2010 Polaris Sportsman XP 550 EPS Owners Manual

2010 Polaris Sportsman XP 550 EPS Manual

2010 Polaris Sportsman XP 550 EPS manual content summary:

  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 1
    Pantone 426C Sportsman 550 XP Sportsman 550 XP EPS Sportsman 850 XP Sportsman 850 XP EPS for Maintenance and Safety Owner's 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.
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    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 1-800-3423764 for assistance.
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    The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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    on hills and rough terrain and in turns. S avoid paved surfaces - pavement may seriously affect handling and control. 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
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    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master
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    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/XP EPS Owner's Manual P/N 9922452 2
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    Introduction ...4 Safety ...7 Features and Controls ...26 Operation ...49 Emission Control Systems ...67 Maintenance ...68 Adjustments ...118 Troubleshooting ...121 Polaris Products...125 Specifications ...126 Declaration of Conformity ...130 Warranty ...131 Maintenance Log ...139 Index ...142 3
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    your vehicle. Your safety is involved when these words and symbols 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
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    . Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV. • Never operate an ATV without proper instruction. Take a training course. • This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years
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    INTRODUCTION 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
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 11
    you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorized ATV RiderCoursesm that is available to you and follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that
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    SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Long Sleeves Eye Protection Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris
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    SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings
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    . 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. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how
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    ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual. 11
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    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. Always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using
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    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
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    improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster
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    . Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 58. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as
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    side, or to either side if ATV is pointed straight uphill. • Turn the ATV around and remount, following the procedure described in the owner's manual. See page 60. If the ATV begins rolling downhill: • Keep body weight uphill. • Never apply engine power. • Never apply the rear brake while rolling
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    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. Always use extra
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    Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 63. Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back
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    over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 62. Skidding or Sliding Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). On
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    and securely attached. • Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. • Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in
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    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
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    have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label
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    SAFETY Safety Labels and Locations General Warning Age 16 Warning Discretionary Warning Reverse Override Warning 4X4 Caution Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and
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    SAFETY Safety Labels and Locations "No Passenger" Warning Tire Pressure/Load Warning "No Passenger" Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNING Improper tire pressure or
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    SAFETY Safety Labels and Locations Rack Warning Rack Warning + + + Clutch Cover Warning Clutch Cover Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part
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    FEATURES AND CONTROLS Switches Headlight Switch 2x4 Mode/Reverse Override Button 4X4 Switch Engine Stop Switch Main Key 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
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    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 OFF RUN OFF RUN position before attempting to start the engine. The engine will not start or run when the switch is off. Both the
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    controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle
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    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. These brakes are hydraulically activated
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    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
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    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. Release the brake lever. 5. To release the parking brake
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    FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary
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    FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 39 for EPS Warning Indicator information. Automatic Transmission Gear
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    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. Always move the 4X4 switch to ADC 4X4
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    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. If
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    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
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    speed, the instrument cluster also displays the following items: engine speed, odometer, resettable trip meters (2), total engine hours of operation, service interval timer and indicator, gear position, fuel level, AWD status, EPS status (if equipped), high beam status, battery voltage warning
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    Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2. Information Display Area - This area displays odometer, tripmeters, engine hour meter and programmable service hour interval. 38
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    - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 42 for resetting instructions. 9. Under / Over Voltage - This warning usually indicates that the ATV is operating
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Display Area Use the MODE button to toggle through the speed display options. MODE button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override button also acts as a MODE button when
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h). Tip: The reverse override button also acts as
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    is programmed at 50 hours at the factory. Use the following procedure to change the service interval. 1. Press the SELECT button until remaining service hours display. 2. Press and hold the MODE button. 3. When the service hours flash, press and release the SELECT button to advance the hours to the
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Display Area 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
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center 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
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 49
    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman 550 XP / XP 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
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman 850 XP / XP 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
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    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman 850 XP / XP 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
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    FEATURES AND CONTROLS Front Rack/Compartment Release the front rack latches and remove the rack to gain access to the front compartment. To reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches. Access
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    , accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. 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
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    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 Brake system/lever travel Brake fluid Auxiliary brake
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    type of tires specified for your vehicle. Always maintain proper tire pressure. 11. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage. 12. Never operate the ATV on a frozen body of water. 13. Do not touch hot
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    OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding
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    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-ventilated 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.
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    OPERATION Driving Procedures 1. Wear a helmet and eye protection. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your path of travel. 6.
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    tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
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    OPERATION Driving on Slippery Surfaces Sideways Skid Turn in direction of skid 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
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    OPERATION Driving Uphill 25° Maximum Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a
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    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. Slow down! 2.
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    OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 36. 2. Avoid steep hills (25° maximum). 3. Shift body weight uphill. 4. Drive straight downhill. 5. Slow down. Excessive speed when
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    , or on the left if the vehicle is pointing straight uphill. 5. Staying uphill of the vehicle, turn the handlebars full left. 6. While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly
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    if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 100, then see
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    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 hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use
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    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle
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    with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when
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    OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in 2/3 the specifications section of 1/3 this manual. 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. When operating over
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    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. 66
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    EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle
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    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed
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    a 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 X Perform these operations more often for vehicles subjected to severe use. E Emission-related
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    MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these
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    MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Q Throttle Cable/ E ETC Switch Remarks Miles (Km) 500 (800) 500 (800) 500 (800) Inspect; adjust; lubricate; replace if necessary Inspect duct for proper sealing/air leaks Inspect; replace as
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    MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. Items not listed in the chart should
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    MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 72 for fluid recommendations, capacities and plug torques. Oil may need to be changed more frequently if Polaris
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    MAINTENANCE Engine Oil Oil and Filter Change See the table on page 72 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 68. Always change the oil filter whenever changing oil. 550
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    MAINTENANCE Engine Oil Oil and Filter Change 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate the
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    MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP Transmission Fluid for this transmission. See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic
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    MAINTENANCE Front Gearcase (Demand Drive) Fluid See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 for the part numbers of
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    MAINTENANCE Rear Gearcase Oil See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 for the part numbers of Polaris products. The
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    MAINTENANCE Rear Gearcase Oil Oil Change 1. 2. 3. 4. 5. 6. 7. 8. Position the vehicle on a level surface. Place a drain pan under the drain hole. Remove the drain plug. Allow the oil to drain completely. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. Remove
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    MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 77 for demand drive fluid maintenance. Check and change the ADC fluid level at the intervals
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    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 Cap to sit for at least 30 minutes. Bleeder 2. Thoroughly clean the areas Valve Screw around and on the ADC reservoir and
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    MAINTENANCE Power Steering Unit If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly. Clean Often Cooling System The engine coolant level is controlled by the recovery system. Recovery
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    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 storage compartment. 1. View the fluid level in the bottle. 2. If the level is low, remove the front rack. 3. Remove
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    MAINTENANCE Cooling System 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
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    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 selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the
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    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. Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are
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    MAINTENANCE Seat Removal 1. Grasp one side of the seat near the rear edge. 2. Pull upward abruptly to disengage the under-seat fasteners. 3. Remove the seat. Side Panel/Footwell Removal Remove the seat before removing a side panel. Remove the screws and rivets securing the side panel or footwell (
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    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. Refer to the specifications section
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    Wheel Removal 1. 2. 3. 4. Stop the engine. Place the transmission in PARK. Lock the parking brake. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 5. Elevate the side of the vehicle by placing a suitable stand under the
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    Aluminum Steel 45 ft. 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 Torque 75 ft. lbs. (102 Nm) 45 ft. lbs. (61 Nm) 90
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    MAINTENANCE Air Filter 1. Remove the seat. 2. Remove the air box cover screws, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type prefilter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filter.
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    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 circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. 1. Remove the
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    pod cover and disconnect the speedometer harnesses from the speedometer. CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 3. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 4. Turn the lamp counterclockwise to
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 98
    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 approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 25 ft.
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 99
    MAINTENANCE Lights Low Beam Adjustment 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. Phillips Screw 95
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 100
    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
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 101
    MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise 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. 4. Turn the
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 102
    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 126 for the recommended 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
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 103
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel. Wet
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 104
    . Reinstall the plugs or install new plugs. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 8. If water has been ingested into the PVT, follow the procedure on page
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 105
    of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Use the following procedure to periodically purge
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 106
    PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury safe: • 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
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 107
    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 flyweights also increases. This, in turn, increases the amount of pinch applied to the
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 108
    There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the repeat the process. 7. Take the vehicle to your dealer for service as soon as possible. 104
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 109
    MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 110
    MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. Remove the seat. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Disconnect the battery hold-down strap. On conventional batteries, remove the battery vent tube. Lift the battery out of the
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 111
    has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 109 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 112
    MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 113
    . Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 114
    MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no charge
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 115
    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose,
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 116
    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. • Always
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 117
    and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 118
    . See page 111. 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 recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 119
    the fluid looks dark or contaminated) • Coolant (test strength) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean, following the instructions on the container. Run the engine for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 120
    battery and recharge it as outlined on page 109. Store the battery in a cool, dry place. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 121
    MAINTENANCE Transporting the ATV Stop the engine. Place the transmission in PARK. Lock the parking brake. Secure the fuel cap, oil cap and seat. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front Aarm bolt pockets,
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 122
    ADJUSTMENTS 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 three cover screws from the right handlebar control and remove the cover. 2. With the
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 123
    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. Tap the throttle lever at each turn, verifying that idle RPM
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 124
    the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. Be sure the handlebars do
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 125
    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 126
    TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.8 VDC Check all connections
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 127
    TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 128
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 129
    POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2877606 2873602 2873603 2877922 2877923 2871653 2872276 2870465 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz./355
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 130
    SPECIFICATIONS Sportsman 550 XP / XP EPS 575 lbs. (261 kg) 730 lbs. (331 kg) (XP) 744 lbs. (337.5 kg) (XPS) Fuel Capacity 5.25 gal. (20 l) (XP) 4.5 gal. (17 l) (XP EPS) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 7.1 oz. (210 ml) Demand Drive Fluid
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 131
    SPECIFICATIONS Sportsman 550 XP / XP EPS Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 132
    SPECIFICATIONS Sportsman 850 XP / XP EPS Maximum Weight Capacity Dry Weight 575 lbs. (261 kg) 767 lbs. (348 kg) (XP) 781 lbs. (354 kg) (XP EPS) Fuel Capacity 5.25 gal. (20 l) (XP) 4.5 gal. (17 l) (XP EPS) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 133
    SPECIFICATIONS Sportsman 850 XP / XP EPS Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 134
    DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 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
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 135
    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 136
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 137
    WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment,
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 138
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 139
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 140
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 141
    WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 142
    responsible for performing the scheduled maintenance identified in the owner's manual. Polaris may deny warranty claims for failures that have been recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 143
    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 services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 139
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 144
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 140
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 145
    MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 141
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 146
    INDEX 0-9 4X4 Switch ...26, 34 C Cold Weather Operation ...53 Consumer Product Safety ...7 Coolant Bottle ...83 Coolant, Radiator...84 Cooling System ...82-84 Corrosion Removal, Chrome...113 Crankcase Emission Control System. 67 A Access, Front Compartment ...48 Accessories ...116 Active Descent
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 147
    Replacement. 97 Taillight/Brakelight/Worklight . 97 Low Beam Adjustment ...95 Low Range Use...104 Lower Headlamp Replacement...97 Lubrication Guide ...72 M Maintenance Chart ...68-71 Master Cylinder ...30 Metric/Standard Display ...41 Mode Switch ...26 Modifications ...9 G Gasoline Handling ...11
  • 2010 Polaris Sportsman XP 550 EPS | Owners Manual - Page 148
    INDEX R Rack/Compartment, Front ...48 Reverse Operation ...63 Reverse Override Switch ...26 Rider Information Center...38-47 Riding Area ...52 Riding Gear ...8-9 T Taillight ...97 Throttle Body Adjustment ...118 Throttle Cable Freeplay ...118-119 Throttle Lever ...28 Tire Tread Depth ...88 Tires
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Pantone 426C
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.
Owner's Manual
for Maintenance and Safety
Sportsman
550 XP
Sportsman
550 XP EPS
Sportsman
850 XP
Sportsman
850 XP EPS