Owners Manual
Page 1
Operation is an adult vehicle only. It contains important safety information. PMS 419 Sportsman Touring 550 EPS Sportsman Touring 850 EPS for those under 16 years of age. This is prohibited for Maintenance and Safety Owner's Manual Read this manual carefully.
Operation is an adult vehicle only. It contains important safety information. PMS 419 Sportsman Touring 550 EPS Sportsman Touring 850 EPS for those under 16 years of age. This is prohibited for Maintenance and Safety Owner's Manual Read this manual carefully.
Owners Manual
Page 35
... seven miles per hour for extended periods and when operating uphill at a slow speed. 33 When the engine is left unattended, always place the transmission in PARK and lock the parking brake. Whenever the ATV is idling, move the lever to a complete stop. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is located on the right side of the vehicle. FEATURES AND CONTROLS Automatic Transmission Gear...
... seven miles per hour for extended periods and when operating uphill at a slow speed. 33 When the engine is left unattended, always place the transmission in PARK and lock the parking brake. Whenever the ATV is idling, move the lever to a complete stop. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is located on the right side of the vehicle. FEATURES AND CONTROLS Automatic Transmission Gear...
Owners Manual
Page 41
... switch to neutral or park 39 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 (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
... switch to neutral or park 39 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 (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
Owners Manual
Page 43
.... FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps Lamp Indicates Vehicle Speed Over Temperature Condition When standard mode is selected, speed displays in miles per hour. See your dealer. 41 Neutral High Beam This lamp illuminates when the transmission is in kilometers per hour. When metric mode is selected, speed displays in neutral and the ignition key is set to indicate an overheated engine...
.... FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps Lamp Indicates Vehicle Speed Over Temperature Condition When standard mode is selected, speed displays in miles per hour. See your dealer. 41 Neutral High Beam This lamp illuminates when the transmission is in kilometers per hour. When metric mode is selected, speed displays in neutral and the ignition key is set to indicate an overheated engine...
Owners Manual
Page 45
... (switch is active. Tip: If the fuel icon fails to your dealer. 3. If the engine is activated. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Gear Display - H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2. All segments including the fuel icon will display for scheduled maintenance. FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. See...
... (switch is active. Tip: If the fuel icon fails to your dealer. 3. If the engine is activated. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Gear Display - H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2. All segments including the fuel icon will display for scheduled maintenance. FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. See...
Owners Manual
Page 50
... 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 48 SPORTSMAN 550 Touring 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 48 SPORTSMAN 550 Touring 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 51
... Display Code Definitions SPORTSMAN 550 Touring 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...
... Display Code Definitions SPORTSMAN 550 Touring 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 52
... 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 50
... 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 50
Owners Manual
Page 53
...Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed 51 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 850 Touring 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...
...Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed 51 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 850 Touring 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...
Owners Manual
Page 55
... allows room to maintain the level between the safe and add marks. 3. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at first. See page 35. See page 93. Fill the fuel tank with vehicle operation and handling. 4. Pull only light loads. 7. PVT Break-in (Clutches/Belt) A proper break-in 1. Pull only...
... allows room to maintain the level between the safe and add marks. 3. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at first. See page 35. See page 93. Fill the fuel tank with vehicle operation and handling. 4. Pull only light loads. 7. PVT Break-in (Clutches/Belt) A proper break-in 1. Pull only...
Owners Manual
Page 75
.../h) while carrying a passenger. 6. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 10. Cargo weight should be affected. 73 Balance, handling, and control may be evenly distributed (1/3 on the front rack and 2/3 on warning labels and in 1/3 the specifications section of this manual. 2. Never exceed the weight capacities specified for your 2/3 ATV on the rear rack) and mounted as low...
.../h) while carrying a passenger. 6. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 10. Cargo weight should be affected. 73 Balance, handling, and control may be evenly distributed (1/3 on the front rack and 2/3 on warning labels and in 1/3 the specifications section of this manual. 2. Never exceed the weight capacities specified for your 2/3 ATV on the rear rack) and mounted as low...
Owners Manual
Page 76
... POLARIS ATV. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the hitch point. Never install automotive accessories on inclines. 550 Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 1500 lbs. (680 kg) 150 lbs. (68 kg) 850 1500 lbs. (680 kg) 150 lbs. (68 kg) 74 If towing a load, reduce rear rack cargo weight...
... POLARIS ATV. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the hitch point. Never install automotive accessories on inclines. 550 Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 1500 lbs. (680 kg) 150 lbs. (68 kg) 850 1500 lbs. (680 kg) 150 lbs. (68 kg) 74 If towing a load, reduce rear rack cargo weight...
Owners Manual
Page 93
... fittings Engine oil change 100 H 6M 1000 (1600) Change the oil and filter Demand drive fluid 100 H 12 M 1000 (1600) Change fluid (normal use) Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid Transmission oil 100 H 12 M 1000 (1600) Change fluid Fuel system 100 H 12 M 1000 (1600) Check for wear, routing, security; adjust (16000) Inspect periodically; replace as needed Item Maintenance Interval Remarks Ź D E Ź Wiring D Clutches (drive and driven) D Front wheel bearings D Brake fluid Ź ADC fluid D Spark arrester D Valve...
... fittings Engine oil change 100 H 6M 1000 (1600) Change the oil and filter Demand drive fluid 100 H 12 M 1000 (1600) Change fluid (normal use) Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid Transmission oil 100 H 12 M 1000 (1600) Change fluid Fuel system 100 H 12 M 1000 (1600) Check for wear, routing, security; adjust (16000) Inspect periodically; replace as needed Item Maintenance Interval Remarks Ź D E Ź Wiring D Clutches (drive and driven) D Front wheel bearings D Brake fluid Ź ADC fluid D Spark arrester D Valve...
Owners Manual
Page 114
... Lug Nut Lug Nut Nut Torque 75 ft. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Torque the wheel nuts to the ground. 6. WARNING! lbs. (102 Nm) Cast Aluminum Steel 45 ft. Lock the parking brake. 3. Lower the vehicle to specification. lbs. (102 Nm) 45 ft. MAINTENANCE Tires Wheel Installation 1. Install the wheel...
... Lug Nut Lug Nut Nut Torque 75 ft. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Torque the wheel nuts to the ground. 6. WARNING! lbs. (102 Nm) Cast Aluminum Steel 45 ft. Lock the parking brake. 3. Lower the vehicle to specification. lbs. (102 Nm) 45 ft. MAINTENANCE Tires Wheel Installation 1. Install the wheel...
Owners Manual
Page 117
... headlamps promptly. Oil from the speedometer. Unplug the headlamp from the wiring harness. Make sure the tab on the wiring. 4. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. If fingers do touch a lamp, clean it . 5. CAUTION! Be sure to remove it with bare fingers. MAINTENANCE Lights Poor lighting can cause burns to cool before servicing. 3. Allow...
... headlamps promptly. Oil from the speedometer. Unplug the headlamp from the wiring harness. Make sure the tab on the wiring. 4. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. If fingers do touch a lamp, clean it . 5. CAUTION! Be sure to remove it with bare fingers. MAINTENANCE Lights Poor lighting can cause burns to cool before servicing. 3. Allow...
Owners Manual
Page 121
... pull the harness assembly away from the back of the light assembly. 2. Test the light for proper operation. Reinstall the harness assembly into the headlight assembly. 4. Turn the lamp counter-clockwise to secure the headlamp. 1. Turn the headlight harness clockwise to remove it. 3. Reinstall the harness connector. 5. MAINTENANCE Lights Lower Headlamp Replacement 1. Install the new lamp. 4. Harness Taillight/Brakelight Lamp Replacement Connector Lamp 119 Remove the harness connector from the headlight assembly. 2. Remove...
... pull the harness assembly away from the back of the light assembly. 2. Test the light for proper operation. Reinstall the harness assembly into the headlight assembly. 4. Turn the lamp counter-clockwise to secure the headlamp. 1. Turn the headlight harness clockwise to remove it. 3. Reinstall the harness connector. 5. MAINTENANCE Lights Lower Headlamp Replacement 1. Install the new lamp. 4. Harness Taillight/Brakelight Lamp Replacement Connector Lamp 119 Remove the harness connector from the headlight assembly. 2. Remove...
Owners Manual
Page 138
... 88. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change fluids as recommended. Air Filter / Air Box 1. See page 113. 2. See page 134. Clean the Exterior Make any time the fluid looks dark or contaminated) • Coolant (test strength/fill) 136 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period...
... 88. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change fluids as recommended. Air Filter / Air Box 1. See page 113. 2. See page 134. Clean the Exterior Make any time the fluid looks dark or contaminated) • Coolant (test strength/fill) 136 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period...
Owners Manual
Page 153
In the country where your product was purchased, Warranty and Service Bulletin repairs may also be authorized to perform the warranty repair. If you move to POLARIS in your new country. Upon residence verification, the servicing dealer will be denied. You may be done by an authorized POLARIS dealer. If you move: If you move to another country, be required...
In the country where your product was purchased, Warranty and Service Bulletin repairs may also be authorized to perform the warranty repair. If you move to POLARIS in your new country. Upon residence verification, the servicing dealer will be denied. You may be done by an authorized POLARIS dealer. If you move: If you move to another country, be required...
Owners Manual
Page 155
... the POLARIS standard limited warranty for a period of 250 hours of engine operation, 2500 kilometers (3100 miles) of any engine parts related to meet these regulations. Repairing or replacing other paid warranty extension. This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it to fail to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation...
... the POLARIS standard limited warranty for a period of 250 hours of engine operation, 2500 kilometers (3100 miles) of any engine parts related to meet these regulations. Repairing or replacing other paid warranty extension. This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it to fail to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation...
Owners Manual
Page 162
... Riding Gear ...8-9 S Safe Operation Practices ...55 Safety Labels ...22-25 Safety Training ...7 Safety Warnings...10-21 Safety, Winch Maintenance...86 Seat Backrest Adjustments ...107 Seat Removal, Operator...108 Seat Removal, Passenger ...107 Seat Suspension, Passenger ...108 Seats...107-108 Severe Use ...88 Shock Loading the Winch ...84-85 Side Panel Removal...109 Sidehilling ...64 Spark Arrester ...123 Spark Plugs ...120-121 Specifications...144-147 Speedometer ...40 Spring Adjustment, Rear Shock . . 131 Starting the Engine ...57 Steering Assembly ...102...
... Riding Gear ...8-9 S Safe Operation Practices ...55 Safety Labels ...22-25 Safety Training ...7 Safety Warnings...10-21 Safety, Winch Maintenance...86 Seat Backrest Adjustments ...107 Seat Removal, Operator...108 Seat Removal, Passenger ...107 Seat Suspension, Passenger ...108 Seats...107-108 Severe Use ...88 Shock Loading the Winch ...84-85 Side Panel Removal...109 Sidehilling ...64 Spark Arrester ...123 Spark Plugs ...120-121 Specifications...144-147 Speedometer ...40 Spring Adjustment, Rear Shock . . 131 Starting the Engine ...57 Steering Assembly ...102...