Owners Manual
Page 27
...: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. See page 33 for extended periods and when operating uphill at a slow speed. 25 Belt Life To extend belt life, use low forward gear when pulling a heavy load at less than 11 km/h for EPS Warning Indicator information. FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering engages when the ignition key is...
...: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. See page 33 for extended periods and when operating uphill at a slow speed. 25 Belt Life To extend belt life, use low forward gear when pulling a heavy load at less than 11 km/h for EPS Warning Indicator information. FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering engages when the ignition key is...
Owners Manual
Page 35
... keep the battery charged. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will flash. Under / Over Voltage - FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4. All segments including the fuel icon will automatically reduce engine power. 8. The time will display for service. 13. Engine Overheat Warning - This indicator illuminates when the hazard switch or a turn signal switch is turned to indicate an overheated engine. See page...
... keep the battery charged. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will flash. Under / Over Voltage - FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4. All segments including the fuel icon will automatically reduce engine power. 8. The time will display for service. 13. Engine Overheat Warning - This indicator illuminates when the hazard switch or a turn signal switch is turned to indicate an overheated engine. See page...
Owners Manual
Page 40
... 1268 1347 1347 1071 1071 FMI 3 4 3 4 16 0 3 4 3 4 8 4 3 2 5 3 5 3 5 3 5 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 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is shorted to a wire at battery voltage. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart...
... 1268 1347 1347 1071 1071 FMI 3 4 3 4 16 0 3 4 3 4 8 4 3 2 5 3 5 3 5 3 5 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 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is shorted to a wire at battery voltage. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart...
Owners Manual
Page 41
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 550 Diagnostic Codes Condition Driver Circuit Grounded Shorted Load* Starter Enable Circuit Driver Circuit Short to B+ All Wheel Drive Control Driver Circuit Short to B+ System Power Voltage Too High Voltage Too low Throttle Safety Signal Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Active Descent Control System Driver Circuit Short to B+ Steering Over Current Shut Down Current Above Normal or Grounded Steering Excessive Current Error...
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 550 Diagnostic Codes Condition Driver Circuit Grounded Shorted Load* Starter Enable Circuit Driver Circuit Short to B+ All Wheel Drive Control Driver Circuit Short to B+ System Power Voltage Too High Voltage Too low Throttle Safety Signal Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Active Descent Control System Driver Circuit Short to B+ Steering Over Current Shut Down Current Above Normal or Grounded Steering Excessive Current Error...
Owners Manual
Page 42
... 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 43
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 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 Current Above Normal/Grounded Current Above Normal...
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 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 Current Above Normal/Grounded Current Above Normal...
Owners Manual
Page 45
... the fuel tank with vehicle operation and handling. 4. Add oil if necessary to familiarize yourself with gasoline. Drive slowly at 25 hours. 8. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Check the fluid level of the transmission after the first 25 hours of the clutches and drive belt will ensure a longer life and better performance. Avoid aggressive acceleration and high speed...
... the fuel tank with vehicle operation and handling. 4. Add oil if necessary to familiarize yourself with gasoline. Drive slowly at 25 hours. 8. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Check the fluid level of the transmission after the first 25 hours of the clutches and drive belt will ensure a longer life and better performance. Avoid aggressive acceleration and high speed...
Owners Manual
Page 61
...speed and cargo weight to extend belt life. 59 OPERATION Hauling Cargo 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on warning labels and in the specifications section of this manual. 2/3 1/3 2. Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. 4. NEVER exceed 10 MPH (16 km/h) when rear...80 km/h) when rear cargo loads are above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg). 5. Never exceed the weight capacities specified for your vehicle on the rear rack) and mounted as low as ...
...speed and cargo weight to extend belt life. 59 OPERATION Hauling Cargo 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on warning labels and in the specifications section of this manual. 2/3 1/3 2. Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. 4. NEVER exceed 10 MPH (16 km/h) when rear...80 km/h) when rear cargo loads are above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg). 5. Never exceed the weight capacities specified for your vehicle on the rear rack) and mounted as low as ...
Owners Manual
Page 62
... weight. Stop the engine. 2. Always block the rear wheels on an incline if possible. Remove the hitch from the vehicle when not towing a trailer. • If towing a load, reduce rear rack cargo weight by the amount of the vehicle. • FOREST 550 Unbraked Trailer Towing Capacity is 1786 lbs. (810 kg) based on EU Directive 76/432/EC. • FOREST 850 Unbraked Trailer Towing Capacity is approved OFF-ROAD ONLY. Maximum 10 cm Parking...
... weight. Stop the engine. 2. Always block the rear wheels on an incline if possible. Remove the hitch from the vehicle when not towing a trailer. • If towing a load, reduce rear rack cargo weight by the amount of the vehicle. • FOREST 550 Unbraked Trailer Towing Capacity is 1786 lbs. (810 kg) based on EU Directive 76/432/EC. • FOREST 850 Unbraked Trailer Towing Capacity is approved OFF-ROAD ONLY. Maximum 10 cm Parking...
Owners Manual
Page 73
...; Engine mounts Exhaust muffler/ pipe D Spark plug E Ź Wiring 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M D Clutches (drive and driven) D Front wheel bearings D Brake fluid Ź ADC fluid D Spark arrester D Valve clearance E D Toe adjustment Headlight aim 100 H 100 H 200 H 200 H 300 H 1000 H 12 M 12 M 24 M 24 M 36 M - 71 replace lines every two years 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; adjust when parts are replaced Adjust...
...; Engine mounts Exhaust muffler/ pipe D Spark plug E Ź Wiring 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M D Clutches (drive and driven) D Front wheel bearings D Brake fluid Ź ADC fluid D Spark arrester D Valve clearance E D Toe adjustment Headlight aim 100 H 100 H 200 H 200 H 300 H 1000 H 12 M 12 M 24 M 24 M 36 M - 71 replace lines every two years 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; adjust when parts are replaced Adjust...
Owners Manual
Page 93
... could result in PARK. 2. lbs. (102 Nm) 45 ft. Lower the vehicle to specification. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. lbs. (61 Nm) 91 lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Torque the wheel nuts to the ground. 5. lbs. (102 Nm...
... could result in PARK. 2. lbs. (102 Nm) 45 ft. Lower the vehicle to specification. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. lbs. (61 Nm) 91 lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Torque the wheel nuts to the ground. 5. lbs. (102 Nm...
Owners Manual
Page 97
... lamp. Hot components can result in PARK. 2. Headlamp: Reach under the bumper and remove the rubber cover from your skin leaves a residue, causing a hot spot that will shorten the life of control or an accident. Do not service the headlamps until they've cooled. MAINTENANCE Lights Poor lighting can cause serious burns to skin. Pull the harness plug to disconnect it .
... lamp. Hot components can result in PARK. 2. Headlamp: Reach under the bumper and remove the rubber cover from your skin leaves a residue, causing a hot spot that will shorten the life of control or an accident. Do not service the headlamps until they've cooled. MAINTENANCE Lights Poor lighting can cause serious burns to skin. Pull the harness plug to disconnect it .
Owners Manual
Page 98
Replace the entire signal lamp assembly. Place the transmission in reverse order. 96 Remove the lamp. 4. Install the new lamp. Rotate the turn signal light becomes inoperable, the lamps cannot be replaced. Reinstall all components in PARK. 2. Apply dielectric grease to remove it. 3. MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal socket counterclockwise to the socket. 5. Rear Turn Signal Lamp Replacement 1. Test the lamp for proper operation. 6.
Replace the entire signal lamp assembly. Place the transmission in reverse order. 96 Remove the lamp. 4. Install the new lamp. Rotate the turn signal light becomes inoperable, the lamps cannot be replaced. Reinstall all components in PARK. 2. Apply dielectric grease to remove it. 3. MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal socket counterclockwise to the socket. 5. Rear Turn Signal Lamp Replacement 1. Test the lamp for proper operation. 6.
Owners Manual
Page 120
... drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength) Fog the Engine 1. Change fluids as recommended in and around the piston rings and ring lands, coating the cylinder with the pre-measured amount of oil. 3. Run the engine for several times using electric start...
... drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength) Fog the Engine 1. Change fluids as recommended in and around the piston rings and ring lands, coating the cylinder with the pre-measured amount of oil. 3. Run the engine for several times using electric start...
Owners Manual
Page 123
... belt burning. Excessive throttle may cause loss of control and vehicle overturn. Belt slippage from a stopped brief, aggressive throttle application to 7 times. Inspect clutch seals for fouled plugs or foreign material in a new belt and/or clutch. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Improper break-in Always break in gas tank or fuel lines. Climbing over large Shift the transmission...
... belt burning. Excessive throttle may cause loss of control and vehicle overturn. Belt slippage from a stopped brief, aggressive throttle application to 7 times. Inspect clutch seals for fouled plugs or foreign material in a new belt and/or clutch. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Improper break-in Always break in gas tank or fuel lines. Climbing over large Shift the transmission...
Owners Manual
Page 128
SPECIFICATIONS SPORTSMAN Forest 550 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug / Gap Lubrication System Seat Steering System Transmission ...
SPECIFICATIONS SPORTSMAN Forest 550 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug / Gap Lubrication System Seat Steering System Transmission ...
Owners Manual
Page 129
SPECIFICATIONS SPORTSMAN Forest 550 Transmission and Gears Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Hitch Winch Headlight Taillights Brake Light Instrument Cluster High/Low/Neutral/Reverse/Parking 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Off Road Style, Deep Tread Design, size 26x1014 AT / 7 psi (48.3 kPa) Pressure Single-Control handlebar hydraulic disc on...
SPECIFICATIONS SPORTSMAN Forest 550 Transmission and Gears Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Hitch Winch Headlight Taillights Brake Light Instrument Cluster High/Low/Neutral/Reverse/Parking 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Off Road Style, Deep Tread Design, size 26x1014 AT / 7 psi (48.3 kPa) Pressure Single-Control handlebar hydraulic disc on...
Owners Manual
Page 130
SPECIFICATIONS SPORTSMAN Forest 850 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug Type / Gap Lubrication System Seat Steering System ...
SPECIFICATIONS SPORTSMAN Forest 850 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug Type / Gap Lubrication System Seat Steering System ...
Owners Manual
Page 131
SPECIFICATIONS SPORTSMAN Forest 850 Transmission and Gears Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Hitch Winch Headlight Taillights Brake Light Instrument Cluster High/Low/Neutral/Reverse/Parking 5.034:1 4.508:1 2.367:1 3.818:1 3.7:1 Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Off Road Style, Deep Tread Design, size 26x1014 AT / 7 psi (48.3 kPa) Pressure Single-Control handlebar hydraulic disc on all...
SPECIFICATIONS SPORTSMAN Forest 850 Transmission and Gears Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Hitch Winch Headlight Taillights Brake Light Instrument Cluster High/Low/Neutral/Reverse/Parking 5.034:1 4.508:1 2.367:1 3.818:1 3.7:1 Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Off Road Style, Deep Tread Design, size 26x1014 AT / 7 psi (48.3 kPa) Pressure Single-Control handlebar hydraulic disc on all...
Owners Manual
Page 142
... Transmission Oil ...76 Transporting the Vehicle ...120 Turn Signal Lamp, Front ...96 Turn Signal Lamp, Rear ...96 Turn Signal Switch ...21 Turning Around on a Hill ...56-57 Turning the Vehicle ...47 S Safety Labels ...16-19 Safety Training ...6 Severe Use ...68 Side Panel Removal...89 Sidehilling ...54 Signal Words ...4 Spark Arrester ...104 Spark Arrester Requirements...67 Spark Plug Inspection ...101-102 Spark Plug Recommendations...101 Spark Plugs ...101-102 Spring Adjustment, Shock ...100 Standard/Metric Display ...35 Starting the Engine ...45 Steering Assembly...
... Transmission Oil ...76 Transporting the Vehicle ...120 Turn Signal Lamp, Front ...96 Turn Signal Lamp, Rear ...96 Turn Signal Switch ...21 Turning Around on a Hill ...56-57 Turning the Vehicle ...47 S Safety Labels ...16-19 Safety Training ...6 Severe Use ...68 Side Panel Removal...89 Sidehilling ...54 Signal Words ...4 Spark Arrester ...104 Spark Arrester Requirements...67 Spark Plug Inspection ...101-102 Spark Plug Recommendations...101 Spark Plugs ...101-102 Spring Adjustment, Shock ...100 Standard/Metric Display ...35 Starting the Engine ...45 Steering Assembly...