Owners Manual
Page 27
... any shifting problems. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is left unattended, always place the transmission in PARK. Whenever the vehicle is moving or idle. EPS remains engaged whether the vehicle is turned to the desired gear. See page 33 for extended periods and when operating uphill at less than 11 km/h for EPS Warning Indicator information. FEATURES AND CONTROLS Electronic Power Steering...
... any shifting problems. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is left unattended, always place the transmission in PARK. Whenever the vehicle is moving or idle. EPS remains engaged whether the vehicle is turned to the desired gear. See page 33 for extended periods and when operating uphill at less than 11 km/h for EPS Warning Indicator information. FEATURES AND CONTROLS Electronic Power Steering...
Owners Manual
Page 32
... km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear (high, low or reverse) Disengaging Active Descent Control The ADC system will automatically engage when all 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 ADC...
... km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear (high, low or reverse) Disengaging Active Descent Control The ADC system will automatically engage when all 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 ADC...
Owners Manual
Page 35
... hazard switch or a turn signal switch is on . 33 All segments including the fuel icon will automatically reduce engine power. 8. A flashing wrench symbol alerts the operator that the vehicle is at a higher RPM or recharge the battery to your authorized POLARIS dealer for scheduled maintenance. This warning usually indicates that the preset service interval has been reached. Do not operate the vehicle if this warning appears. Fuel Gauge - Check Engine Warning...
... hazard switch or a turn signal switch is on . 33 All segments including the fuel icon will automatically reduce engine power. 8. A flashing wrench symbol alerts the operator that the vehicle is at a higher RPM or recharge the battery to your authorized POLARIS dealer for scheduled maintenance. This warning usually indicates that the preset service interval has been reached. Do not operate the vehicle if this warning appears. Fuel Gauge - Check Engine Warning...
Owners Manual
Page 40
... in the chart to the electronic control unit is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is shorted to a wire at battery voltage. SPORTSMAN Forest 550 Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too High Voltage Too...
... in the chart to the electronic control unit is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is shorted to a wire at battery voltage. SPORTSMAN Forest 550 Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too High Voltage Too...
Owners Manual
Page 41
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 550 Diagnostic Codes Condition Driver Circuit Grounded Shorted Load* Starter Enable Circuit Driver Circuit Short to B+ All Wheel Drive Control Driver Circuit Short to B+ System Power Voltage Too High Voltage Too low Throttle Safety Signal Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Active Descent Control System Driver Circuit Short to B+ Steering Over Current Shut Down Current Above Normal or Grounded Steering Excessive Current Error Current...
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 550 Diagnostic Codes Condition Driver Circuit Grounded Shorted Load* Starter Enable Circuit Driver Circuit Short to B+ All Wheel Drive Control Driver Circuit Short to B+ System Power Voltage Too High Voltage Too low Throttle Safety Signal Voltage Too High Voltage Too Low Signal Out of Range Throttle Stuck Active Descent Control System Driver Circuit Short to B+ Steering Over Current Shut Down Current Above Normal or Grounded Steering Excessive Current Error Current...
Owners Manual
Page 42
... 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 43
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 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 Current Above Normal/Grounded Current Above...
FEATURES AND CONTROLS Instrument Cluster Rider Information Center SPORTSMAN Forest 850 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 Current Above Normal/Grounded Current Above...
Owners Manual
Page 45
... and high speed operation during the break-in of the clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling. 4. Check the engine oil level on the daily pre-ride inspection checklist. Drive slowly at 20 hours, one month or 500 miles (800 km), whichever comes first. Perform regular checks on fluid levels, controls and areas...
... and high speed operation during the break-in of the clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling. 4. Check the engine oil level on the daily pre-ride inspection checklist. Drive slowly at 20 hours, one month or 500 miles (800 km), whichever comes first. Perform regular checks on fluid levels, controls and areas...
Owners Manual
Page 61
... weight capacities specified for use on this manual. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. Remove the hitch from the vehicle when not towing a trailer. • If towing a load, reduce rear rack cargo weight by the amount of 1/3 this vehicle. The combination of rear rack cargo weight and tongue weight must not exceed the maximum weight capacity of the vehicle. Towing Loads Towing is approved OFF-ROAD...
... weight capacities specified for use on this manual. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. Remove the hitch from the vehicle when not towing a trailer. • If towing a load, reduce rear rack cargo weight by the amount of 1/3 this vehicle. The combination of rear rack cargo weight and tongue weight must not exceed the maximum weight capacity of the vehicle. Towing Loads Towing is approved OFF-ROAD...
Owners Manual
Page 73
...and driven) Front wheel bearings Brake fluid ADC fluid Spark arrestor E Valve clearance Toe adjustment Headlight aim 71 replace as needed 50 H 50 H 50 H 50 H 6M 6M 6M 6M E Throttle Body Intake Duct Drive belt Cooling system Radiator Cooling hoses Engine oil change Demand drive fluid (normal use) Rear gearcase oil Transmission oil Fuel system Engine mounts Exhaust muffler/ pipe E Spark plug 1000 (1600) Inspect coolant strength seasonally; adjust Inspect...
...and driven) Front wheel bearings Brake fluid ADC fluid Spark arrestor E Valve clearance Toe adjustment Headlight aim 71 replace as needed 50 H 50 H 50 H 50 H 6M 6M 6M 6M E Throttle Body Intake Duct Drive belt Cooling system Radiator Cooling hoses Engine oil change Demand drive fluid (normal use) Rear gearcase oil Transmission oil Fuel system Engine mounts Exhaust muffler/ pipe E Spark plug 1000 (1600) Inspect coolant strength seasonally; adjust Inspect...
Owners Manual
Page 93
Lower the vehicle to specification. 75 ft. lbs. (61 Nm) 91 Install the wheel nuts and finger-tighten them. 4. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut ...the ground. 5. Place the transmission in an accident or overturn. Loose nuts could result in PARK. 2. lbs. (102 Nm) 45 ft. Torque the wheel nuts to come off during operation, which could cause a tire to specification. Place the wheel on the hub with the valve stem...
Lower the vehicle to specification. 75 ft. lbs. (61 Nm) 91 Install the wheel nuts and finger-tighten them. 4. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut ...the ground. 5. Place the transmission in an accident or overturn. Loose nuts could result in PARK. 2. lbs. (102 Nm) 45 ft. Torque the wheel nuts to come off during operation, which could cause a tire to specification. Place the wheel on the hub with the valve stem...
Owners Manual
Page 97
... plastic part of the headlight. 4. Open the front rack cover. 3. Go to reassemble the headlight. Remove the lamp. Place the transmission in loss of the headlight. Position light: Rotate the socket to disconnect it . Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Reverse all steps to step 6. Pull the harness plug to remove it...
... plastic part of the headlight. 4. Open the front rack cover. 3. Go to reassemble the headlight. Remove the lamp. Place the transmission in loss of the headlight. Position light: Rotate the socket to disconnect it . Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Reverse all steps to step 6. Pull the harness plug to remove it...
Owners Manual
Page 98
Rotate the turn signal light becomes inoperable, the lamps cannot be replaced. Remove the lamp. 4. Test the lamp for proper operation. 6. Rear Turn Signal Lamp Replacement 1. Place the transmission in reverse order. 96 Install the new lamp. Reinstall all components in PARK. 2. Replace the entire signal lamp assembly. Apply dielectric grease to remove it. 3. MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal socket counterclockwise to the socket. 5.
Rotate the turn signal light becomes inoperable, the lamps cannot be replaced. Remove the lamp. 4. Test the lamp for proper operation. 6. Rear Turn Signal Lamp Replacement 1. Place the transmission in reverse order. 96 Install the new lamp. Reinstall all components in PARK. 2. Replace the entire signal lamp assembly. Apply dielectric grease to remove it. 3. MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal socket counterclockwise to the socket. 5.
Owners Manual
Page 120
... with POLARIS Carbon Clean, following fluid levels. Run the engine for several times using electric start. Torque to the inside of gasoline. 118 Oil will be completely drained of each spark plug cap and reinstall the caps onto the plugs. 5. Turn the engine over several minutes so the Carbon Clean reaches the injectors. Reinstall the spark plugs. Treat the fuel system with the pre-measured amount of engine oil. MAINTENANCE Cleaning...
... with POLARIS Carbon Clean, following fluid levels. Run the engine for several times using electric start. Torque to the inside of gasoline. 118 Oil will be completely drained of each spark plug cap and reinstall the caps onto the plugs. 5. Turn the engine over several minutes so the Carbon Clean reaches the injectors. Reinstall the spark plugs. Treat the fuel system with the pre-measured amount of engine oil. MAINTENANCE Cleaning...
Owners Manual
Page 123
... in gas tank or fuel lines. Use the throttle quickly and effectively. Excessive throttle may cause loss of control and vehicle overturn. Excessive throttle may cause loss of control and vehicle overturn. PVT system Clutch malfunction See your dealer. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. WARNING! Slippage from water Dry out the PVT. Use low range or turn...
... in gas tank or fuel lines. Use the throttle quickly and effectively. Excessive throttle may cause loss of control and vehicle overturn. Excessive throttle may cause loss of control and vehicle overturn. PVT system Clutch malfunction See your dealer. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. WARNING! Slippage from water Dry out the PVT. Use low range or turn...
Owners Manual
Page 128
SPECIFICATIONS SPORTSMAN Forest 550 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug / Gap Lubrication System Seat Steering System Transmission ...
SPECIFICATIONS SPORTSMAN Forest 550 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug / Gap Lubrication System Seat Steering System Transmission ...
Owners Manual
Page 129
SPECIFICATIONS SPORTSMAN Forest 550 Transmission and Gears Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Parking Brake Hitch Winch Headlight Taillights Brake Light Instrument Cluster High/Low/Neutral/Reverse/Parking 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Off Road Style, Deep Tread Design, size 26x1014 AT / 5 psi (34.5 kPa) Pressure Single-Control handlebar hydraulic disc on all...
SPECIFICATIONS SPORTSMAN Forest 550 Transmission and Gears Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires Type Front Tires Type Rear Brakes, Front/Rear Brakes, Auxiliary Parking Brake Hitch Winch Headlight Taillights Brake Light Instrument Cluster High/Low/Neutral/Reverse/Parking 5.034:1 4.508:1 2.693:1 3.818:1 3.7:1 Off Road Style, Deep Tread Design, size 26x8-14 AT / 7 psi (48.3 kPa) Pressure Off Road Style, Deep Tread Design, size 26x1014 AT / 5 psi (34.5 kPa) Pressure Single-Control handlebar hydraulic disc on all...
Owners Manual
Page 130
SPECIFICATIONS SPORTSMAN Forest 850 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug Type / Gap Lubrication System Seat Steering System ...
SPECIFICATIONS SPORTSMAN Forest 850 Maximum Weight Load 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 Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Engine Power Bore x Stroke Alternator Output Compression Ratio Starting System Ignition System Idle RPM Ignition Timing Spark Plug Type / Gap Lubrication System Seat Steering System ...
Owners Manual
Page 132
... TRADE NAME SPORTSMAN FOREST 500 SPORTSMAN FOREST 550 SPORTSMAN FOREST 850 2011 2011 2011 MODEL YEARS European Community Person Authorized to Compile the Technical File: Ross Clifford, General Manager POLARIS Britain Ltd Forge Mills Park, Station Road Coleshill, Warwickshire B46 1HT European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is dependent on many factors, including: • Instrument and calibration...
... TRADE NAME SPORTSMAN FOREST 500 SPORTSMAN FOREST 550 SPORTSMAN FOREST 850 2011 2011 2011 MODEL YEARS European Community Person Authorized to Compile the Technical File: Ross Clifford, General Manager POLARIS Britain Ltd Forge Mills Park, Station Road Coleshill, Warwickshire B46 1HT European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is dependent on many factors, including: • Instrument and calibration...
Owners Manual
Page 142
... Transmission Oil ...76 Transporting the Vehicle ...120 Turn Signal Lamp, Front ...96 Turn Signal Lamp, Rear ...96 Turn Signal Switch ...21 Turning Around on a Hill ...56-57 Turning the Vehicle ...47 S Safety Labels ...16-19 Safety Training ...6 Severe Use ...68 Side Panel Removal...89 Sidehilling ...54 Signal Words ...4 Spark Arrestor ...104 Spark Arrestor Requirements ...67 Spark Plug Inspection ...101-102 Spark Plug Recommendations...101 Spark Plugs ...101-102 Spring Adjustment, Shock ...100 Standard/Metric Display ...35 Starting the Engine ...45 Steering Assembly...
... Transmission Oil ...76 Transporting the Vehicle ...120 Turn Signal Lamp, Front ...96 Turn Signal Lamp, Rear ...96 Turn Signal Switch ...21 Turning Around on a Hill ...56-57 Turning the Vehicle ...47 S Safety Labels ...16-19 Safety Training ...6 Severe Use ...68 Side Panel Removal...89 Sidehilling ...54 Signal Words ...4 Spark Arrestor ...104 Spark Arrestor Requirements ...67 Spark Plug Inspection ...101-102 Spark Plug Recommendations...101 Spark Plugs ...101-102 Spring Adjustment, Shock ...100 Standard/Metric Display ...35 Starting the Engine ...45 Steering Assembly...