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2009 Polaris Sportsman XP 850 & 550 Review


BuckBilly
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    • By GatorHunter
      Clymer ATV Manual - Polaris ATVs
      You can also find ATV Manuals on Amazon.
      Here is my list, some I have had, some I got online
      I have put all Manuals on my dedicated server, so the links won't go dead. Most the manuals listed below are on the server and there may be some on the server that's not on the list. Scroll to the bottom of this post to get the link.
      If you need a Manual that's not on the list, leave a reply, I will try to locate it, if I can't, I'm sure another member would share if they have it.
      If you have manuals that are not in the list and you would like to share them, leave a reply, with a link to your manuals and I will add them to my post so they are all in one spot.
      Thank you, and enjoy
      GH
      1985 thru 1995 Polaris service manual
      Below is the list of machines this Manual covers
      1985 Scrambler
      1985 Trail Boss
      1986 Scrambler
      1986 Trail Boss
      1987 Trail Boss
      1987 Trail Boss 4X4
      1987 Cyclone
      1988 Trail Boss 2X4
      1988 Trail Boss 4X4
      1988 Trail Boss 250 R/ES
      1989 Trail Boss
      1989 Trail Boss 2X4
      1989 Trail Boss 4X4
      1989 Big Boss 4X6
      1990 Trail Blazer
      1990 Trail Boss 250
      1990 Trail Boss 2X4
      1990 Trail Boss 2X4 350L
      1990 Trail Boss 4X4
      1990 Trail Boss 4X4 350L
      1990 Big Boss 4X6
      1991 Trail Blazer
      1991 Trail Boss 250
      1991 Trail Boss 2X4
      1991 Trail Boss 2X4 350L
      1991 Trail Boss 4X4
      1991 Trail Boss 4X4 350L
      1991 Big Boss 4X6
      1991 Big Boss 6X6
      1992 Trail Blazer
      1992 Trail Boss 250
      1992 Trail Boss 2X4
      1992 Trail Boss 2X4 350L
      1992 Trail Boss 4X4
      1992 Trail Boss 4X4 350L
      1992 Big Boss 4X6
      1992 Big Boss 6X6
      1993 250 2X4
      1993 350 2X4
      1993 250 4X4
      1993 350 4X4
      1993 250 6X6
      1993 350 6X6
      1993 Trail Boss
      1993 Trail Blazer
      1993 Sportsman
      1994 300 2X4
      1994 400 2X4
      1994 300 4X4
      1994 400 4X4
      1994 300 6X6
      1994 400 6X6
      1994 Trail Boss 2W
      1994 Trail Blazer 2W
      1994 Sportsman 4X4
      1994 Sport
      1995 300 2X4
      1995 400 2X4
      1995 300 4X4
      1995 400 6X6
      1995 Trail Boss
      1995 Trail Blazer
      1995 Sportsman 4X4
      1995 Sport
      1995 Xplorer 4X4
      1995 Scrambler
      1995 Magnum 2x4
      1995 Madnum 4X4
      1996 thru 1998 Polaris service manual
      Below is the list of machines this Manual covers
      1996 Trail Blazer
      1996 Trail Boss
      1996 Xplorer 300
      1996 Xpress 300
      1996 Xplorer 400
      1996 Xpress 400
      1996 Sport
      1996 Scrambler 4X4
      1996 Sportsman 4X4
      1996 Sportsman 500
      1996 400 6X6
      1996 Magnum 2X4
      1996 Magnum 4X4
      1996 Magnum 6X6
      1997 Trail Blazer
      1997 Trail Boss
      1997 Xplorer 300
      1997 Xpress 300
      1997 Xplorer 400
      1997 Xpress 400
      1997 Xplorer 500
      1997 Sport 400
      1997 Scrambler 4X4
      1997 Scrambler 500
      1997 Sportsman 4X4
      1997 Sportsman 500
      1997 400 6X6
      1997 Magnum 2X4
      1997 Magnum 4X4
      1997 Magnum 6X6
      1998 Trail Blazer
      1998 Trail Boss
      1998 Xplorer 300
      1998 Xpress 300
      1998 Sport 400
      1998 Scrambler 400
      1998 Scrambler 500
      1998 Xplorer 400
      1998 Magnum 2X4
      1998 Magnum 4X4
      1998 Sportsman 500
      1998 Big Boss 500 6X6
      1996 thru 2003 Sportsman 400 and 500, Xplorer 500 4X4 service manual
      Below is the list of machines this Manual covers
      1996 Sportsman 400
      1996 Sportsman 500
      1996 Xplorer 500 4X4
      1997 Sportsman 400
      1997 Sportsman 500
      1997 Xplorer 500 4X4
      1998 Sportsman 400
      1998 Sportsman 500
      1998 Xplorer 500 4X4
      1999 Sportsman 400
      1999 Sportsman 500
      1999 Xplorer 500 4X4
      2000 Sportsman 400
      2000 Sportsman 500
      2000 Xplorer 500 4X4
      2001 Sportsman 400
      2001 Sportsman 500
      2001 Xplorer 500 4X4
      2002 Sportsman 400
      2002 Sportsman 500
      2002 Xplorer 500 4X4
      2003 Sportsman 400
      2003 Sportsman 500
      2003 Xplorer 500 4X4
      2001 Sportsman 90 service manual
      2001 Scrambler 50 and 90 service manual
      2001 Sportsman 500 DUSE Parts Manual rev.2
      A01CH50AD
      2001 Sportsman 500 HO Parts Manual rev.3
      A01CH50AA
      A01CH50AB
      A01CH50AE
      A01CH50AK
      2001 Sportsman 500 DUSE HO Parts Manual rev.3
      A01CH50AF
      2001 Sportsman 500 RSE HO Parts Manual rev.3
      A01CH50AJ
      2001 Worker 500 Parts Manual rev.3
      A01CH50EB
      2002 Sportsman 6X6 Parts Manual rev. 1
      A02CL50AA
      2002 Big Boss 6X6 INTL Parts Manual rev.1
      A02CL50DA
      2002 Sportsman 500 HO Parts Manual rev.4
      A02CH50AA
      A02CH50AB
      A02CH50AE
      A02CH50AK
      2002 Sportsman 500 RSE Parts Manual rev.4
      A02CH50AC
      2002 Sportsman 500 DUSE Parts Manual rev.4
      A02CH50AD
      2002 Sportsman X Parts Manual rev.4
      A02CH50AJ
      2002 Sportsman 500 HO Freedom Parts Manual rev.4
      A02CH50AL
      2002 Sportsman 500 PSE HO Parts Manual rev.4
      A02CH50AM
      2002 Sportsman 500 Parts Manual rev.4
      A02CH50AN
      2002 Desert Sportsman 500 Parts Manual rev.4
      A02CH50FA
      2002 Worker 500 Parts Manual rev.4
      A02CH50AAEB
      2002 Sportsman 700 Parts Manual rev.2
      A02CH68AA
      A02CH68AB
      A02CH68AC
      A02CH68CA
      A02CH68CB
      2002 Sportsman 700 service manual
      2003 Sportsman 6X6 Owners Manual
      2003 Sportsman 6X6 Parts Manual rev.1
      A03CL50AA
      2003 Sportsman 6X6 service manual
      2003 Sportsman 400 and 500 HO service manual
      2003 Sportsman 400 Parts Manual
      A03CH42AA
      A03CH42AB
      A03CH42AC
      2003 Sportsman 500 HO Parts Manual
      A03CH50AA
      A03CH50AA
      A03CH50AA
      A03CH50AA
      A03CH50AA
      A03CH50AA
      2003 Sportsman 600 and 700 Owners Manual
      2003 Sportsman 600 and 700 service manual
      2003 Sportsman 700 Parts Manual rev.4
      2003 Predator Parts Manual rev. 1
      A03GJ50AA
      A03GJ50AB
      2003 Trail Boss 330 service manual
      2004 Sportsman 6X6 Parts Manual
      A04CL50AA
      2004 Sportsman 6X6 Owners Manual
      2004 Sportsman 6X6 service manual
      2004 Sportsman 400,500,600 and 700 Owners manual
      2004 Sportsman 400 Parts Manual rev.1
      A04CH42AA
      A04CH42AE
      A04CH42AG
      2004 Sportsman 400 Parts Manual rev.1
      A04CH42AQ
      A04CH42AT
      A04CH42AV
      A04CH42AS
      A04CH42AR
      2004 Sportsman 500 Parts Manual rev.1
      A04CH50AA
      A04CH50AC
      A04CH50AE
      A04CH50AG
      2004 Sportsman 500 Parts Manual rev.1
      A04CH50AO
      A04CH50AQ
      A04CH50AR
      A04CH50AS
      A04CH50AT
      A04CH50AV
      A04CH50AW
      2004 Sportsman 600 Parts Manual rev.2
      A04CH59AF
      A04CH59AH
      A04CH59AJ
      A04CH59AT
      A04CH59AV
      2004 Sportsman 600 Parts Manual rev.1
      A04CH59AK
      A04CH59AL
      A04CH59AN
      A04CH59AW
      2004 Sportsman 600 and 700 service manual
      2004 Sportsman 700 Parts Manual rev.2
      A04CH68AC
      A04CH68AF
      A04CH68AH
      A04CH68AJ
      A04CH68AT
      A04CH68AV
      2004 Sportsman 700 Parts Manual
      A04CH68AK
      A04CH68AL
      A04CH68AN
      A04CH68AO
      2004 Sportsman 700 MV Parts Manual
      A04CH68MB
      2004 Sportsman 700 MV service manual
      2004 Ranger 2X4 Parts Manual
      A04RB42AA
      2004 Ranger 4X4 Parts Manual
      A04RD50AA
      2004 Ranger 6X6 Parts Manual
      A04RF50AA
      2005 Sportsman 6X6 Parts Manual
      A05CL50AA
      2005 Sportsman 6X6 Owners Manual
      2005 Sportsman 6X6 service manual
      2005 Sportsman 400,500.600 and 700 Owners Manual
      2005 Sportsman 400 Parts Manual
      A05MH42AB
      A05MH42AG
      A05MH42AH
      2005 Sportsman 400 and 500 service manual
      2005 Sportsman 500 HO/INT'L Parts Manual
      A05MH50AB
      A05MH50AC
      A05MH50AG
      A05MH50AH
      A05MH50FB
      2005 Sportsman 600 Parts Manual
      A05MH59AK
      A05MH59AN
      2005 Sportsman 700 Parts Manual
      A05MH68AK
      A05MH68AN
      2005 Sportsman 700 EFI Parts Manual
      A05MH68AC
      A05MH68AS
      A05MH68AU
      A05MH68AW
      2005 Sportsman 700 EFI and 800 EFI Service Manaul
      2005 Sportsman 800 EFI Parts Manual
      A05MH76AC
      A05MH76AU
      A05MH76AW
      2005 Sportsman MV7 Parts Manaul
      A05MH68AP
      2005 Sportsman MV7 service manual
      2006 Outlaw 500 service manual
      2007 Sportsman 6X6 service manual
      2007 Sportsman 450 service manual
      2007 Sportsman 500 EFI service manual
      2007 Sportsman 500 X2 EFI service manual
      2007 Sportsman 700 service manual
      2007 Sportsman 800 service manual
      2007 Sportsman 800 EFI service manual
      2007 Sportsman 700 MV Parts Manual
      A07MH68MA
      2007 Sportsman 700 MV service manual
      2007 Outlaw 500 service manual
      2007 Ranger 700 EFI 6X6 Parts Manual
      R07RF68AD
      R07RF68AF
      2007 Ranger XP 4X4 service manual
      2007 Ranger XP 6X6 service manual
      2008 Sportsman 500 service manual
      2008 Sportsman 500 EFI service manual
      2008 Sportsman X2 500 EFI service manual
      2008 Sportsman Touring 500 EFI service manual
      2008 Sportsman X2 700 service manual
      2008 Sportsman 800 EFI service manual
      2008 Sportsman 800 Touring service manual
      2008 Ranger 6X6 700 EFI Parts Manual
      R08RF68AD
      R08RF68AF
      2009 Sportsman 6X6 800 EFI service manual
      2009 Sportsman 90 service manual
      2009 Sportsman 300 service manual
      2009 Sportsman 400 HO service manual
      2009 Sportsman 500 HO service manual
      2009 Sportsman 500 EFI service manual
      2009 Sportsman X2 500 EFI service manual
      2009 Sportsman Touring 500 EFI service manual
      2009 Sportsman 800 EFI service manual
      2009 Sportsman X2 800 EFI service manual
      2009 Sportsman Touring 800 EFI service manual
      2009 Sportsman XP 550 service manual
      2009 Sportsman XP 550 EPS service manual
      2009 Sportsman XP 850 service manual
      2009 Sportsman XP 850 EPS service manual
      2009 Outlaw 90 service manual
      2009 Outlaw 450 MXR service manual
      2009 Outlaw 525 S service manual
      2009 Outlaw 525 IRS service manual
      2009 Predator 50 service manual
      2009 Ranger RZR service manual
      2009 Ranger RZR S service manual
      2009 Ranger INT'L service manual
      2009 Ranger 2x4 service manual
      2009 Ranger 4x4 Crew service manual
      2009 Ranger 6x6 service manual
      2009 Ranger 500 4x4 EFI service manual
      2009 Ranger RZR 170 service manual
      2009 Ranger XP 700 4x4 service manual
      2009 Ranger HD 700 4x4 service manual
      2009 Scrambler 500 service manual
      2009 Trail Blazer 330 service manual
      2009 Trail Boss 330 service manual
      2010 Ranger RZR service manual
      2010 Ranger RZR S service manual
      2010 Ranger INT'L service manual
      2011 Ranger RZR SW service manual
      2011 Ranger RZR service manual
      2011 Ranger RZR S service manual
      2011 Ranger RZR 4 service manual
      Other Stuff
      2500lb Polaris Winch Install Instructions and Parts List
      2500lb Warn Winch Install Instructions
      2500lb Warn Winch Parts Manual
      Warn Winch Motor Rotation Instructions
      Warn - The Basic Guide to Winching Techniques
      Sportsman 600 and 700 Ignition Replacement Kit Install Instructions
      Polaris Special Tools - ATV,Snowmobile,Watercraft
      Download Manuals HERE
       
      Some ATV manuals available in the downloads section at https://www.quadcrazy.com/files/
      Find them on on:
      Get 15% at emanualsonline.com with coupon code EMOAFF
      Get 20% at emanualsonline.com with coupon code BLAZE and $50 purchase
    • By weblex
      Hi. I'm owning 2014 Sportsman Forest 850. Due to operation there is a problem with the decals and I would like to update them. But, as it turned out, this model is rare and finding the necessary stickers is a very difficult task, especially considering that the part of the decals set that I'm looking for is no longer produced - number 2 on the pic below with part number 7179065.
      I've tried to contact Polaris support asking them to sell me this decals or send image in any possible format to print by myself but unfortunately no luck and it's sad, because I have owned various models of Polaris for over 10 years and a fan of this manufacturer.
      Perhaps someone can send graphic files so I can print the stickers myself or show me how to get them?
      Or is there another solution to this problem? Small fresh decals make the ATV look completely different.
      Thank you in advance for any help or idea.
       

    • By jamison1969
      I have a 97" polaris sportsman 500 and the 4 wheel drive wont work, it just didnt work one day. I dont know when or why it went out. It has a 4 wheel drive button on the handle bars and it is on and i have turned it on and off but no go............ any thoughts or ideas, please help. I need it for sat. i will never get out on this small lake for ice fishing with out my wheeler, thanks in advance jamie.
    • By KeysPropertyGuy
      I feel credible information is important; and I personally have friends and family all over this country that share the same passion for Side by Side Adventures that I do. This article is for all of you and the " Newbee's " like myself that are just entering the SXS Market, and don't know which way to turn when it comes to fixing belt/clutch issues upon upgrading your tires on your Side by Side to handle a particular situation such as mud and swamp riding, that put high torque on your drivetrain.
      In my case it is my 2021 Polaris RZR XP 1000 Premium that I just purchased. This is the product I will be speaking specifically about. This is a VERY expensive process make no mistake about it! I have over $2,500 in useless STM Powersports clutch parts, for my application and another $2,000 plus in tires and rims that I can't use, DON'T BE THIS GUY!
      First, giving credit where due, Dustin (Tech at STM Powersports) was very willing and responsive when trying to make his companies product fix my issue. For those of you who are not interested in all the details. Their clutches are not designed to handle heavy mud and swamp applications period, and can't be tuned, as they advertise, to work, in my opinion. I personally have over a hundred hours of hands on testing to back that statement up. Upon further investigation, STM Powersports seems to be a snowmobile clutch manufacture out of Michigan that has morphed into building SXS clutches that apparently work on snowmobiles and sand dune SXS racing applications, they say. Can't see them being any different with other manufactures either as all that use a belt run on the same principle, but I can only speak for my Polaris Application.
      My Problem- When upgrading my tire from the stock 30" tire to a 30" Aqua Torque Sand Mud Tire ( totally bad as* tire FYI ) that was EXACTLY what I needed for my mud, sand, and swamp riding here in Florida, I started burning up belts every 9 to 29 miles, which made no sense at all, so than began my research.
      Solution (so I was told) - I need a " Performance Clutch " that is adjustable so that I can tune it for my particular situation/application.  Made Sense, and I am mechanically inclined, being in the mechanical field over 30 years, so I thought it would be fun and I could get to learn something new at the same time. Always good to keep learning.
      My Goal - To save just one person who reads this a whole lot of money, time, and aggravation. I have spent well over a 100 hrs of personal tuning and testing with guidance from Dustin from STM PowerSports, watching all their tuning video's, and using some common sense once I understood the principle of how the clutch functioned, and what adjustments effected speed, rpm, etc. etc. etc. to no resolve.
      My Process - Doing some quick " Google " research " apparently I should of done a hell of a lot more, I was guided to Vivid Racing who sold me this STM PowerSports mess. They apparently are one of STM PowerSports product distributors.  When I ordered this product I was EXTREMELY detailed on what I needed due to my current riding conditions, the exact make, year, and model of my Kart, my weight, and the weight, make, and size of the tire I was replacing my stock tires with. The sales rep confirmed my needs, and assured me that a STM PowerSports Clutch was what I needed, to the tune of over $2,500. As soon as I started having issues though, my Vivid Racing sales rep could not be reached anymore, would never return any of my calls, and apparently after a week of this, no longer worked there, ie I was S.O.L.
      Pulling out my parts packaging I was able to find the # of the manufacture and found Dustin, a Technical Support Advisor for the Company, that also raced SXS. Any of you that want the real detailed information on the exact tuning that was done and detailed information for your own knowledge, please leave me your # and I would be happy to share all of that with you.
      To make a long story a little shorter, after over a month and a half of phone calls to STM PowerSports, changing clutch weights and position on the clutch arms, primary and secondary clutch springs, and doing test runs after every single adjustment and still smokin my belts; Dustin at STM Powersports was convinced there was something wrong with my 2021 Polaris RZR XP 1000 Premium. Even though it was brand new and only had 279 miles on it at the time.
      He said the transmission had to be out of alignment with the motor or something had to be binding in the transmission or drive-train.  Taking his advise, and that out of the equation, I spent over $300 on a professional motor transmission alignment tool, only to re confirm that everything was spot on. I again followed his directions on his " Binding Drive-Train theory and jacked everything off the ground ( another $150 in jackstands ) just to find out that everything spun freely, nothing was binding, and nothing seemed out of order there either.
      I also need to add, that during this testing " Process " I had gone thru 7 belts at approx $150 bucks a piece. I had previously installed a Razorback Belt Temp Sensor on my Kart so with every adjustment I could watch my belt temps and compare everything. The only thing I didn't know at the time (and guess it is kind of relative to your riding area, and temperature of where you are riding) is that normal temps are anywhere between 130 and 180 when really pushing it, on average for my Kart when it is running right. What I can tell you is, when it's not, at 250 Degrees your belt starts so de-laminate, 260 pieces come off, and 275 it blows up into a thousand pieces like popcorn. With this STM PowerSports clutch I could not drive down a hard packed sand road with my kart in 2 wheel low or high 4 wheel low or high for more then 9 miles before the belt temps would start hitting 250, so something was wrong; and all through this process it was never the STM  Powersports Clutch, it was my 2021 Polaris RZR XP 1000 Premium.
      Even after all my testing, per his direction, Dustin from STM PowerSports was still convinced it was my Kart, and not his companies product. He advised me to put all my stock parts back on, run it another time, and then get back to him.
      I again agreed, but told him that the whole reason that I purchased his companies product in the first place, was that I didn't want to run my stock tires and I already knew that my stock clutch set up can't handle my new tires for some reason??? or I wouldn't have spent over $2,500 dollars buying a new STM Powersports clutch from his company. I did as he requested and here are the results.
      Conclusion - My concern, I was leaving to do some serious riding on the Hatfield McCoy Trail System in West Virginia the following week. I was now praying to God that something would give! I was out of time to test his theories that were obviously just guesses at this point. My 2021 Polaris RZR XP 1000 Premium can't keep a drive-belt on it that can last 19 miles, at times, say nothing of the hundreds of miles that I was looking forward to be driving in West Virginia.
      I stripped off all STM Powersports Clutch parts, put on yet another new drive-belt, installed my stock clutches an tires, and took it for one last test run at River Ranch before loading it in the trailer to head to West Virginia. As I didn't have much time and honestly at this point, I was ready to call everything off. With all the original stock set up back on, I put it to the test, with my fingers and toes crossed (translates to praying my butt off) I put the hammer down for my last afternoon of testing I had left.
      I hit every mud hole, water hole, river, and small lake that I could find. If you have ever been to River Ranch in Florida you will know I didn't have to look far. I clocked ten miles, interesting, 20 miles, getting nervous now, 30 miles, it's going to blow any time now for sure, 40 miles???, now i'm kinda dumb founded! At 49 miles the belt temps were still only running 167 degrees tops, which I never had seen before. As everything was already paid and ready for West Virginia, I said the worst that could happen, is I would have to rent a Kart for the week and listen to more bashing from my friends. 
      Now for the BIG test. To the Appalachian Mountains where there are some real mountains and challenging situations, for real! 
      Results - In 6 Days I put on an additional 649 Miles, hard miles on my 2021 Polaris RZR XP 1000 Premium " just one belt " that already had 49 miles on it when I started, with not a lick of problems. The belt temperature never hit 200 degrees even after long crazy hill climbs. So, if your wondering why I am calling this product " BS " for the type of riding conditions I purchased it for, well all I can tell you is, it isn't my driving style, or an issue with my New Polaris RZR XP 1000 Premium, or the belt that I was consistently running (which Dustin Recommended I run). In my opinion it's with a STM PowerSports, a Michigan Company that is " Marketing " and " Selling "  a clutch product that they have not done any proper R & D on for the application they sold it to me for, or are Marketing/Selling it to everyone else who also has Mud/Swamp riding needs. They have no problem taking your money, and your stuck with it once you purchase  it, just so ya know.
      To my friends an all the Newbee's like me out there, I wish I could finish this article with a solution for y'all, but for now I am out of money, time, and patience to go through this process again. I have heard rumors that Duraclutch was designed by guys that are Mud Boggers and do swap riding as well as R&D their product for this application??? If there is anyone out there that reads this and has found a " Tested " solution to my problem I would love to hear about it. The Aqua Torque Tires I purchased are an truly amazing product, they apparently just weigh more then the stock tires and STM Powersports has no business selling their product to people that mud and swamp ride in" high torque " situations. They should be letting the public know that OR " Man UP " and spend the time, money, and do the right thing, and test an develop a product that actually works for the application they are selling it for, Before they sell it.  They seem to have no problem bragging that their product is made in America, while my Chinese Stock Polaris Clutch clearly out preforms their product for stock application needs, and a quarter of the cost! 
    • Dream Car Giveaway
    • By DonB
      Had fire start in muffler due to failing fuel pump &/or fuel pressure regulator.  Must I spend the $750+ for a new assembly from Arctic Cat?!?  Here's what I've tried so far.
      Replaced fuel pump & regulator - both from Quantum. PSI is 60 rather than the 42 the dealer advises it should be, so problem persists.  I've now twice replaced the Quantum regulator & discussed w/ Quantum. They advise that they don't have an alternative regulator that would bring PSI down to 42. I've tried several in-line, adjustable pressure regulators but they either didn't work or I couldn't get a constant pressure from them. FYI, I've only tried the adjustable regulators for Fuel Injected engines however, it seems that they require vacuum to function properly.  When I can temporarily get the PSI right, everything works great.  Anyone else ever dealt with this problem, and, if so how did you fix it?  Perhaps I should adapt the fuel system to include a gas tank return line?
      Any insights are greatly appreciated, Don
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