Owners Manual
Page 31
... the transmission in extreme cold or with the engine speed above idle or while the vehicle is moving could cause transmission damage. Extreme Use 30 AH Battery If your POLARIS dealer to purchase a 30 AH battery. 1. See page 109. 3. Gear Selector NOTICE: Shifting gears with multiple electrical accessories, please see your factory-installed 18 AH battery cannot maintain a charge because of operation in PARK and lock the parking brake. Belt Life To extend belt...
... the transmission in extreme cold or with the engine speed above idle or while the vehicle is moving could cause transmission damage. Extreme Use 30 AH Battery If your POLARIS dealer to purchase a 30 AH battery. 1. See page 109. 3. Gear Selector NOTICE: Shifting gears with multiple electrical accessories, please see your factory-installed 18 AH battery cannot maintain a charge because of operation in PARK and lock the parking brake. Belt Life To extend belt...
Owners Manual
Page 37
... 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 39
... goes off when the engine is started. A direction indicator flashes when a turn signal is inoperative. Neutral High Beam Direction Indicators This lamp illuminates when the transmission is in neutral and the ignition key is in miles per hour. See your dealer. 37 See your authorized POLARIS dealer for service. FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps Lamp Indicates Vehicle Speed Over Temperature Condition When standard mode is...
... goes off when the engine is started. A direction indicator flashes when a turn signal is inoperative. Neutral High Beam Direction Indicators This lamp illuminates when the transmission is in neutral and the ignition key is in miles per hour. See your dealer. 37 See your authorized POLARIS dealer for service. FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps Lamp Indicates Vehicle Speed Over Temperature Condition When standard mode is...
Owners Manual
Page 46
... to the electronic control unit is shorted to B+ SPN 51 51 110 110 110 110 105 105 102 102 636 523 523 523 651 651 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 44 SPORTSMAN 550 Touring Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too...
... to the electronic control unit is shorted to B+ SPN 51 51 110 110 110 110 105 105 102 102 636 523 523 523 651 651 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 44 SPORTSMAN 550 Touring Diagnostic Codes Component Throttle Position Sensor Engine Temperature Sensor Condition Voltage Too...
Owners Manual
Page 47
... 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 48
... 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 46
... 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 46
Owners Manual
Page 49
... 520203 520203 520203 520211 520211 FMI 5 3 4 5 3 4 3 4 3 4 2 7 5 3 4 3 4 All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed 47 Transmit Err No TX Message for 2 Seconds EPAS CAN Comm. 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...
... 520203 520203 520203 520211 520211 FMI 5 3 4 5 3 4 3 4 3 4 2 7 5 3 4 3 4 All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed 47 Transmit Err No TX Message for 2 Seconds EPAS CAN Comm. 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...
Owners Manual
Page 51
... sustained idle. 5. Do not operate at first. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Check the fluid level of the transmission after the first 25 hours of the clutches and drive belt will ensure a longer life and better performance. Pull only light loads. See page 50. 6. Vary the throttle positions. Change both the oil and the filter at slower speeds...
... sustained idle. 5. Do not operate at first. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Check the fluid level of the transmission after the first 25 hours of the clutches and drive belt will ensure a longer life and better performance. Pull only light loads. See page 50. 6. Vary the throttle positions. Change both the oil and the filter at slower speeds...
Owners Manual
Page 68
... determining the weight you are adding to overturn. • TOWING is approved OFF-ROAD ONLY. • DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the racks raises the center of gravity of control or brake instability. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to the hitch point designated for your vehicle. •...
... determining the weight you are adding to overturn. • TOWING is approved OFF-ROAD ONLY. • DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the racks raises the center of gravity of control or brake instability. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to the hitch point designated for your vehicle. •...
Owners Manual
Page 69
... km/h) while carrying a passenger. 5. Slow down. 8. Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. 3. OPERATION Hauling Cargo Never exceed the weight capacities specified for your vehicle on the rear rack) and mounted as low as possible. 2. Cargo weight should be affected. 67 When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 9. NEVER...
... km/h) while carrying a passenger. 5. Slow down. 8. Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. 3. OPERATION Hauling Cargo Never exceed the weight capacities specified for your vehicle on the rear rack) and mounted as low as possible. 2. Cargo weight should be affected. 67 When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 9. NEVER...
Owners Manual
Page 70
... the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of tongue weight. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to tow a trailer on-road. • Do not tow any trailer on your POLARIS warranty. Remove the hitch from the vehicle when not towing a trailer. • If towing a load, reduce rear rack cargo weight by...
... the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of tongue weight. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to tow a trailer on-road. • Do not tow any trailer on your POLARIS warranty. Remove the hitch from the vehicle when not towing a trailer. • If towing a load, reduce rear rack cargo weight by...
Owners Manual
Page 75
... H 12 M 1000 (1600) Inspect for leaks at tank cap, lines, filter, pump; clean; replace as needed 2000 (3200) Change every two years 2000 (3200) Change every two years 3000 (4800) Clean out 10000 Inspect; replace as needed Item Maintenance Interval Remarks Ź Ź Ź Ź Ź D E Ź Wiring D Clutches (drive and driven) D Front wheel bearings D Brake fluid Ź ADC fluid D Spark arrestor D Valve clearance E D Toe adjustment Headlight aim 100 H 100 H 200...
... H 12 M 1000 (1600) Inspect for leaks at tank cap, lines, filter, pump; clean; replace as needed 2000 (3200) Change every two years 2000 (3200) Change every two years 3000 (4800) Clean out 10000 Inspect; replace as needed Item Maintenance Interval Remarks Ź Ź Ź Ź Ź D E Ź Wiring D Clutches (drive and driven) D Front wheel bearings D Brake fluid Ź ADC fluid D Spark arrestor D Valve clearance E D Toe adjustment Headlight aim 100 H 100 H 200...
Owners Manual
Page 96
... in PARK. 2. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. MAINTENANCE Tires Wheel Installation 1. Loose nuts could cause a tire to specification. 75 ft. lbs. (102 Nm) 45 ft. Place the transmission in an accident or overturn. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Lock the parking brake...
... in PARK. 2. Wheel Type Aluminum Steel Nut Type Lug Nut Lug Nut Nut Torque 75 ft. MAINTENANCE Tires Wheel Installation 1. Loose nuts could cause a tire to specification. 75 ft. lbs. (102 Nm) 45 ft. Place the transmission in an accident or overturn. lbs. (61 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service. Lock the parking brake...
Owners Manual
Page 99
MAINTENANCE Lights Poor lighting can cause burns to skin. Clean headlights frequently and replace burned out headlamps promptly. If fingers do touch a lamp, clean it . 5. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp,... when driving. Turn the lamp counter-clockwise to cool before servicing. 3. Oil from the wiring harness. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. Allow lamps to remove it with bare fingers. Install the new lamp. Headlight and ...
MAINTENANCE Lights Poor lighting can cause burns to skin. Clean headlights frequently and replace burned out headlamps promptly. If fingers do touch a lamp, clean it . 5. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp,... when driving. Turn the lamp counter-clockwise to cool before servicing. 3. Oil from the wiring harness. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. Allow lamps to remove it with bare fingers. Install the new lamp. Headlight and ...
Owners Manual
Page 103
Turn the lamp counter-clockwise to remove it. 3. Reinstall the harness connector. 5. Install the new lamp. 4. Connector Lamp 101 MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Test the light for proper operation. Replace the entire signal lamp assembly. Remove the harness connector from the back of the light assembly. 2. Taillight/Brakelight Lamp Replacement 1.
Turn the lamp counter-clockwise to remove it. 3. Reinstall the harness connector. 5. Install the new lamp. 4. Connector Lamp 101 MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Test the light for proper operation. Replace the entire signal lamp assembly. Remove the harness connector from the back of the light assembly. 2. Taillight/Brakelight Lamp Replacement 1.
Owners Manual
Page 120
... models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change fluids as recommended. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems. 3. See page 76. Clean the air box. MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Oil and Filter Change the oil and filter. Air Filter / Air...
... models) (change every two years) • Rear gearcase • Transmission • Brake fluid (change fluids as recommended. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems. 3. See page 76. Clean the air box. MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Oil and Filter Change the oil and filter. Air Filter / Air...
Owners Manual
Page 128
...) 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 129
SPECIFICATIONS SPORTSMAN 550 Touring Lubrication System Transmission Type Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tire Size/Pressure, Front Tire Size/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 26 x 8 - 14 / 7 psi (48.3 kPa) 26 x ...
SPECIFICATIONS SPORTSMAN 550 Touring Lubrication System Transmission Type Front Suspension Rear Suspension Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tire Size/Pressure, Front Tire Size/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 26 x 8 - 14 / 7 psi (48.3 kPa) 26 x ...
Owners Manual
Page 130
...) 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 630w 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 630w 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 141
... Spring Adjustment, Rear Shock ...113 Starting the Engine ...52 Steering Assembly ...84 Steering Lock ...31 Stop Switch ...22 Storage ...116-120 Storage Box, Front ...32 Storage Tips ...118-119 Suspension, Passenger Seat ...90 Switches 4X4 Switch ...21, 33 Engine Stop Switch...22 Hazard Switch...22 Headlight Switch ...23 Horn Switch ...22 Main Key Switch ...21 MODE Button...23 Momentary High-Beam Switch 22 Override Switch ...23 Turn Signal Switch ...22 O Oil Engine ...75-77 Rear Gearcase ...83 Transmission ...78-79 Oil and Filter Change ...76-77 Oil Change Rear...
... Spring Adjustment, Rear Shock ...113 Starting the Engine ...52 Steering Assembly ...84 Steering Lock ...31 Stop Switch ...22 Storage ...116-120 Storage Box, Front ...32 Storage Tips ...118-119 Suspension, Passenger Seat ...90 Switches 4X4 Switch ...21, 33 Engine Stop Switch...22 Hazard Switch...22 Headlight Switch ...23 Horn Switch ...22 Main Key Switch ...21 MODE Button...23 Momentary High-Beam Switch 22 Override Switch ...23 Turn Signal Switch ...22 O Oil Engine ...75-77 Rear Gearcase ...83 Transmission ...78-79 Oil and Filter Change ...76-77 Oil Change Rear...