I have a question for you smart guys out there. I had my first oil change done on my 09 Sportsman 550. I drove easy a couple of times since, one time was using a lawn roller filled with sand. Not too heavy for the machine of course. I went to check the oil yesterday and the dipstick was broken off right above were the lines are to check the oil level. The rest of it looked like it had been in a blender (all knicked and cut up). No i didnt cross thread the dipstick. The dealer replaced the dipstick with a new one and checked the machine out, however they said they didn't see anything wrong. I know something had to cause it. Any help will be appreciated.

Thank you.

 

Did they change the oil filter?. Did they check with Polaris for service bulletins on this issue?. You need to change the filter, chances are any metal pieces are trapped there rather than rattling around in the engine.

You also need your dealer to document this with Polaris, in case you have engine failure. Particularly if it fails after the warranty expires.

 

I agree

 

Yeah they did change the oil and filter. The dealership said they would check for bulletins regarding my problem, however I'm not sure they reported the problem with Polaris for warranty. So thank you for mentioning that.

Thanks again.

 

i recall the same issue someone had posted on here a while back.

 

When I went to change my oil for the second time found the same thing .Bottom part of the dipstick missing..Called dealer who then called Polaris.They were told that they had two (2) other reports of this happening.There reply was dipstick removed while atv was running or not properly installed.I personally service my own atv's and know neither of these were the cause.Was also told not to worry there is a screen in the pickup that will stop the parts getting into the motor...Now have 1500 miles since and no problem yet..I also have the 5 year extended warrenty ...2009 Sunset Red Sportsman 550 XP

 

The 850s have a similar situation..on those a counterbalance shaft weight is very close to the dipstick. The ones I have heard of on the 850s breaking were caused by the either the dipstick being crossthreaded(screwed in crooked),the dipstick not being screwed in when the machine was started(ie just sitting in the hole) and lastly trying to remove the dipstick with the engine running. The guy that started his with the dipstick just sitting in the hole said it shot out lol.
Look inside the dipstick hole and see if you can see what might be hitting it..I think the 550 might also have a counterbalance shaft near the dipstick. I Haven't seen a 550 dipstick..is it metal or plastic? Is it possible the dipsticks are getting bent somehow allow something,such as a counterbalance shaft,to contact it?

 

The 550 has a yellow plastic dipstick i assume just like the 850. I also have never started my XP with the dipstick just sitting in the hole or have I cross threaded it. I dont know, maybe it was just a fluke. Hopefully I wont have any more problems with it. I just hit 100 miles on the odometer yesterday and didnt have any problems in the 20 miles I rode it. Do you think I can remove the dipstick completely before starting the machine to see whats moving close to the dipstick. I dont want oil in my face lol.

Thanks
Brandon

 

I had mine break off too. Not sure of the cause, probably my negligence. I think it was cracked and it snapped off without me knowing when I put it in. The dealer tore my machine down and pulled out pieces for hours, warranty did cover it, but doubt that will be the case everywhere. If it is plastic, there probably isn't too much to worry about, just keep changing the oil every few hours for a while to flush out all the small pieces and keep the filter from being plugged. Check the dipstick over thoroughly prior to putting it in. My best guess is that I had it out for an oil change and stepped on it, something fell on it, or the dog stepped on it, etc... I did notice that my new dipstick is much more brittle than the original (both were grey plastic) - perhaps this will make it unable to retain its shape with a crack in it.

 

I wouldn't start it without the dipstick in..try looking in the hole with a good light..you can see the counterbalance shaft pretty easily on the 850. My dipstick on the 850 is the hard grey plastic..
I presume so it wont flex..if the dipstick were soft flexible plastic and got a bow in it it could contact the counter balance shaft weight..maybe the 550 is the same way and the dip stick got a little bow in it somehow?