Target User:
DIY enthusiasts and professional mechanics worldwide.
Utility For Owners:
Essential resource for efficient and correct vehicle maintenance and repair.
Value Proposition:
Inexpensive method to maintain and repair the vehicle, leveraging factory-level information.
Content Highlight:
Detailed illustrations, step-by-step instructions, necessary diagrams and pictures for all service and repair procedures.
Vehicle Variants Covered:
Sportsman 550, Sportsman X2 550, Sportsman 550 EPS/INTL, Sportsman Touring 550 EPS, Sportsman 550/550 EPS/INTL, Sportsman X2 550/Tour 550 EPS
Estimated Page Count:
N/A (PDF format, page count varies with print settings)
Manual Classification:
Factory Workshop Service and Repair Manual
Primary Language:
English
Digital Format:
PDF (Portable Document Format)
Delivery Method:
Digital Download
Powertrain:
Engine Service, Transmission System, Clutching (PVT) System, Drive Belt System, Drive Clutch Service, Final Drive System, Gearcase - Centralized Hilliard, Bearing Carrier System, Differential Gearcase
Chassis And Body:
Body/Frame System, Steering System, Suspension System, Ball Joint Service, Stabilizer Bar, Shocks/Springs System, Wheels-Wheel Hubs
Electrical And Fuel:
Electronic Fuel Injection (EFI), Electronic Control Unit (ECU), Fuel Pressure Regulator, Idle Air Control, Throttle Position Sensor, Fuel System, EFI Diagnostics, Cooling System, Radiator-Thermostat, Electrical System, Instrument Cluster, Ignition System, Lighting System, Fuse & Relay, Charging System, Battery System, Starter Motor System
Brakes:
Brakes System, Hydraulic Brake System
Engine Management:
Covers the entire EFI system, ECU, sensors, and actuators for precise engine control.
Maintenance Procedures:
Periodic Maintenance, Fluid Checks and Changes, Filter Replacements, Spark Plug Service, Belt Inspection and Replacement
Repair Procedures:
Engine Disassembly and Assembly, Transmission Overhaul, Clutch Adjustment and Replacement, Suspension Component Replacement, Brake System Bleeding and Repair, Electrical Component Testing and Replacement
Diagnostics And Troubleshooting:
EFI Diagnostics, General Troubleshooting, Wiring Diagram Interpretation
Troubleshooting Guides:
Dedicated troubleshooting section with systematic approaches to diagnose common and uncommon problems.
Diagnostic Capabilities:
Advanced EFI diagnostics, component testing, fault code interpretation (implied by ECU and EFI sections)
Repair Scope:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds.
Instructional Style:
Step-by-step written instructions with detailed illustrations, diagrams, and pictures.
Special Tools Included:
Manual lists special tools required for specific procedures, essential for accurate repairs.
Engine Model:
Fuji ES550PLE
Engine Configuration:
1-Cylinder, 4-Stroke
Engine Cooling System:
Liquid-Cooled
Engine Displacement:
549 cc
Horsepower Estimate:
Typically in the range of 40-45 HP (exact figure requires model-specific verification, manual covers this)
Torque Estimate:
Estimated around 40-45 lb-ft (exact figure requires model-specific verification, manual covers this)
Fuel Delivery System:
Electronic Fuel Injection (EFI)
Efi Components Covered:
Fuel Pressure Regulator, Idle Air Control, Throttle Position Sensor
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Gear Selection:
Selectable 2WD/4WD, often with locking front differential on EPS models. Manual covers gear selector and linkage.
Clutching System:
Primary and Secondary Clutch (PVT) service, including drive belt inspection and replacement.
Drive Systems Covered:
Front and Rear Drive Shafts, Propshaft & U-Joint Service, Centralized Hilliard Gearcase, Differential Gearcase
Wheelbase Typical:
Approximately 50-55 inches (varies by model variant, consult manual for exact specs)
Dry Weight Typical:
Approximately 700-800 lbs (varies by model variant, consult manual for exact specs)
Towing Capacity Typical:
Typically rated at 1,500 lbs (verify with specific model documentation)
Cargo Capacity:
Front and rear racks, with some X2 models featuring a tilt-bed (details in manual)
Atv Safety Standards:
Adherence to ANSI/SVIA 1-2010 safety standards (implied for ATVs of this era)
Braking System:
Hydraulic disc brakes front and rear, detailed in the manual.
Steering Assistance:
Electronic Power Steering (EPS) on applicable models, covered in steering system section.
Lighting System:
Headlights, taillights, brake lights (details in electrical system section).
Instrument Cluster Features:
Digital display showing speed, RPM, odometer, trip meter, fuel level, 2WD/4WD indicator, gear indicator, and warning lights. Covered in electrical system section.
Eps Functionality:
Electronic Power Steering (EPS) reduces steering effort and dampens handlebar kickback, improving rider comfort and control. Detailed in steering system section.
Diagnostic Ports:
Likely features a diagnostic port for ECU communication and fault code retrieval, crucial for EFI diagnostics.
Oil Change Interval:
Typically every 100 hours or 6 months of use (refer to manual for precise intervals).
Spark Plug Replacement:
Typically recommended every 1,000-2,000 miles or annually (refer to manual).
Gearcase Oil Change:
Recommended at least annually or per operating hours (refer to manual).
Engine Oil Type And Viscosity:
SAE 5W-50 Synthetic (Polaris recommends their own brand, but compatible lubricants are detailed in the manual).
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water (specific Polaris coolant or equivalent).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid (consult manual for precise specification and bleeding procedures).
Differential Gearcase Oil:
Polaris Demand Drive Fluid or equivalent (specified in manual).
Common Wear Items:
Drive belts (PVT), suspension bushings, ball joints, brake pads (standard for ATVs of this type). Manual provides guidance for inspection and replacement.
Efi Component Considerations:
Though generally reliable, throttle position sensors and idle air control valves can require cleaning or replacement over time (covered in diagnostics).
Manufacturer Origin:
Polaris Industries, a prominent American manufacturer of powersports vehicles.
Sportsman Lineup Context:
The Sportsman line is Polaris's flagship ATV series, known for its versatility and off-road capability. The 550 platform represents a significant iteration in their engine development for this class.
Production Era:
The 550cc engine was a key offering during the late 2000s and early 2010s, providing a balance of power and utility for the Sportsman line.
