Polaris Sportsman X2 550 EPS Owner's Manual
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Polaris Sportsman X2 550 EPS Owner's Manual

Maintenance and safety
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See also: Owner's Manual for Maintenance and Safety
PMS 419
Sportsman X2 550 EPS
Owner's Manual
for Maintenance and Safety
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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  • Page 1 PMS 419 Sportsman X2 550 EPS Owner's Manual for Maintenance and Safety 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.
  • Page 2 WARNING The engine exhaust from this product contains chemicals known to 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- 342-3764 for assistance.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 POLARIS® and SPORTSMAN® are registered trademarks of POLARIS Industries Inc. Copyright 2013 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 discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    Troubleshooting ..... . . 143 POLARIS Products..... 147 Specifications .

  • Page 6: Introduction

    INTRODUCTION The following signal words and symbols appear throughout this manual and on 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. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 7 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

  • Page 8: 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.

  • Page 9: Safety

    ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members.

  • Page 10: Safe Riding Gear

    Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. A passenger (on approved models) should wear a helmet that includes a rigid chin guard.

  • Page 11: Eye Protection

    Riding pants with kneepads and a jersey with shoulder pads provide the best protection. Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

  • Page 12: Safety Warnings

    SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. 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.

  • Page 13: Handling Gasoline

    SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 14: Protective Apparel

    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. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

  • Page 15: Operating On Pavement

    SAFETY Safety Warnings Carrying a Passenger in the Cargo Box A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death. Never allow a passenger to ride in the cargo box.

  • Page 16: Physical Control Of The Atv

    SAFETY Safety Warnings Physical Control of the ATV Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.

  • Page 17: Improper Hill Climbing

    SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 65. Never operate in TURF mode while operating on a hill or other irregular terrain.

  • Page 18: Stalling While Climbing A Hill

    SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

  • Page 19: Operating On Slippery Terrain

    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 until you've learned and practiced the skills necessary to control the ATV on such terrain.

  • Page 20: Skidding Or Sliding

    SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

  • Page 21: Operating Through Deep Water

    SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 70):...

  • Page 22: Poor Visibility

    SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the...

  • Page 23: Operating A Damaged Atv

    SAFETY 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 operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 24: General Warning

    If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. General Warning...

  • Page 25: Age 16 Warning

    SAFETY Safety Labels and Locations General Warning Passenger Safety/Discretionary Warning Age 16 Warning Reverse Override Warning 4X4 Caution Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger. NEVER operate this vehicle if you are under age 16.
  • Page 26 SAFETY Safety Labels and Locations Passenger Safety//Discretionary Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.
  • Page 27 SAFETY Safety Labels and Locations Tire Pressure/Load Warning WARNING Tire Pressure/Load Improper tire pressure or overloading Warning can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 7.0 psi (48.3 kPa) Rear: 7.0 psi (48.3 kPa) •...

  • Page 28: Clutch Cover Warning

    SAFETY Safety Labels and Locations Warning Rack Warning Hitch Capacity Clutch Cover Label Warning (under seat) Rack Warning, Front WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum combined Front Rack and Container Load: 120 lbs.

  • Page 29: Box Warning

    SAFETY Safety Labels and Locations Box Warning WARNING Remove flammable material containers from box before filling. WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load - 400 lbs. (181 kg) 7173890...

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Switches Headlight Switch 4X4 Switch Mode/Reverse Override Button Engine Main Key Stop Switch Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, depress the override switch. WARNING! Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death.

  • Page 31: Main Key Switch

    FEATURES AND CONTROLS Switches Main Key Switch Use the main key switch to start the engine. See page 59. 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 4X4, 2X4 or TURF mode. See pages 38-39. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

  • Page 32: Operation

    FEATURES AND CONTROLS Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle 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.

  • Page 33: Brake Lever

    FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result 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.
  • Page 34 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 hygroscopic, meaning it rapidly absorbs moisture from the air.

  • Page 35: Parking Brake

    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.
  • Page 36 FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
  • Page 37 FEATURES AND CONTROLS Auxiliary Foot Brake Brake Fluid Level Brake Fluid Check the brake fluid level Reservoir frequently for the auxiliary brake system. The reservoir is located under the front storage box. See page 43. Maintain the fluid level between the maximum and minimum marks.
  • Page 38 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the Selector vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop.

  • Page 39: Fuel Tank Cap

    If your factory-installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, please see your POLARIS dealer to purchase a 30 AH battery. 1. Fully charge the new battery before installing it. See page 132.

  • Page 40: All Wheel Drive System

    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.

  • Page 41: Engaging 4X

    FEATURES AND CONTROLS All Wheel Drive System 2X4 Mode When the switch is on 2X4, the ATV is in two-wheel drive at all times. TURF Mode When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage.

  • Page 42: Engaging Active Descent Control

    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 automatically engage when all four of the following conditions occur:...

  • Page 43: Passenger Seat

    FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when operating without a passenger. Always return the seat to the 1-up position for single-rider operation.
  • Page 44 Repeat the set-up procedure. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your POLARIS dealer for service. 8. To return the vehicle to single-rider operation, reverse all steps. Always...

  • Page 45: Front Box/Compartment

    FEATURES AND CONTROLS Front Box/Compartment Release the front box anchor latches and remove the box assembly to gain access to the front compartment. To reinstall the box, hold the box as shown in the rack illustration. Position the front edge in the tabs, Latches then push the box downward and secure the latches.

  • Page 46: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster.

  • Page 47: Indicator Lamps

    ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
  • Page 48 If this occurs, take the ATV to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 49 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center 1. Gear Display - This area displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2.
  • Page 50 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.
  • Page 51 FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 52 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 warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
  • Page 53 Failure Mode Indicator (FMI) If the CHECK ENGINE light illuminates, retrieve the error codes from the display. Please see your Polaris dealer for all major repairs. 1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG”...
  • Page 54 FEATURES AND CONTROLS Instrument Cluster 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 electronic control unit and the item listed in the chart.
  • Page 55 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Sportsman X2 550 EPS Diagnostic Codes Component Condition Throttle Position Sensor Voltage Too High Voltage Too Low Engine Temperature Sensor Voltage Too High Voltage Too Low Temperature Too High Engine Overheat Shutdown...
  • Page 56 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Sportsman X2 550 EPS Diagnostic Codes EPS Models Only Steering Over Current Shut Down Current Above Normal or 520221 Grounded Steering Excessive Current Error Current Above Normal or 520222 Grounded Steering Torque Sensor T1 Partial...

  • Page 57: Operation

    Break-In Period The break-in period for your new POLARIS ATV is the first 25 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

  • Page 58: Pre-Ride Checklist

    Indicator lights/switches Ensure operation Engine stop switch Ensure proper operation Air filter, pre-filter Inspect, clean Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/taillight Check operation, apply POLARIS dielectric grease when lamp is replaced Riding gear...

  • Page 59: Safe Operation Practices

    OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

  • Page 60: Trail Etiquette

    Respect the environment in which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

  • Page 61: Starting The Engine

    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 brake is not engaged.

  • Page 62: Driving Procedures

    OPERATION Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 56. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.

  • Page 63: Turning The Vehicle

    OPERATION Turning the Vehicle Both rear wheels drive equally at all times (except when operating in TURF mode). This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.

  • Page 64: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. 2.
  • Page 65 OPERATION Driving with a Passenger 12. Do not cross a hillside with a passenger on board. See page 66. 13. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times.

  • Page 66: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Turn in Sideways direction of skid 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.

  • Page 67: Driving Uphill

    OPERATION Driving Uphill 15° 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. Never operate in TURF mode while operating on a hill or other irregular terrain.
  • Page 68 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.

  • Page 69: Driving Downhill

    OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
  • Page 70 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)
  • Page 71 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

  • Page 72: Driving Through Water

    OPERATION Driving Through Water Maximum Depth Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2.

  • Page 73: Driving Over Obstacles

    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.

  • Page 74: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 75: Parking On An Incline

    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.

  • Page 76: Hauling Cargo

    OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never carry cargo in the rear box when operating the ATV in the 2-up mode with a passenger.
  • Page 77 OPERATION Hauling Cargo 1. Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. 2. Cargo weight should be mounted as low as possible. 3. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving...

  • Page 78: Towing Loads

    ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use. Maximum Towing Capacities Do not exceed the following maximum capacities when towing.

  • Page 79: Dumping Cargo

    OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Lock the parking brake. 4.

  • Page 80: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

  • Page 81: Winch Safety Precautions

    WINCH GUIDE Winch Safety Precautions 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.
  • Page 82 WINCH GUIDE Winch Safety Precautions 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23.

  • Page 83: Winch Operation

    WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 84 WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 85 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
  • Page 86 WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 87.
  • Page 87 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 88: Winch Cable Care

    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 89 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 90 WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.

  • Page 91: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 92: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 93: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 158.

  • Page 94: Periodic Maintenance Chart

    Emission-related service (failure to conduct this maintenance will not void the emissions warranty but may affect emissions) Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
  • Page 95 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Air filter, Weekly Inspect; replace as needed main element Brake pad wear 10 H Monthly 100 (160) Inspect periodically Battery 20 H Monthly 200 (320) Check terminals;...
  • Page 96 Inspect; adjust (16000) D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

  • Page 97: Lubrication Guide

    Grease fittings (3 pumps maximum) every 500 miles, Shaft Yoke before long periods of storage, or after pressure washing or submerging. A-Arms, Front POLARIS All- Grease fittings after extreme use or if suspension and Rear Season Grease becomes squeaky. Front...

  • Page 98: Engine Oil

    POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W- 50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W- 50 oil. Follow the manufacturer's recommendations for ambient temperature operation.

  • Page 99: Oil Level

    MAINTENANCE Engine Oil Oil Level Check the oil level when the engine is cold. Never check the oil with the engine running. 1. Position the vehicle on a level surface. 2. Access the oil dipstick and fill tube from the left side of the ATV. Remove the dipstick.

  • Page 100: Oil And Filter Change

    MAINTENANCE Engine Oil Oil and Filter Change See the table on page 95 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 91. Always change the oil filter whenever changing oil.
  • Page 101 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 counter-clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

  • Page 102: Transmission Oil

    Periodic Maintenance Chart beginning on page 91. See the table on page 95 for fluid recommendations, capacities and plug torques. See page 147 for the part numbers of POLARIS products. Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the ATV behind the footwell.
  • Page 103 MAINTENANCE Transmission Oil Oil Change 1. Remove the footwell. 2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. 3. Clean and reinstall the drain plug. Torque to specification. 4. Remove the fill plug. Add the proper amount of the recommended oil.
  • Page 104 • ADC is the primary mode of all-wheel-drive operation. Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 147 for the part numbers of POLARIS products. Maintain the fluid level at the bottom of the fill hole threads.

  • Page 105: Fluid Change

    MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level. 2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads. 3.

  • Page 106: Fluid Level

    We recommend the use of POLARIS Demand Drive Fluid for the ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 147 for the part numbers of POLARIS products. NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.
  • Page 107 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 to sit for at least 30 minutes. Bleeder 2. Thoroughly clean the areas Valve Screw around and on the ADC reservoir and bleeder valves...

  • Page 108: Rear Gearcase Oil

    Periodic Maintenance Chart beginning on page 91. See the table on page 95 for fluid recommendations, capacities and plug torques. See page 147 for the part numbers of POLARIS products. The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.

  • Page 109: Oil Change

    MAINTENANCE Rear Gearcase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain hole. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.

  • Page 110: Cooling System

    Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. POLARIS Antifreeze is already premixed and ready to use.
  • Page 111 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 box. 3.

  • Page 112: Radiator Coolant

    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 drained for maintenance or repair.

  • Page 113: Hand Brake

    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 self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.

  • Page 114: Toe Alignment

    1/4-1/2 inch (6-12 mm) toe 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.

  • Page 115: Seat Removal

    MAINTENANCE Seat Removal 1. Remove any cargo from the cargo box before removing the seat. 2. Stand beside the vehicle. Pull the cargo box release strap upward. Lift the front of the cargo box. 3. Grasp edge of the seat near the opposite rear corner.

  • Page 116: Wheel Removal

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK.

  • Page 117: Wheel Installation

    MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped).

  • Page 118: Air Filter

    MAINTENANCE Air Filter 1. Remove the seat. See page 113. Strap 2. Remove the air box cover strap, and remove the air box cover. 3. Remove the filter. 4. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 119: Fuse Replacement

    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.

  • Page 120: Headlight Lamp Replacement

    MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fingers.

  • Page 121: High Beam Adjustment

    MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft.

  • Page 122: Headlight Housing Replacement

    MAINTENANCE Lights Low Beam Adjustment Phillips Screw 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. Headlight Housing Replacement 1.

  • Page 123: Lower Headlamp Replacement

    MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise 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. Harness 4.

  • Page 124: Spark Plugs

    Refer to the specifications section beginning on page 148 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 POLARIS-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 9-11 ft.
  • Page 125 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There 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.

  • Page 126: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 127: Spark Arrester

    MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.

  • Page 128: Pvt System

    • 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 in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 129 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 drive belt.

  • Page 130: Pvt Drying

    MAINTENANCE PVT System When To Use Low Range and High Range The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).

  • Page 131: Battery Removal

    (black) cable last. Your ATV is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.

  • Page 132: Battery Installation

    If your factory-installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, please see your POLARIS dealer to purchase a 30 AH battery. Before installing the 30 AH battery, remove the plastic spacer at the bottom of the battery compartment.

  • Page 133: Battery Storage

    POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

  • Page 134: Battery Charging

    MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 135 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.

  • Page 136: Throttle Cable Freeplay

    MAINTENANCE 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 four cover screws from the right handlebar control and remove the cover.
  • Page 137 6. If idle speed remains above or below the recommended 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.
  • Page 138 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.

  • Page 139: Camber And Caster

    The camber and caster are non-adjustable. Front and Rear Springs The front and rear shock absorber Adjuster springs are adjusted by rotating the adjuster either clockwise or counter- clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer.

  • Page 140: Transporting The Atv

    Accessories Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see...

  • Page 141: Cleaning And Storage

    Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

  • Page 142: Polishing The Vehicle

    Polishing 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.

  • Page 143: Storage Tips

    • Coolant (test strength/fill) 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, rings, valves and exhaust systems.
  • Page 144 5. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline. Air Filter / Air Box 1.

  • Page 145: Troubleshooting

    PVT sys- Clutch malfunction See your POLARIS dealer. Poor engine perfor- Check for fouled plugs or foreign material in gas tank mance or fuel lines. See your dealer.
  • Page 146 Inspect plugs and replace if neces- sary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure...
  • Page 147 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat Set gap to specs or replace plugs range Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug(s)

  • Page 148: Engine Overheating

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug(s) Inspect, clean and/or replace spark...

  • Page 149: Polaris Products

    2877923 Demand Drive Plus Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug Coolant 2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l) 2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season 2871322 All Season Grease (3 oz./89 ml cartridge)

  • Page 150: Specifications

    SPECIFICATIONS Sportsman X2 550 EPS Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger, cargo, accessories) Dry Weight 813 lbs. (368.8 kg) Fuel Capacity 5.25 gal. (20 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2 qts. (1.9 l) Transmission Oil Capacity 37 oz.
  • Page 151 SPECIFICATIONS Sportsman X2 550 EPS Transmission H/L/N/R/P Gear Reduction, Low 5.034:1 Gear Reduction, Reverse 4.508:1 Gear Reduction, High 2.693:1 Drive Ratio, Front 3.818:1 Tires/Pressure, Front Maxxis AT 26 x 8 - 14 / 7 psi (48.3 kPa) Tires/Pressure, Rear Maxxis AT 26 x 10 - 14 / 7 psi (48.3 kPa)

  • Page 152: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 153 Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
  • Page 154 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 155 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied.
  • Page 156 SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
  • Page 157 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase...
  • Page 158 *As related to the evaporative emission control system. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 159 POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 160: Maintenance Log

    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) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 161 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 162: Index

    INDEX 4X4 Switch ....29 Consumer Product Safety ..7 Coolant Bottle ....109 Coolant, Radiator.
  • Page 163 INDEX Fluid Hand Brake ....111 ADC ....104-105 Handlebar Adjustment .
  • Page 164 Headlight Switch ... . . 29 Polaris Product List ... . 147 Main Key Switch ... . . 29 Polishing the Vehicle.
  • Page 165 INDEX Toe Alignment ....112 Vehicle Identification Numbers ..6 Towing Capacities ....76 Vehicle Immersion .
  • Page 166 - dismount passenger when conditions require make sure passenger reads and understands this label and passenger safety label READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No.

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