Polaris sportsman 850 touring мануал

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5. Sportsman 850 Touring EPS
6. Owner’s manual for maintenance and safety

• Page 1
  PMS 419 Sportsman 550 Touring Sportsman 850 Touring Owner’s Manual for Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
• Page 2
  WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800- 342-3764 for assistance.
• Page 3
  The text is printed on 100% recycled with 40% post-consumer waste (PCW).
• Page 4
  READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922730 Rev 01 Printed in USA *9922730…
• Page 5
  • Victory Motorcycles ® • Low emission vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever pro-…
• Page 6
  POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc. Copyright 2010 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

• Page 7: Table Of Contents

  Troubleshooting ……127 POLARIS Products ……131 Specifications.

• Page 8: Introduction

  INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

• Page 9
  Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

• Page 10: Vehicle Identification Numbers

  Record your vehicle’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys.

• Page 11: Safety

  ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members.

• Page 12: Safe Riding Gear

  Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

• Page 13: Equipment Modifications

  Riding pants with kneepads and a jersey with shoulder pads provide the best protection. Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

• Page 14: Safety Warnings

  SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

• Page 15: Handling Gasoline

  SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Page 16: Protective Apparel

  SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

• Page 17: Operating On Pavement

  SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use.

• Page 18: Physical Control Of The Atv

  SAFETY Safety Warnings Physical Control of the ATV Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If a person’s feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.

• Page 19: Improper Hill Climbing

  SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner’s manual. See page 63. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.

• Page 20: Stalling While Climbing A Hill

  SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

• Page 21: Operating On Slippery Terrain

  SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.

• Page 22: Improper Tire Maintenance

  SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner’s manual and on safety labels.

• Page 23: Operating Through Deep Water

  SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it’s unavoidable to enter water that exceeds the recommended maximum depth (see page 68):…

• Page 24: Poor Visibility

  SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the…

• Page 25: Operating A Damaged Atv

  SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills.

• Page 26: Age 16 Warning

  If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Reverse Override Warning/AWD Caution…

• Page 27
  SAFETY Safety Labels and Locations General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: •…
• Page 28
  SAFETY Safety Labels and Locations Passenger Warning/Discretionary Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL Passenger Warning Discretionary Warning NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.

• Page 29: Clutch Cover Warning

  SAFETY Safety Labels and Locations Rack/Box Rack/Box Warning Warning Hitch Capacity Label Clutch Cover Warning (under seat) Rack/Box Warning WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. •…

• Page 30: Features And Controls

  FEATURES AND CONTROLS Switches Headlight Switch Switch Mode/Reverse Override Switch Main Key Engine Switch Stop Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, release the throttle and depress the override button.

• Page 31: Engine Stop Switch

  FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. Move the stop switch to the RUN position before attempt- ing to start the engine. The engine will not start or run when the switch is off.

• Page 32: Throttle Lever

  The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with POLARIS Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle.

• Page 33: Brake Lever

  FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes.

• Page 34
  FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

• Page 35: Parking Brake

  FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4.

• Page 36
  FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
• Page 37
  FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear Gear selector is located on the Selector right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop.

• Page 38: Passenger Seat

  Test the seat latch by attempting to pull the seat upward. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your POLARIS dealer for ser- vice. See pages 95-96 for passenger seat adjustment procedures.

• Page 39: Fuel Tank

  FEATURES AND CONTROLS Fuel Tank Always refuel with the engine Fuel Tank stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap and add fuel. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

• Page 40
  FEATURES AND CONTROLS Front Storage Box Open the front storage box to access the under-compartment area. 1. Release the front box cover latches and lift the cover. 2. Release the plunger latches that secure the box to the frame. 3. Close the cover and Cover Latches Plunger Latches lift the unlatched…

• Page 41: All Wheel Drive System

  FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is ADC 4X4 controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

• Page 42: Engaging 4X

  FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off.

• Page 43: Engaging Active Descent Control

  FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four of the follow- ing conditions occur:…

• Page 44: Instrument Cluster

  FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.

• Page 45: Indicator Lamps

  ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

• Page 46
  If this occurs, take the ATV to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.

• Page 47: Rider Information Center

  FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. Gear Display — This area displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park — = Gear Signal Error (or shifter between gears) 2.

• Page 48
  FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehi- cle speed lockout function and can be used at any operating speed.
• Page 49
  FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or dis- charged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
• Page 50
  Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
• Page 51
  4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See pages 48-51 for code definitions and failure descriptions. Please see your Polaris dealer for all major repairs.
• Page 52
  FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
• Page 53
  FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 550 Touring Diagnostic Codes Component Condition Idle Air Control Driver Circuit Grounded 520193 Shorted Load* 520193 Starter Enable Circuit Driver Circuit Short to B+ 1321 All Wheel Drive Control Driver Circuit Short to B+ 520207 System Power Voltage Too High…
• Page 54
  FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 850 Touring Diagnostic Codes Component Condition Throttle Position Sensor Voltage Too High Voltage Too Low Engine Temperature Sensor Voltage Too High Voltage Too Low Temperature Too High Engine Overheat Shutdown…
• Page 55
  FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 850 Touring Diagnostic Codes Component Condition Chassis Relay Driver Circuit Open/Grounded 520208 Driver Circuit Short to B+ 520208 Driver Circuit Grounded 520208 All Wheel Drive Control Driver Circuit Open/Grounded 520207…

• Page 56: Operation

  Break-In Period The break-in period for your new POLARIS ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gaso- line. No single action on your part is as important as following the pro- cedures for a proper break-in.

• Page 57
  OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 35. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 81. Add oil if necessary to maintain the level between the safe and add marks. 3.
• Page 58
  OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it’s in safe operating condition. Item Remarks Page Passenger seat latch…

• Page 59: Safe Operation Practices

  OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle.

• Page 60: Trail Etiquette

  Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your POLARIS dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

• Page 61: Starting The Engine

  OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.

• Page 62: Driving Procedures

  OPERATION Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 54. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.

• Page 63: Turning The Vehicle

  OPERATION Turning the Vehicle Both rear wheels drive equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2.

• Page 64: Driving With A Passenger

  OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfort- ably and safely reach the grab handles and footrests. 2.

• Page 65
  OPERATION Driving with a Passenger 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a pas- senger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 64. 13.

• Page 66: Driving On Slippery Surfaces

  OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.

• Page 67: Driving Uphill

  OPERATION Driving Uphill 15° Maximum Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

• Page 68
  OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.

• Page 69: Driving Downhill

  OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

• Page 70
  OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)
• Page 71
  OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Leave the transmission in forward and shut off the engine. 4.

• Page 72: Driving Through Water

  OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have Maximum Depth gradual inclines.

• Page 73: Driving Over Obstacles

  OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3.

• Page 74: Driving In Reverse

  OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

• Page 75: Parking On An Incline

  OPERATION Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

• Page 76: Hauling Cargo

  OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never carry cargo on the rear rack when operating the ATV in the 2-up mode with a passenger.

• Page 77
  OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications sec- tion of this manual. 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.

• Page 78: Towing Loads

  ATV warranty. Never install a hitch longer than 4″ (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use. Maximum Towing Capacities Do not exceed maximum towing capacities. Avoid towing on inclines.

• Page 79: Emission Control Systems

  CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrestor that was tested and quali- fied to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

• Page 80: Maintenance

  Inspect, clean, lubricate, adjust and replace parts as nec- essary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 144.

• Page 81: Maintenance Chart Key

  Improperly performing the procedures marked with a n could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key Perform more often for vehicles subjected to severe use.

• Page 82
  50 H 500 (800) Lubricate Front suspension 50 H 500 (800) Lubricate Rear suspension 50 H 500 (800) Lubricate Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized POLARIS dealer perform these services.
• Page 83
  MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) E Throttle Cable/ 50 H 500 (800) Inspect; adjust; lubricate; ETC Switch replace if necessary E Throttle Body 50 H 500 (800) Inspect duct for proper seal- Intake Duct ing/air leaks Drive belt…

• Page 84: Lubrication Guide

  DOT 4 Only Page 30. ADC Fluid Demand Drive Page 87. PLUS Fluid Front Prop POLARIS Grease fittings (3 pumps maximum) every 500 miles, Shaft Yoke Premium U-Joint before long periods of storage, or after pressure Lube washing or submerging.

• Page 85: Engine Oil

  Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 80 for fluid recommendations, capacities and plug torques. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer’s recommenda- tions for ambient temperature operation.

• Page 86: Oil And Filter Change

  MAINTENANCE Engine Oil Oil and Filter Change See the table on page 80 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 76. Always change the oil filter whenever changing oil.

• Page 87
  Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil fil- ter wrench (available from your POLARIS dealer), turn the filter counter-clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

• Page 88: Transmission Oil

  MAINTENANCE Transmission Oil POLARIS recommends the use of POLARIS AGL PLUS Transmission Fluid for this transmission. See the table on page 80 for fluid recom- mendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 76.

• Page 89
  MAINTENANCE Transmission Oil Oil Change 1. Remove the footwell. 2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. 3. Clean and reinstall the drain plug. Torque to specification. 4. Remove the fill plug. Add the proper amount of the recommended oil.
• Page 90
  Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginning on page 76. See page 131 for the part numbers of POLARIS products. Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
• Page 91
  We recommend the use of POLARIS Demand Drive Plus Fluid for the ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 131 for the part numbers of POLARIS products. NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.

• Page 92: Fluid Change

  MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level Bleeder surface. Before performing the Screw fluid change, allow the vehicle to sit for at least 30 minutes. Bleeder 2. Thoroughly clean the areas Valve Screw around and on the ADC reservoir and bleeder valves…

• Page 93: Rear Gearcase Oil

  Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 76. See page 131 for the part numbers of POLARIS products. The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.

• Page 94: Steering Assembly

  Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Premium 60/40 anti- freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is already premixed and ready to use.

• Page 95
  MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. See page 1. View the fluid level in the bottle. 2.

• Page 96: Radiator Coolant

  Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair.

• Page 97: Hand Brake

  MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.

• Page 98: Toe Alignment

  1.5 mm more than the front measurement on each side of the vehicle to obtain the recommended 0″ to 1/8″ (0-3 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service.

• Page 99
  MAINTENANCE Seats Passenger Seat Removal 1. Pull the latch at the rear of the seat. 2. Pivot the rear of the seat upward and remove the front legs of the seat base from the frame. 3. To reinstall the seat, position the front legs of the seat base under the frame.
• Page 100
  MAINTENANCE Seats Passenger Seat Suspension 1. Remove the passenger seat. 2. Remove the fastener retaining the passenger seat shock to the passenger seat support. 3. Pivot the seat support upward to access the lower shock fastener. Remove the lower shock fastener. 4.
• Page 101
  MAINTENANCE Side Panel/Footwell Removal 1. Remove the seat before removing a side panel. 2. To remove a side panel or footwell, remove the fasteners securing it to the frame. Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Hex Head Screw Plastic Rivet…

• Page 102: Tire Tread Depth

  MAINTENANCE Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

• Page 103: Front Wheel Hub Tightening

  Tires Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized POLARIS dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK.

• Page 104: Wheel Installation

  MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5.

• Page 105: Air Filter

  MAINTENANCE Air Filter 1. Remove the seat. Screws 2. Remove the air box cover screws, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

• Page 106: Fuse Replacement

  MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short cir- cuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.

• Page 107: Headlight Lamp Replacement

  MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean head- lights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fin- gers.

• Page 108: High Beam Adjustment

  MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 25 ft.

• Page 109
  MAINTENANCE Lights Low Beam Adjustment Phillips Screw The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw.

• Page 110: Headlight Housing Replacement

  MAINTENANCE Lights Headlight Housing Replacement 1. Remove the five (5) headlight pod screws. 2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 3. Unplug the headlamp from the wiring harness. 4. Use a small screwdriver to remove the o-rings from the headlight mounting tabs.

• Page 111: Lower Headlamp Replacement

  MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. Harness 4.

• Page 112: Spark Plugs

  Refer to the specifications section beginning on page 132 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Torque Specification Plug Condition New Spark Plug 9-11 ft.

• Page 113
  MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white.

• Page 114: Vehicle Immersion

  MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

• Page 115: Spark Arrestor

  MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.

• Page 116: Pvt System

  • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

• Page 117
  MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the fly- weights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

• Page 118: Pvt Drying

  MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) High PVT Drying There may be some instances when water is accidently ingested into the…

• Page 119: Battery Removal

  (black) cable last. Your ATV is equipped with a sealed battery, which requires little main- tenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.

• Page 120: Battery Installation

  POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

• Page 121: Battery Charging

  MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installa- tion of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.

• Page 122
  MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.

• Page 123: Camber And Caster

  Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.

• Page 124: Throttle Cable Freeplay

  MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment. Throttle Cable Freeplay 1. Remove the four cover screws from the right han- dlebar control and remove the cover.

• Page 125
  6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your POLARIS dealer for service. 7. With the engine running, turn the handlebars fully to the left and right.

• Page 126: Cleaning And Storage

  Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a gar- den hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

• Page 127: Polishing The Vehicle

  Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Page 128: Storage Tips

  122. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

• Page 129
  5. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.

• Page 130: Transporting The Atv

  Accessories Auxiliary power outlets provide 12-volt power for operating accesso- ries. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see your POLARIS dealer.

• Page 131: Troubleshooting

  PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to…

• Page 132
  Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer…
• Page 133
  TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug(s)

• Page 134: Engine Overheating

  TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs…

• Page 135: Polaris Products

  Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger…

• Page 136: Specifications

  SPECIFICATIONS SPORTSMAN 550 Touring Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 765 lbs. (347 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weight 150 lbs.

• Page 137
  SPECIFICATIONS SPORTSMAN 550 Touring Lubrication System Pressurized Wet Sump Transmission Type Automatic PVT (POLARIS Variable Transmis- sion) In-Line H-L-N-R-P Front Suspension Dual a-arm, 9″ (22.9 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10″ (25.4 cm) travel Gear Reduction, Low 5.034:1…
• Page 138
  SPECIFICATIONS SPORTSMAN 850 Touring Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 798 lbs. (362 kg) Front Rack/Storage Box Capacity 120 lbs. (54 kg) Rear Rack Capacity 240 lbs. (109 kg) Hitch Tongue Weight 150 lbs.
• Page 139
  SPECIFICATIONS SPORTSMAN 850 Touring Lubrication System Pressurized Wet Sump Transmission Type Automatic PVT (POLARIS Variable Transmis- sion) In-Line H-L-N-R-P Front Suspension Dual a-arm, 9″ (22.9 cm) travel Rear Suspension Dual a-arm with Rolled IRS, 10″ (25.4 cm) travel Gear Reduction, Low 5.034:1…

• Page 140: Declaration Of Conformity

  2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS…

• Page 141: Warranty

  WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that…

• Page 142
  This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at POLARIS’ exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
• Page 143
  HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA- TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
• Page 144
  You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and…
• Page 145
  How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
• Page 146
  This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
• Page 147
  POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls.

• Page 148: Maintenance Log

  MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) OR HOURS…

• Page 149
  MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) OR HOURS…

• Page 150: Index

  INDEX 4X4 Switch ….26, 37 Cold Weather Operation ..57 Consumer Product Safety ..7 Coolant Bottle .

• Page 151
  INDEX Fluid Hand Brake ….93 Active Descent Control..87 Handlebar Adjustment ..119 ADC .
• Page 152
  Periodic Maintenance Chart ..76-79 Operating on Pavement ..13 Polaris Product List … . 131 Operating on Public Roads ..13 Polishing the Vehicle.
• Page 153
  INDEX Severe Use ….76 Taillight Lamp Replacement ..107 Side Panel Removal … . . 97 Throttle Body Adjustment .