2009 Polaris Sportsman 550/850 XP and XP EPS ATV Owner's Manual (P/N 9921973)

This Polaris owner’s manual, P/N 9921973, Revision 02 (printed in USA), covers the 2009 Sportsman 550 XP, 550 XP EPS, 850 XP, and 850 XP EPS.

PDF Text Search, Illustrations and Page Count

Search and diagram detail: The main text supports keyword searches, while the cover pages and some illustration labels are not searchable. There are no embedded PDF bookmarks. Small fuse-box legends require enlargement; the non-EPS layouts have noticeably lighter lettering.

Supplied as one printable, 144-page PDF, including 141 numbered pages and three unnumbered cover and safety pages.

Owner Maintenance and Drive-System Operation

The selected topics below are supplemented by instructions for seasonal storage and transporting the ATV.

• Engine and filtration: Oil and filter changes, spark plug inspection, air filter and pre-filter service, and spark arrestor clean-out.

• Drivetrain fluids: Step-by-step transmission, Demand Drive and rear gearcase fluid changes, plus Active Descent Control (ADC) fluid replacement and bleeding.

• PVT operation: Polaris Variable Transmission range selection, drive-belt break-in, water-ingestion drying procedures, and a Drive Belt Wear/Burn troubleshooting chart.

• Chassis adjustments: Throttle cable freeplay adjustment, toe alignment checks, suspension spring settings, handlebar adjustment, and brake and steering inspections.

• Electrical service: Fuse replacement, headlight and taillight service, beam adjustment, and separate battery maintenance instructions for conventional and sealed batteries.

• EFI and EPS information: Instrument cluster operation, Electronic Fuel Injection diagnostic display codes, and Electronic Power Steering warning and fault-code information.

Suited to adult owners handling minor maintenance who are familiar with safe service practices; the maintenance chart identifies work reserved for an authorized Polaris dealer.

Maintenance Planning and Service Limits

Usage-based periodic maintenance charts help you identify service intervals by hours, calendar time or mileage, whichever comes first. Severe-use guidance addresses mud, water, prolonged low-speed work and cold-weather operation, while the maintenance log provides space to record completed service.

The lubrication guide separates engine oil, transmission fluid, front gearcase fluid, rear gearcase oil and ADC fluid requirements. It pairs these with component-specific fill and drain plug torques; separate illustrations identify the engine drain plug locations for the two engines.

Major repair work: This is an owner’s manual with minor maintenance instructions. Polaris directs major repairs to the separate Polaris Service Manual and specifies a Factory Certified Master Service Dealer technician for that work.

Before starting any service work, operators must review the documented fluid handling procedures and safety guidelines to prevent personal injury or mechanical damage.

PVT, ADC and Illustrated Adjustment References

The PVT section explains how range selection affects belt grip and heat. Its troubleshooting chart distinguishes operating conditions that contribute to belt wear from clutch malfunctions requiring dealer attention.

ADC fluid-change instructions cover bleeding at both differential valves, supported by labeled views of the bleeder screw and cap. Brake fluid in the ADC circuit can damage its rubber components; engaging 4X4 while the rear wheels are spinning can damage the drive shaft and gearcase.

Front-compartment component views, toe alignment illustrations, high-beam aiming diagrams and throttle cable adjuster views support the maintenance text. These show access points and adjustment references alongside the procedures.

EFI Codes and Symptom-Based Troubleshooting

Separate diagnostic charts for the two engine configurations list Suspect Parameter Numbers (SPN) and Failure Mode Indicators (FMI). Covered components include the throttle position sensor, engine temperature sensor and idle air control, with additional steering sensor and communication faults for EPS models.

The instrument cluster instructions explain viewing active codes. This display is informational, and retrieving inactive codes from the unit’s history requires dealer assistance; a displayed code alone does not establish the failed component.

Troubleshooting tables address starting problems, backfiring, stalling, misfires, loss of power and overheating. Model-specific specification tables also provide altitude-based shift-weight and clutch-spring charts, rather than clutch overhaul instructions.

Selected Throttle and Alignment Settings

The throttle cable section specifies 2–3 mm of freeplay between the throttle arm stop pin and throttle arm, checked with the handlebars straight ahead.

The toe alignment check specifies 1/8–1/4 in. (3–6 mm) toe-out. The manual distinguishes this inspection from tie-rod adjustment, which it assigns to an authorized Polaris dealer.