Owners Manual
Page 36
... or idle. Remove the fuel tank cap and add fuel. Use either leaded or unleaded gasoline with the engine speed above idle or while the vehicle is idling, move the lever to the desired gear. The fuel tank is turned to the ON position. Fuel Tank Cap 33 FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is designed to allow for EPS Warning Indicator information. Belt Life To extend belt...
... or idle. Remove the fuel tank cap and add fuel. Use either leaded or unleaded gasoline with the engine speed above idle or while the vehicle is idling, move the lever to the desired gear. The fuel tank is turned to the ON position. Fuel Tank Cap 33 FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is designed to allow for EPS Warning Indicator information. Belt Life To extend belt...
Owners Manual
Page 39
... four wheels when the vehicle descends a hill or incline. FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking 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...
... four wheels when the vehicle descends a hill or incline. FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking 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...
Owners Manual
Page 42
... or 4X4). 12. See your dealer for service. 39 Under / Over Voltage - Drive at idle and high electrical load (lights, cooling fan, accessories) is applied. Check Engine Warning Indicator - This area displays vehicle ground speed or engine rotational speed when the corresponding display is started. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will automatically reduce engine power. 8. It may also occur when the...
... or 4X4). 12. See your dealer for service. 39 Under / Over Voltage - Drive at idle and high electrical load (lights, cooling fan, accessories) is applied. Check Engine Warning Indicator - This area displays vehicle ground speed or engine rotational speed when the corresponding display is started. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will automatically reduce engine power. 8. It may also occur when the...
Owners Manual
Page 47
... 105 105 102 102 636 523 523 523 651 651 1268 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 44 Sportsman 550 XP / XP EPS Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too High Voltage Too Low Voltage Too High Voltage Too Low Temperature Too High...
... 105 105 102 102 636 523 523 523 651 651 1268 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 44 Sportsman 550 XP / XP EPS Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too High Voltage Too Low Voltage Too High Voltage Too Low Temperature Too High...
Owners Manual
Page 48
... Information Center Sportsman 550 XP / XP EPS Diagnostic Codes Component Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Condition Driver Circuit Grounded Shorted Load* Driver Circuit Short to B+ Driver Circuit Short to B+ Voltage Too High Voltage Too low Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Driver Circuit Short to B+ EPS Models Only Current Above Normal or Grounded Steering Excessive Current Error Current Above Normal or Grounded Steering Torque Sensor...
... Information Center Sportsman 550 XP / XP EPS Diagnostic Codes Component Idle Air Control Starter Enable Circuit All Wheel Drive Control System Power Throttle Safety Signal Condition Driver Circuit Grounded Shorted Load* Driver Circuit Short to B+ Driver Circuit Short to B+ Voltage Too High Voltage Too low Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Driver Circuit Short to B+ EPS Models Only Current Above Normal or Grounded Steering Excessive Current Error Current Above Normal or Grounded Steering Torque Sensor...
Owners Manual
Page 49
... 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 46
... 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 46
Owners Manual
Page 50
... 47 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...
... 47 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...
Owners Manual
Page 52
... all safety warnings outlined in 1. NOTICE: Excessive heat build-up during the first three hours of use the first two full tanks of gasoline. Vary the throttle positions. Pull only light loads. 7. Engine and Drivetrain Break-in the safety section of this owner's manual. See page 73. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. PVT Break-in (Clutches/Belt...
... all safety warnings outlined in 1. NOTICE: Excessive heat build-up during the first three hours of use the first two full tanks of gasoline. Vary the throttle positions. Pull only light loads. 7. Engine and Drivetrain Break-in the safety section of this owner's manual. See page 73. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. PVT Break-in (Clutches/Belt...
Owners Manual
Page 68
... warning labels and in serious damage to maintain stable driving conditions. Towing Loads Always attach a towed load to extend belt life. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. • The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of 1/3 this manual. Use...
... warning labels and in serious damage to maintain stable driving conditions. Towing Loads Always attach a towed load to extend belt life. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. • The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of 1/3 this manual. Use...
Owners Manual
Page 74
... 50 H 50 H 50 H 50 H 6M 6M 6M 6M 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 E Q Spark plug 1000 (1600) Inspect coolant strength seasonally; replace as needed 50 H 50 H 100 H 100 H 100 H 100 H 100 H 6M 6M 6M 12 M 12 M 12 M 12 M 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M X Wiring Q Clutches (drive 100 H 100 H 200 H 200 H 300 H 1000 H 12...
... 50 H 50 H 50 H 50 H 6M 6M 6M 6M 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 E Q Spark plug 1000 (1600) Inspect coolant strength seasonally; replace as needed 50 H 50 H 100 H 100 H 100 H 100 H 100 H 6M 6M 6M 12 M 12 M 12 M 12 M 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M X Wiring Q Clutches (drive 100 H 100 H 200 H 200 H 300 H 1000 H 12...
Owners Manual
Page 75
... Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Transmission Oil Synthetic Sportsman XP Transmission Fluid 15-17 ft. Page 76. (14-19 Nm) (14-19 Nm) Demand Drive Demand Drive Fluid (Front LT Premium Gearcase) Fluid Rear Gearcase Oil ATV Angle Drive Fluid (or GL5 8090 weight gear lube) DOT 4 Only Polaris ADC Fluid 9.3 oz. (275 ml) 7.1 oz. (210 ml) 8-10 ft. lbs. Page 80. Polaris Premium Grease fittings (3 pumps maximum) every 500 miles, U-Joint...
... Engine Oil PS-4 PLUS Performance Synthetic 2W-50 Transmission Oil Synthetic Sportsman XP Transmission Fluid 15-17 ft. Page 76. (14-19 Nm) (14-19 Nm) Demand Drive Demand Drive Fluid (Front LT Premium Gearcase) Fluid Rear Gearcase Oil ATV Angle Drive Fluid (or GL5 8090 weight gear lube) DOT 4 Only Polaris ADC Fluid 9.3 oz. (275 ml) 7.1 oz. (210 ml) 8-10 ft. lbs. Page 80. Polaris Premium Grease fittings (3 pumps maximum) every 500 miles, U-Joint...
Owners Manual
Page 93
... a tire to specification. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. lbs. (61 Nm) 90 lbs. (102 Nm) Cast Aluminum Steel 45 ft. Install the wheel nuts and finger-tighten them. 5. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. WARNING! Lower the vehicle to specification...
... a tire to specification. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. lbs. (61 Nm) 90 lbs. (102 Nm) Cast Aluminum Steel 45 ft. Install the wheel nuts and finger-tighten them. 5. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. WARNING! Lower the vehicle to specification...
Owners Manual
Page 96
... lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. CAUTION! Be sure to cool before servicing. 3. Oil from the speedometer. Hot components can result in the housing. 6. Make sure the tab on the wiring. 4. If fingers do touch a lamp, clean it . 5. Unplug the headlamp from the wiring harness...
... lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. CAUTION! Be sure to cool before servicing. 3. Oil from the speedometer. Hot components can result in the housing. 6. Make sure the tab on the wiring. 4. If fingers do touch a lamp, clean it . 5. Unplug the headlamp from the wiring harness...
Owners Manual
Page 97
... Include rider weight on the wall. Position the vehicle on the right side of the headlight beam should be adjusted slightly upward or downward. The adjustment screw is Adjustment located on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to make a mark on the wall. Start the engine. MAINTENANCE Lights High Beam Adjustment The headlight beam can...
... Include rider weight on the wall. Position the vehicle on the right side of the headlight beam should be adjusted slightly upward or downward. The adjustment screw is Adjustment located on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to make a mark on the wall. Start the engine. MAINTENANCE Lights High Beam Adjustment The headlight beam can...
Owners Manual
Page 99
Reverse the steps to remove the o-rings from the locking tabs. 6. Remove the five (5) headlight pod screws. 2. Pull the headlight housing up and out of the pod. 7. Unplug the headlamp from the speedometer. 3. Use a small screwdriver to install the new housing and reassemble the pod. 96 Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 4. MAINTENANCE Lights Headlight Housing Replacement 1. Carefully pull the assembly up to release it from the headlight mounting tabs. 5.
Reverse the steps to remove the o-rings from the locking tabs. 6. Remove the five (5) headlight pod screws. 2. Pull the headlight housing up and out of the pod. 7. Unplug the headlamp from the speedometer. 3. Use a small screwdriver to install the new housing and reassemble the pod. 96 Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 4. MAINTENANCE Lights Headlight Housing Replacement 1. Carefully pull the assembly up to release it from the headlight mounting tabs. 5.
Owners Manual
Page 100
Reinstall the harness assembly into the headlight assembly. 4. Turn the lamp counterclockwise to secure the headlamp. 1. Test the light for proper operation. MAINTENANCE Lights Lower Headlamp Replacement 1. Remove the harness connector from the headlight assembly. 2. Reinstall the harness connector. 5. Turn the headlight harness clockwise to remove it. 3. Harness Taillight/Brakelight Lamp Replacement Taillight 97 Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the back of the light assembly. 2. Install the...
Reinstall the harness assembly into the headlight assembly. 4. Turn the lamp counterclockwise to secure the headlamp. 1. Test the light for proper operation. MAINTENANCE Lights Lower Headlamp Replacement 1. Remove the harness connector from the headlight assembly. 2. Reinstall the harness connector. 5. Turn the headlight harness clockwise to remove it. 3. Harness Taillight/Brakelight Lamp Replacement Taillight 97 Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the back of the light assembly. 2. Install the...
Owners Manual
Page 118
...; 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. Torque to the inside of each spark plug cap and reinstall the caps onto the plugs. 5. Turn the engine over several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. If Polaris fuel system additive...
...; 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. Torque to the inside of each spark plug cap and reinstall the caps onto the plugs. 5. Turn the engine over several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. If Polaris fuel system additive...
Owners Manual
Page 124
.../low ground speed Utility use fast, aggressive throttle application to engage clutch. Excessive throttle may cause loss of control and vehicle overturn. See page 104. Improper break-in Always break in gas tank or fuel lines. Drive at a higher speed or use fast, objects from water Dry out the PVT. position WARNING! Belt slippage from a stopped brief, aggressive throttle application to engage clutch. Poor engine performance Check for fouled plugs...
.../low ground speed Utility use fast, aggressive throttle application to engage clutch. Excessive throttle may cause loss of control and vehicle overturn. See page 104. Improper break-in Always break in gas tank or fuel lines. Drive at a higher speed or use fast, objects from water Dry out the PVT. position WARNING! Belt slippage from a stopped brief, aggressive throttle application to engage clutch. Poor engine performance Check for fouled plugs...
Owners Manual
Page 129
SPECIFICATIONS Sportsman 550 XP / XP EPS 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...
SPECIFICATIONS Sportsman 550 XP / XP EPS 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...
Owners Manual
Page 131
SPECIFICATIONS Sportsman 850 XP / XP EPS 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 Type / Gap Lubrication ...
SPECIFICATIONS Sportsman 850 XP / XP EPS 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 Type / Gap Lubrication ...