Owners Manual
Page 37
... Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. When the engine is moving could cause transmission damage. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of the vehicle. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is idling...
... Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. When the engine is moving could cause transmission damage. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of the vehicle. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is idling...
Owners Manual
Page 43
... 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 (24 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 (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission...
Owners Manual
Page 46
... (lights, cooling fan, accessories) is started. This warning usually indicates that the preset service interval has been reached. See your dealer. 5. See your dealer for scheduled maintenance. The segments of the fuel gauge show the level of fuel in a 12-hour or 24-hour format. Tip: If the fuel icon fails to high beam. 6. Drive at a higher RPM or recharge the battery to indicate an overheated engine...
... (lights, cooling fan, accessories) is started. This warning usually indicates that the preset service interval has been reached. See your dealer. 5. See your dealer for scheduled maintenance. The segments of the fuel gauge show the level of fuel in a 12-hour or 24-hour format. Tip: If the fuel icon fails to high beam. 6. Drive at a higher RPM or recharge the battery to indicate an overheated engine...
Owners Manual
Page 52
..., fuel pump, etc.), or the item has failed. SPORTSMAN 550 Touring 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 Engine Overheat Shutdown Voltage Too High Voltage Too Low Voltage Too High Voltage Too Low Circuit Fault Voltage Too Low (to Calibrate) Voltage Too High Signal Fault Driver...
..., fuel pump, etc.), or the item has failed. SPORTSMAN 550 Touring 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 Engine Overheat Shutdown Voltage Too High Voltage Too Low Voltage Too High Voltage Too Low Circuit Fault Voltage Too Low (to Calibrate) Voltage Too High Signal Fault Driver...
Owners Manual
Page 53
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 550 Touring 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 T1...
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 550 Touring 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 T1...
Owners Manual
Page 54
... 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 55
... IC CAN Comm. FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 Touring 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 SPN...
... IC CAN Comm. FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN 850 Touring 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 SPN...
Owners Manual
Page 57
... on fluid levels, controls and areas outlined on the dipstick. Pull only light loads. 7. Change both the oil and the filter at sustained idle. 5. Check the engine oil level on the daily pre-ride inspection checklist. Add oil if necessary to familiarize yourself with gasoline. Vary the throttle positions. Break in the clutches and belt by operating at first. PVT Break-in (Clutches/Belt) A proper...
... on fluid levels, controls and areas outlined on the dipstick. Pull only light loads. 7. Change both the oil and the filter at sustained idle. 5. Check the engine oil level on the daily pre-ride inspection checklist. Add oil if necessary to familiarize yourself with gasoline. Vary the throttle positions. Break in the clutches and belt by operating at first. PVT Break-in (Clutches/Belt) A proper...
Owners Manual
Page 77
... hilly terrain, reduce speed and cargo weight to extend belt life. 6. Slow down. 5. 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 2/3 labels and in the specifications sec1/3 tion of this manual. 1. Do not obstruct the headlight beam with extreme caution whenever hauling or towing loads. Always operate the vehicle with cargo...
... hilly terrain, reduce speed and cargo weight to extend belt life. 6. Slow down. 5. 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 2/3 labels and in the specifications sec1/3 tion of this manual. 1. Do not obstruct the headlight beam with extreme caution whenever hauling or towing loads. Always operate the vehicle with cargo...
Owners Manual
Page 78
... exceed the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on inclines. 550 EFI Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 1500 lbs. (680 kg) 150 lbs. (68 kg) 850 EFI 1500 lbs. (680 kg) 150 lbs. (68 kg) 74 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the vehicle and will void your Polaris ATV...
... exceed the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on inclines. 550 EFI Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 1500 lbs. (680 kg) 150 lbs. (68 kg) 850 EFI 1500 lbs. (680 kg) 150 lbs. (68 kg) 74 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the vehicle and will void your Polaris ATV...
Owners Manual
Page 83
...; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar E Q Spark plug Remarks Miles (Km) 1000 (1600) Inspect; every 25 hours if extreme use . adjust when parts are replaced Adjust as needed 2000 (3200) Change every two years 2000 (3200) Change every two years; replace worn parts 1000 (1600) Inspect; Q Front wheel Q Brake fluid X ADC fluid Q Spark arrestor E Q Valve clearance Q Toe adjustment Headlight aim X Perform these services...
...; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar E Q Spark plug Remarks Miles (Km) 1000 (1600) Inspect; every 25 hours if extreme use . adjust when parts are replaced Adjust as needed 2000 (3200) Change every two years 2000 (3200) Change every two years; replace worn parts 1000 (1600) Inspect; Q Front wheel Q Brake fluid X ADC fluid Q Spark arrestor E Q Valve clearance Q Toe adjustment Headlight aim X Perform these services...
Owners Manual
Page 104
... PARK. 2. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Torque the wheel nuts to come off during operation, which could cause a tire to specification. lbs. (102 Nm) Cast Aluminum Steel 45 ft. Lock the parking brake. 3. MAINTENANCE Tires Wheel Installation 1. lbs. (102 Nm) 45 ft. Wheel Type Aluminum Steel Nut Type Lug Nut Lug...
... PARK. 2. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Torque the wheel nuts to come off during operation, which could cause a tire to specification. lbs. (102 Nm) Cast Aluminum Steel 45 ft. Lock the parking brake. 3. MAINTENANCE Tires Wheel Installation 1. lbs. (102 Nm) 45 ft. Wheel Type Aluminum Steel Nut Type Lug Nut Lug...
Owners Manual
Page 107
... lamp. Unplug the headlamp from the wiring harness. Turn the lamp counter-clockwise to skin. CAUTION! Make sure the tab on the wiring. 4. Clean headlights frequently and replace burned out headlamps promptly. Hot components can result in the housing. 6. Always make sure lights are adjusted properly for best visibility. MAINTENANCE Lights Poor lighting can cause burns to remove it with...
... lamp. Unplug the headlamp from the wiring harness. Turn the lamp counter-clockwise to skin. CAUTION! Make sure the tab on the wiring. 4. Clean headlights frequently and replace burned out headlamps promptly. Hot components can result in the housing. 6. Always make sure lights are adjusted properly for best visibility. MAINTENANCE Lights Poor lighting can cause burns to remove it with...
Owners Manual
Page 111
... operation. MAINTENANCE Lights Lower Headlamp Replacement 1. Reinstall the harness assembly into the headlight assembly. 4. Turn the lamp counter-clockwise to secure the headlamp. 1. Install the new lamp. 4. Remove the headlamp and install the new headlamp. 3. Turn the back of the light assembly. 2. Remove the harness connector from the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Harness Taillight/Brakelight Lamp Replacement Connector...
... operation. MAINTENANCE Lights Lower Headlamp Replacement 1. Reinstall the harness assembly into the headlight assembly. 4. Turn the lamp counter-clockwise to secure the headlamp. 1. Install the new lamp. 4. Remove the headlamp and install the new headlamp. 3. Turn the back of the light assembly. 2. Remove the harness connector from the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Harness Taillight/Brakelight Lamp Replacement Connector...
Owners Manual
Page 132
... fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change fluids as recommended in and around the piston rings and ring lands, coating the cylinder with a protective film of gasoline. 128 Allow it to specification. 4. To access the plug hole, use a section of oil. 3. Turn the engine over several minutes so the Carbon Clean reaches the injectors. If Polaris fuel system...
... fluid (ADC models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change fluids as recommended in and around the piston rings and ring lands, coating the cylinder with a protective film of gasoline. 128 Allow it to specification. 4. To access the plug hole, use a section of oil. 3. Turn the engine over several minutes so the Carbon Clean reaches the injectors. If Polaris fuel system...
Owners Manual
Page 140
...) Transmission Fluid Capacity 32 oz. (946 ml) Rear Gearcase Fluid Capacity 7.1 oz. (210 ml) Fuel System Visteon Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Engine ES550PLE011 Displacement 549 cc Bore x Stroke 96.6 x 75 mm Alternator Output 490w @ 1350 RPM/Peak 630w Compression Ratio 9.6:1 Starting System Electric Ignition System Visteon EFI (ECU Controlled) Ignition Timing 13° +/- 3° BTDC @ 1650 RPM Idle RPM** 1750 +/- 50 Throttle Body/Size Mikuni/42 mm Spark Plug / Gap...
...) Transmission Fluid Capacity 32 oz. (946 ml) Rear Gearcase Fluid Capacity 7.1 oz. (210 ml) Fuel System Visteon Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Engine ES550PLE011 Displacement 549 cc Bore x Stroke 96.6 x 75 mm Alternator Output 490w @ 1350 RPM/Peak 630w Compression Ratio 9.6:1 Starting System Electric Ignition System Visteon EFI (ECU Controlled) Ignition Timing 13° +/- 3° BTDC @ 1650 RPM Idle RPM** 1750 +/- 50 Throttle Body/Size Mikuni/42 mm Spark Plug / Gap...
Owners Manual
Page 141
SPECIFICATIONS SPORTSMAN 550 Touring EPS Lubrication System Transmission Type Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tire Type/Pressure, Front Tire Type/Pressure, Rear Brakes, Front/Rear Brake, Auxiliary Brake, Parking Headlight Taillight Brake Light Instrumentation Pressurized Wet Sump Automatic PVT (Polaris Variable Transmission) In-Line H-L-N-R-P Dual a-arm, 9" (22.9 cm) travel Dual a-arm with Rolled IRS, 10" (25.4 cm) travel 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 Maxxis AT 26 x 8 - 14 7 psi (48.3...
SPECIFICATIONS SPORTSMAN 550 Touring EPS Lubrication System Transmission Type Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tire Type/Pressure, Front Tire Type/Pressure, Rear Brakes, Front/Rear Brake, Auxiliary Brake, Parking Headlight Taillight Brake Light Instrumentation Pressurized Wet Sump Automatic PVT (Polaris Variable Transmission) In-Line H-L-N-R-P Dual a-arm, 9" (22.9 cm) travel Dual a-arm with Rolled IRS, 10" (25.4 cm) travel 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 Maxxis AT 26 x 8 - 14 7 psi (48.3...
Owners Manual
Page 142
...) Rear Gearcase Fluid Capacity 7.1 oz. (210 ml) Fuel System Bosch Multi-Port Sequential Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Engine EH085OLE013 Displacement 850 cc Bore x Stroke 87 x 71.5 mm Alternator Output 475w @ 1200 RPM/Peak 575w Compression Ratio 11.0:1 Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° +/- 5° BTDC @ 1200 RPM Idle RPM 1200 +/- 50 Throttle Body/Size Mikuni Dual Bore/40 mm Spark Plug...
...) Rear Gearcase Fluid Capacity 7.1 oz. (210 ml) Fuel System Bosch Multi-Port Sequential Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Engine EH085OLE013 Displacement 850 cc Bore x Stroke 87 x 71.5 mm Alternator Output 475w @ 1200 RPM/Peak 575w Compression Ratio 11.0:1 Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° +/- 5° BTDC @ 1200 RPM Idle RPM 1200 +/- 50 Throttle Body/Size Mikuni Dual Bore/40 mm Spark Plug...
Owners Manual
Page 151
... control system. 147 Polaris Industries Inc. WARRANTY U.S.A. Repairing or replacing other components not covered by this warranty is the responsibility of vehicle travel, or 30 calendar months from defects in addition to the Polaris standard limited warranty for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* • Fuel Line Fittings • Purge Valves • Clamps* • Vapor Hoses • Pressure...
... control system. 147 Polaris Industries Inc. WARRANTY U.S.A. Repairing or replacing other components not covered by this warranty is the responsibility of vehicle travel, or 30 calendar months from defects in addition to the Polaris standard limited warranty for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* • Fuel Line Fittings • Purge Valves • Clamps* • Vapor Hoses • Pressure...
Owners Manual
Page 158
... Signal Words ...4 Spark Arrestor ...111 Spark Plug Inspection ...108-109 Spark Plug Recommendations...108 Spark Plug Torque Specification . . 108 Spark Plugs ...108-109 Specifications...136-139 Spring Adjustment, Rear Shock . . 121 Standard/Metric Display ...44 Starting the Engine ...57 Steering Assembly ...90 Storage ...124-129 Storage Box, Front...36 Storage Tips ...127-129 Suspension, Passenger Seat ...96 Switches 4X4 Switch ...26, 37 Engine Stop Switch ...27 Headlight Switch ...27 Main Key Switch ...27 Mode/Reverse Override Switch 26 T Taillight Lamp Replacement ...107 Throttle Body...
... Signal Words ...4 Spark Arrestor ...111 Spark Plug Inspection ...108-109 Spark Plug Recommendations...108 Spark Plug Torque Specification . . 108 Spark Plugs ...108-109 Specifications...136-139 Spring Adjustment, Rear Shock . . 121 Standard/Metric Display ...44 Starting the Engine ...57 Steering Assembly ...90 Storage ...124-129 Storage Box, Front...36 Storage Tips ...127-129 Suspension, Passenger Seat ...96 Switches 4X4 Switch ...26, 37 Engine Stop Switch ...27 Headlight Switch ...27 Main Key Switch ...27 Mode/Reverse Override Switch 26 T Taillight Lamp Replacement ...107 Throttle Body...