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Polaris Sportsman 550 EPS INTL 2010 Service Repair Manual

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The 2010 Sportsman 550 EPS INTL is a premium, high-performance utility All-Terrain Vehicle (ATV) renowned for its robust engineering and rider-focused features. This model, part of the Sportsman 550/850 Gen...
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Type: Atv
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Polaris Sportsman 550 EPS INTL 2010 Service Repair Manual
The 2010 Sportsman 550 EPS INTL is a premium, high-performance utility All-Terrain Vehicle (ATV) renowned for its robust engineering and rider-focused features. This model, part of the Sportsman 550/850 Gen 2 generation, distinguishes itself with a powerful 550cc ProStar engine, Electronic Power Steering (EPS) for enhanced control and reduced fatigue, and an On-Demand All-Wheel Drive system. Designed for demanding terrain and extended use, it offers a comfortable and capable platform for work or recreation, competing with other premium utility ATVs through its advanced technology and reliable performance. This comprehensive Factory Service Repair Manual is designed to provide in-depth technical guidance for the Sportsman 550 EPS INTL. It covers a wide array of critical systems, including the engine, fuel injection, drivetrain, steering, suspension, brakes, and electrical systems, complete with detailed wiring diagrams. The manual offers extensive maintenance procedures, diagnostic techniques, troubleshooting guides, and specific repair instructions for everything from routine servicing to complete engine overhauls, making it an essential resource for owners and professional technicians alike.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 550 EPS INTL
Year:
2010
Vehicle Type:
ATV (All-Terrain Vehicle)
Generation
Generation Identifier:
Polaris Sportsman 550/850 Gen 2
Codes
Engine Code:
Not explicitly stated, but presumed to be a variant of Polaris' ProStar engine family for this era.
👋 Introduction
Market Position
Market Position:
The Polaris Sportsman 550 EPS INTL 2010 was positioned as a premium, high-performance utility ATV, known for its power, comfort, and Electronic Power Steering (EPS) for enhanced handling, particularly in demanding terrain and for longer rides.
Competitive Analysis
Competitive Analysis:
Competed against other premium utility ATVs from manufacturers like Can-Am (Outlander series), Yamaha (Grizzly series), and Honda (FourTrax Foreman/Rancher series), differentiating itself with its powerful engine, advanced EPS technology, and Polaris's ProStar engine lineage.
Key Features
Key Features:
Electronic Power Steering (EPS), 550cc ProStar engine, independent suspension, shaft drive, AWD, robust chassis, and a focus on rider comfort and control.
📋 Manual Details
Coverage Areas
Coverage Areas:
General Information, Maintenance, Engine, Electronic Fuel Injection, Body, Steering, Suspension, Clutching, Final Drive, Transmission (4x4/6x6), Brakes, Electrical System, Wiring Diagrams, and more.
Page Count
Page Count:
Hundreds of pages (exact count not specified but implied to be comprehensive)
Manual Type
Manual Type:
Factory Service Repair Manual
Manual Authenticity:
Actual Genuine Factory Service Repair Manuals, not third-party publications.
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine, fuel system (EFI), drivetrain, suspension, steering, brakes, electrical system, chassis, body panels, and accessories.
Electrical System Coverage:
Detailed coverage of the entire electrical system, including battery, charging system, ignition system, lighting, EFI components, EPS system, and auxiliary circuits, supported by comprehensive wiring diagrams.
Procedures Included
Procedures Included:
Diagnosis of engine fault symptoms, maintenance procedures, repair and overhaul, component testing, wiring diagram tracing and verification, engine management system analysis, common fixes, troubleshooting guides, and pre-emptive maintenance tips.
Diagnostic Procedures:
Includes step-by-step diagnostic procedures for identifying and resolving common and complex issues across all major systems, utilizing factory-specific testing techniques.
Technical Depth
Technical Depth:
Comprehensive; covers fundamentals to advanced diagnostics and repair, intended for owners and professional technicians.
Engine Rebuild Depth:
Provides detailed procedures for engine disassembly, inspection, component replacement (pistons, rings, valves, etc.), and reassembly, including torque specifications and clearances.
📊 Manual Specifications
File Format
File Format:
PDF
Compatibility:
Compatible with all PC-based Windows operating systems and Mac. Can be burned to CD-ROM.
Print Quality
Print Quality:
High Resolution, fully printable
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download - Printable)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 4-valve, Single Cylinder (ProStar 550)
Displacement:
549 cc (approximate)
Cooling System:
Liquid-cooled
Bore X Stroke:
Not explicitly stated in product description, but typical for this engine family.
Performance
Horsepower:
Not explicitly stated in product description, but estimated in the 35-40 HP range.
Torque:
Not explicitly stated in product description, but sufficient for utility and towing.
Fuel System
Fuel System:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approximately 4.0 gallons (15.1 L)
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Optional Transmission:
N/A (Standard PVT)
Features
Drive System:
On-Demand All-Wheel Drive (AWD)
Final Drive:
Shaft Drive
📐 Dimensions
Exterior
Length:
Approximately 83.2 in (211.3 cm)
Width:
Approximately 46 in (116.8 cm)
Height:
Approximately 49.5 in (125.7 cm)
Wheelbase:
Approximately 50.5 in (128.3 cm)
Weights
Dry Weight:
Approximately 673 lbs (305 kg)
Towing Capacity:
1,500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
🛡️ Safety Features
Ratings
Safety Ratings:
ATVs are not subjected to traditional automotive crash test ratings. Safety is based on design and intended use.
Active Features
Active Safety Features:
Electronic Power Steering (EPS) for reduced steering effort and improved control, On-Demand AWD, Engine Braking System (EBS) on some models (check specific configuration).
Passive Features
Passive Safety Features:
Handguards, comfortable seating position, integrated lighting.
💡 Technology Features
Infotainment
Infotainment System:
Basic dashboard indicators (speedometer, odometer, fuel gauge, etc.). No advanced infotainment system typical of automotive applications.
Driver Assistance
Driver Assistance Features:
Electronic Power Steering (EPS).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 100 hours or 6 months for engine oil and filter, depending on operating conditions. Refer to manual for specific intervals.
Spark Plug Replacement:
Refer to manual for specific mileage/hour interval. Typically inspected at initial service and replaced as needed.
Air Filter Maintenance:
Frequent inspection and cleaning recommended, especially in dusty conditions. Replacement interval varies.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 20W-50 (Polaris recommends their specific brand). Consult manual for exact specification.
Engine Oil Capacity:
Approximately 2.1 US quarts (2.0 L) with filter change. Refer to manual.
Transmission Fluid Type:
Polaris AGL or equivalent synthetic gear lubricant. Consult manual for exact specification.
Coolant Type:
Ethylene Glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. Consult manual for specific type and capacity.
Known Issues
Common Issues And Fixes:
Potential issues may include drive belt wear, charging system concerns, EPS unit longevity, and suspension component wear over time. The manual provides detailed troubleshooting for these.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Polaris Industries Inc. has a long history in powersports, starting with snowmobiles in the 1950s and expanding significantly into ATVs with the Sportsman line becoming a dominant force in the market.
Model Evolution
Model Evolution:
The Sportsman 550 EPS INTL represents an evolution of Polaris's mid-size to large-bore utility ATVs, incorporating advancements like the ProStar engine and Electronic Power Steering to enhance performance and rider ergonomics.
Production
Production Location:
Primarily manufactured in the USA by Polaris.
🏆 Awards & Recognition
Recognitions
Industry Recognitions:
Polaris Sportsman models are consistently recognized for their performance and utility in industry reviews and by consumers, though specific awards for the 2010 550 EPS INTL may not be readily available.
Ratings
Consumer Ratings:
Generally well-regarded by owners for its power, comfort, and capability, especially with EPS.
Certifications
Certifications:
ATVs are certified for off-road use. Specific safety or emissions certifications depend on the region of sale.
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