage Too High Voltage Too low Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Speed Too High Speed Too Low EPS Models Only Steering Over...
Owners Manual
Page 46
.... Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Check the engine oil level on the daily pre-ride inspection checklist. Break in the clutches and belt by operating at sustained idle. 5. See page 67. Always exercise extreme caution whenever handling gasoline. 2. Do not operate at slower speeds during the break-in 1. Change both the oil and the filter...
.... Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Check the engine oil level on the daily pre-ride inspection checklist. Break in the clutches and belt by operating at sustained idle. 5. See page 67. Always exercise extreme caution whenever handling gasoline. 2. Do not operate at slower speeds during the break-in 1. Change both the oil and the filter...
Owners Manual
Page 61
... 8 km/h when towing loads in the rack or box and the load on the vehicle warning labels. • Never exceed the stated load capacity for your vehicle. • HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with loads that extend over rough or hilly terrain, reduce speed and cargo to the vehicle, include the weight of the vehicle. •...
... 8 km/h when towing loads in the rack or box and the load on the vehicle warning labels. • Never exceed the stated load capacity for your vehicle. • HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with loads that extend over rough or hilly terrain, reduce speed and cargo to the vehicle, include the weight of the vehicle. •...
Owners Manual
Page 62
... rear rack) and mounted as low as possible. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in the specifications section of 1/3 this vehicle. Always install Polaris-approved (or equivalent) accessories designed for your vehicle warranty. Use low forward gear when hauling or towing heavy cargo to the vehicle and will void your vehicle on warning labels and 2/3 in serious damage to extend belt...
... rear rack) and mounted as low as possible. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in the specifications section of 1/3 this vehicle. Always install Polaris-approved (or equivalent) accessories designed for your vehicle warranty. Use low forward gear when hauling or towing heavy cargo to the vehicle and will void your vehicle on warning labels and 2/3 in serious damage to extend belt...
Owners Manual
Page 68
... M 12 M 12 M 12 M 12 M E Throttle Body Intake Duct Drive belt Cooling system X Radiator X Cooling hoses X Engine oil change X Demand drive fluid X Rear gearcase oil X Transmission oil Fuel system X Engine mounts Exhaust muffler/ pipe Q Spark plug E X Wiring 1000 (1600) Inspect coolant strength seasonally; replace worn parts 1000 (1600) Inspect; replace as needed 2000 (3200) Change every two years 2000 (3200) Change every two years; replace as needed 1000 (1600) Inspect for leaks at tank cap, lines, filter, pump; every 25 hours if extreme use conditions (see page 74) 3000...
... M 12 M 12 M 12 M 12 M E Throttle Body Intake Duct Drive belt Cooling system X Radiator X Cooling hoses X Engine oil change X Demand drive fluid X Rear gearcase oil X Transmission oil Fuel system X Engine mounts Exhaust muffler/ pipe Q Spark plug E X Wiring 1000 (1600) Inspect coolant strength seasonally; replace worn parts 1000 (1600) Inspect; replace as needed 2000 (3200) Change every two years 2000 (3200) Change every two years; replace as needed 1000 (1600) Inspect for leaks at tank cap, lines, filter, pump; every 25 hours if extreme use conditions (see page 74) 3000...
Owners Manual
Page 69
... Drive Fluid (or GL5 8090 weight gear lube) DOT 4 Only Demand Drive Plus Fluid 10-14 ft. Page 74. MAINTENANCE Lubrication Guide Check and lubricate all components at Fluid Change 2 qt. (1.9 l) 2 qt. (1.9 l) 32 oz. (950 ml) 9.3 oz. (275 ml) 7.1 oz. (210 ml) ----Fill Plug Torque ----Drain Plug Torque Inspection Procedure 550 Engine Oil PS-4 PLUS Performance Synthetic 2W-50 850 Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Transmission Oil Synthetic SPORTSMAN XP Transmission Fluid...
... Drive Fluid (or GL5 8090 weight gear lube) DOT 4 Only Demand Drive Plus Fluid 10-14 ft. Page 74. MAINTENANCE Lubrication Guide Check and lubricate all components at Fluid Change 2 qt. (1.9 l) 2 qt. (1.9 l) 32 oz. (950 ml) 9.3 oz. (275 ml) 7.1 oz. (210 ml) ----Fill Plug Torque ----Drain Plug Torque Inspection Procedure 550 Engine Oil PS-4 PLUS Performance Synthetic 2W-50 850 Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Transmission Oil Synthetic SPORTSMAN XP Transmission Fluid...
Owners Manual
Page 88
... maintenance service. lbs. (102 Nm) 45 ft. Always ensure that all nuts are torqued to come off during operation, which could result in PARK. 2. Loose nuts could cause a tire to specification. 75 ft. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. Install the wheel nuts and finger-tighten them. 4. Lower the vehicle to specification. Torque the wheel...
... maintenance service. lbs. (102 Nm) 45 ft. Always ensure that all nuts are torqued to come off during operation, which could result in PARK. 2. Loose nuts could cause a tire to specification. 75 ft. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. Install the wheel nuts and finger-tighten them. 4. Lower the vehicle to specification. Torque the wheel...
Owners Manual
Page 91
... transmission in PARK. 3. MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be 5 cm below the mark on the wall. 6. The headlight should be approximately 7.6 m from the floor to the center of the headlight beam should be adjusted slightly upward or downward. 1. Position the vehicle on...headlight screws to adjust the beam upward or downward or to high beam. 5. The most intense part of the headlight and make a mark on the wall at the same height. 7.6 m X X 5 cm NOTE: Include rider weight on the seat when measuring. 4. Start the engine.Turn the headlight switch...
... transmission in PARK. 3. MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be 5 cm below the mark on the wall. 6. The headlight should be approximately 7.6 m from the floor to the center of the headlight beam should be adjusted slightly upward or downward. 1. Position the vehicle on...headlight screws to adjust the beam upward or downward or to high beam. 5. The most intense part of the headlight and make a mark on the wall at the same height. 7.6 m X X 5 cm NOTE: Include rider weight on the seat when measuring. 4. Start the engine.Turn the headlight switch...
Owners Manual
Page 115
... 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) Fog the Engine 1. Remove the spark plugs and add 2-3 tablespoons of gasoline. 112 Apply dielectric grease to specification. 4. Reinstall the spark plugs. To access the plug holes, use a section of clear 1/4" hose and a small plastic...
... 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) Fog the Engine 1. Remove the spark plugs and add 2-3 tablespoons of gasoline. 112 Apply dielectric grease to specification. 4. Reinstall the spark plugs. To access the plug holes, use a section of clear 1/4" hose and a small plastic...
Owners Manual
Page 118
... neutral, advance the throttle to about 1/8 throttle in gas tank or fuel lines. The belt will become more frequently. RPM/low ground speed Utility use fast, aggressive throttle application to 7 times. Excessive throttle may cause loss of control and vehicle overturn. Belt slippage from failure to engage clutch. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Slippage from water Dry out the PVT. Drive...
... neutral, advance the throttle to about 1/8 throttle in gas tank or fuel lines. The belt will become more frequently. RPM/low ground speed Utility use fast, aggressive throttle application to 7 times. Excessive throttle may cause loss of control and vehicle overturn. Belt slippage from failure to engage clutch. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Slippage from water Dry out the PVT. Drive...
Owners Manual
Page 123
SPECIFICATIONS SPORTSMAN 550 XP Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug / Gap Lubrication System Driving ...
SPECIFICATIONS SPORTSMAN 550 XP Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug / Gap Lubrication System Driving ...
Owners Manual
Page 125
... x Stroke 87 x 71.5 Alternator Output 475w @1200 RPM/Peak 575w Compression Ratio 11:1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1200 +/- 100 RPM Ignition Timing 6 +/- 5 BTDC @ 1200 RPM, Engine warm Spark Plug Type / Gap Champion REA6MC / .035 in. (0.9 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm...
... x Stroke 87 x 71.5 Alternator Output 475w @1200 RPM/Peak 575w Compression Ratio 11:1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1200 +/- 100 RPM Ignition Timing 6 +/- 5 BTDC @ 1200 RPM, Engine warm Spark Plug Type / Gap Champion REA6MC / .035 in. (0.9 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension Dual a-arm with 9.2" (23 cm) travel Rear Suspension Progressive rate with 10.2" (26 cm...
Owners Manual
Page 136
... Rack/Compartment ...27 Fuel Tank Cap...26 Fuse Replacement ...87 L Lights ...88-91 Headlight Beam Adjustment...88 Headlight Lamp ...89 Position Light Lamp ...89 Rear Turn Signal...90 Taillight/Brakelight/Worklight . 91 Low Beam Adjustment ...88 Low Range Use...101 Lubrication Guide ...66 M Maintenance Chart ...62-65 Metric/Standard Display ...35 Mirrors ...22 Mode Switch ...20 Modifications ...6 G Gear Selector...25 Gearcase Oil, Rear ...72-73 Gloves ...15 N Noise Emission Control System ...61 O Oil Engine...
... Rack/Compartment ...27 Fuel Tank Cap...26 Fuse Replacement ...87 L Lights ...88-91 Headlight Beam Adjustment...88 Headlight Lamp ...89 Position Light Lamp ...89 Rear Turn Signal...90 Taillight/Brakelight/Worklight . 91 Low Beam Adjustment ...88 Low Range Use...101 Lubrication Guide ...66 M Maintenance Chart ...62-65 Metric/Standard Display ...35 Mirrors ...22 Mode Switch ...20 Modifications ...6 G Gear Selector...25 Gearcase Oil, Rear ...72-73 Gloves ...15 N Noise Emission Control System ...61 O Oil Engine...
Owners Manual
Page 137
... Clutch Cover Alert...19 General Alert ...17 Hill Operation Alert...17 Hitch Capacity Label ...19 Rack Warning, Front and Rear 19 Reverse Override Warning ...17 Tire Pressure/Load Alert ...18 Safety Training ...6 Severe Use ...62 Side Panel Removal...83 Sidehilling ...54 Signal Words ...4 Spark Arrestor ...98 Spark Arrestor Requirements ...61 Spark Plug Inspection ...95-96 Spark Plug Recommendations...95 Spark Plugs ...95-96 Spring Adjustment, Shock ...94 Standard/Metric Display ...35 Starting the Engine ...45 Steering Assembly...
... Clutch Cover Alert...19 General Alert ...17 Hill Operation Alert...17 Hitch Capacity Label ...19 Rack Warning, Front and Rear 19 Reverse Override Warning ...17 Tire Pressure/Load Alert ...18 Safety Training ...6 Severe Use ...62 Side Panel Removal...83 Sidehilling ...54 Signal Words ...4 Spark Arrestor ...98 Spark Arrestor Requirements ...61 Spark Plug Inspection ...95-96 Spark Plug Recommendations...95 Spark Plugs ...95-96 Spring Adjustment, Shock ...94 Standard/Metric Display ...35 Starting the Engine ...45 Steering Assembly...