Owners Manual
Page 28
... turned to the desired gear. See page 33 for extended periods of the vehicle. FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is moving could cause transmission damage. Automatic Transmission Gear Selector The transmission gear selector is left unattended, always place the transmission in PARK. Belt Life To extend belt life, use low forward gear in PARK. The transmission is moving or idle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Stop the vehicle, release...
... turned to the desired gear. See page 33 for extended periods of the vehicle. FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is moving could cause transmission damage. Automatic Transmission Gear Selector The transmission gear selector is left unattended, always place the transmission in PARK. Belt Life To extend belt life, use low forward gear in PARK. The transmission is moving or idle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Stop the vehicle, release...
Owners Manual
Page 31
..., the vehicle is in 4X4, and the 4X4 Switch indicator icon in 4X4. There is ADC 4X4 controlled by the 4X4 switch. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is no limit to the length of time the vehicle may remain in the instrument cluster display will automatically disengage.
..., the vehicle is in 4X4, and the 4X4 Switch indicator icon in 4X4. There is ADC 4X4 controlled by the 4X4 switch. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is no limit to the length of time the vehicle may remain in the instrument cluster display will automatically disengage.
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
... fuel icon will automatically reduce engine power. 8. See page 36 for scheduled maintenance. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will flash. The vehicle should be brought to your authorized Polaris dealer for service. 13. See page 36 for 5-10 seconds. Drive at idle and high electrical load (lights, cooling fan, accessories) is inoperative. Do not operate the vehicle if this warning...
... fuel icon will automatically reduce engine power. 8. See page 36 for scheduled maintenance. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will flash. The vehicle should be brought to your authorized Polaris dealer for service. 13. See page 36 for 5-10 seconds. Drive at idle and high electrical load (lights, cooling fan, accessories) is inoperative. Do not operate the vehicle if this warning...
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 Current Shut...
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 Current Shut...
Owners Manual
Page 46
... miles (800 km), whichever comes first. Fill the fuel tank with vehicle operation and handling. 4. Pull only light loads. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at sustained idle. 5. Drive slowly at slower speeds during the break-in period as recommended. OPERATION Break-In Period Engine and Drivetrain Break-in of the clutches and drive belt...
... miles (800 km), whichever comes first. Fill the fuel tank with vehicle operation and handling. 4. Pull only light loads. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at sustained idle. 5. Drive slowly at slower speeds during the break-in period as recommended. OPERATION Break-In Period Engine and Drivetrain Break-in of the clutches and drive belt...
Owners Manual
Page 61
... the rear rack. Unsecured loads can alter vehicle handling and may be adversely affected, causing the vehicle to the hitch point designated for this vehicle. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the racks raises the center of gravity of these items must not exceed the maximum weight capacity. • REDUCE SPEED AND...
... the rear rack. Unsecured loads can alter vehicle handling and may be adversely affected, causing the vehicle to the hitch point designated for this vehicle. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the racks raises the center of gravity of these items must not exceed the maximum weight capacity. • REDUCE SPEED AND...
Owners Manual
Page 62
... to extend belt life. Always install Polaris-approved (or equivalent) accessories designed for your vehicle warranty. Cargo weight should be certified to tow a trailer on-road. • Do not tow any trailer on a grade steeper than 10 cm. Never install a hitch longer than 15°. • Always attach a towed load to maintain stable driving conditions. The combination of rear rack cargo weight and tongue weight must not exceed the maximum weight capacity...
... to extend belt life. Always install Polaris-approved (or equivalent) accessories designed for your vehicle warranty. Cargo weight should be certified to tow a trailer on-road. • Do not tow any trailer on a grade steeper than 10 cm. Never install a hitch longer than 15°. • Always attach a towed load to maintain stable driving conditions. The combination of rear rack cargo weight and tongue weight must not exceed the maximum weight capacity...
Owners Manual
Page 68
...12 M 12 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; pressure test system yearly 1000 (1600) Inspect; apply dielectric grease to connectors subjected to water, mud, etc. 1000 (1600) Inspect; replace as needed 1000 (1600) Inspect for leaks at tank cap, lines, filter, pump; replace worn parts 1000 (1600) Inspect; adjust Inspect...
...12 M 12 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; pressure test system yearly 1000 (1600) Inspect; apply dielectric grease to connectors subjected to water, mud, etc. 1000 (1600) Inspect; replace as needed 1000 (1600) Inspect for leaks at tank cap, lines, filter, pump; replace worn parts 1000 (1600) Inspect; adjust Inspect...
Owners Manual
Page 69
... lower control arms are subjected to severe use, grease zerks have been provided for additional lubrication 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 15-17 ft. Item Recommended Lubricant Capacity...
... lower control arms are subjected to severe use, grease zerks have been provided for additional lubrication 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 15-17 ft. Item Recommended Lubricant Capacity...
Owners Manual
Page 88
... transmission in an accident or overturn. Loose nuts could result in PARK. 2. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Always ensure that all nuts are torqued to come off during operation, which could cause a tire to specification. 75 ft. Wheel Type Aluminum Steel Nut Type Lug...
... transmission in an accident or overturn. Loose nuts could result in PARK. 2. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Always ensure that all nuts are torqued to come off during operation, which could cause a tire to specification. 75 ft. Wheel Type Aluminum Steel Nut Type Lug...
Owners Manual
Page 112
Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components • Radiator • Switches and controls • Transmission seals • Fuel system components • Cab and body panels • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to evaporate any water that will scratch the finish. 109 Polishing the Vehicle Polaris recommends...
Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components • Radiator • Switches and controls • Transmission seals • Fuel system components • Cab and body panels • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to evaporate any water that will scratch the finish. 109 Polishing the Vehicle Polaris recommends...
Owners Manual
Page 115
...; 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. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of fresh oil. 6. Run the engine for several times using electric start. Reinstall the spark plugs. Turn the engine over several minutes so the Carbon Clean reaches the injectors. Change fluids as...
...; 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. Stop the engine. 2. Remove the spark plugs and add 2-3 tablespoons of fresh oil. 6. Run the engine for several times using electric start. Reinstall the spark plugs. Turn the engine over several minutes so the Carbon Clean reaches the injectors. Change fluids as...
Owners Manual
Page 118
...). Slippage from failure to 7 times. With the transmission in neutral, advance the throttle to engage clutch. Use the throttle quickly and effectively. Belt slippage from a stopped brief, aggressive throttle application to about 1/8 throttle in gas tank or fuel lines. TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm...
...). Slippage from failure to 7 times. With the transmission in neutral, advance the throttle to engage clutch. Use the throttle quickly and effectively. Belt slippage from a stopped brief, aggressive throttle application to about 1/8 throttle in gas tank or fuel lines. TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm...
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
... Engine EHO850LE Displacement 850 cc Bore 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...
... Engine EHO850LE Displacement 850 cc Bore 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...
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...