Polaris Sportsman 9922581 User manual

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.
Pantone 426 C
International
Owner's Manual
for Maintenance and Safety
Sportsman 550 XP
Sportsman 850 XP
Sportsman 850 XP EPS

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

Pantone 426 C
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922581 Rev 02
Printed in U.S.A.

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER®utility vehicles
• Victory Motorcycles®
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the Polaris Service Manual and
should be performed only by a factory-certified Master Service Dealer®
(MSD) technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at www.polarisin-
dustries.com.

2
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris
Industries Inc.
Copyright 2009 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. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2010 SPORTSMAN 550/850 XP / 850 XP EPS International Owner’s Manual
P/N 9922581

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Emission Control Systems . . . . . . . . . . . . . . . 61
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 115
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 119
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 120
Declaration of Conformity . . . . . . . . . . . . . . . 124
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 129
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4
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.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5
INTRODUCTION
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the protec-
tion of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the opera-
tion of this vehicle in your area.
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.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
####
VIN Engine Serial Number
Key
Number 550 850

6
SAFETY
Failure to follow the warnings in this manual can result in serious injury or death.
This Polaris vehicle is not a toy and can be hazardous to operate. A collision or
rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this Polaris vehicle.
Safety Training
When you purchased your new Polaris vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this informa-
tion on a regular basis.
If you purchased a used Polaris vehicle from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a
trailer with this vehicle on public roads is prohibited. See your Polaris
dealer about configuring the vehicle to be certified to tow a trailer on-
road.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equip-
ment has been added, or if any modifications have been made, that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers and large racks may change vehicle handling. Use only
Polaris-approved accessories. Know their function and effect on the vehicle.
WARNING

7
SAFETY
Rider Safety
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Read and understand all warnings, cautions and
operating procedures in this manual and on the
safety labels before operating the vehicle.
Never operate this vehicle without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor. Contact an
authorized Polaris dealer or visit the Polaris web site
at www.polarisindustries.com.
Never permit others to operate the vehicle unless
they have read and understand this manual and all
product labels, and have completed a certified safety training course.
Never allow anyone under 16 years of age to
operate this vehicle.
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.
WARNING