Engine Mechanical:
Includes detailed procedures for engine overhaul, cylinder head, pistons, rings, connecting rods, crankshaft, oil pump, oil pan, camshaft, valve train, bearings, seals, gaskets, timing components (chain/gear), freeze plugs.
Fuel System:
Covers carburetor (including assembly, diaphragm, pump, valves, jets), fuel pump, fuel filter, fuel lines, fuel tank, and related components.
Ignition System:
Details spark plugs, spark plug wires, ignition coils, CDI unit (if applicable), and timing.
Exhaust System:
Covers muffler, downpipe, catalytic converter (if applicable), headers, exhaust gaskets, and heat wrap.
Cooling System:
Includes radiator, radiator fan, oil radiator (oil cooling), coolant hoses, fan shroud, and thermostat.
Transmission Drivetrain:
Covers transmission fluid changes, clutches (pressure plate, clutch shoe, clutch case), transfer case (transfer case, transfer plate), and related components. (Note: AT Filters mentioned in tags suggest automatic transmission coverage, but details for 2009 XP 550 may vary).
Brakes System:
Details brake pad replacement, brake shoe replacement, rotor replacement, brake lines (clutch lines mentioned, likely refers to brake lines), and general brake system maintenance.
Wheels Tires:
Covers tire rotation, tire replacement, wheel alignment, lug nuts, hub caps, and wheel covers.
Suspension Steering:
Includes shocks, struts, steering system components, and suspension system details.
Electrical System:
Provides coverage for wiring harnesses (engine harness, chassis harness, main harness), electrical pin connectors, sensors (oil sensor, pressure sensor, oil pressure sensor), relays (headlight, starter, ignition), voltage meter, switches, battery replacement, and starter replacement.
Body Chassis:
Covers body panels, door hinges, door panels, dashboard, center console, glovebox, emblems, fuel cap, fuel door, grilles, hood, jack, lifting, mud guards/flaps, bumpers, fenders, trim replacement, windshield, window regulator, door handle, and hood latch.
Lighting Accessories:
Details interior lighting, headlights, taillights, fog lights, third brake light, bulb replacement, HID/projector headlights, turn signals, and side markers.
Routine Maintenance:
Oil change, transmission fluid change, fluid changes, air filter replacement, spark plug replacement, tire rotation.
Engine Repair:
Complete engine rebuild, cylinder head removal/installation, piston/ring replacement, crankshaft service, valve adjustments, camshaft replacement, timing chain/gear replacement.
Fuel System Repair:
Carburetor cleaning and rebuilding, fuel pump replacement, fuel filter replacement.
Ignition System Repair:
Spark plug wire testing and replacement, ignition coil replacement.
Transmission Drivetrain Repair:
Clutch service, transfer case maintenance, drive shaft inspection.
Brake System Repair:
Brake pad/shoe replacement, brake rotor resurfacing/replacement, brake line bleeding, brake caliper service.
Suspension Steering Repair:
Shock/strut replacement, steering component replacement, wheel bearing service.
Electrical Diagnostics Repair:
Wiring harness troubleshooting, sensor testing and replacement, relay diagnosis, battery testing, starter motor replacement.
Body Panel Repair:
Panel removal/installation, hinge lubrication/adjustment, trim replacement, headlight/taillight replacement, bumper repair/replacement.
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides.
Depth:
Comprehensive from routine maintenance to full mechanical rebuilds and advanced electrical diagnostics. Includes detailed diagrams and specifications.
Specialized Procedures:
Machining and balancing procedures for engine components are listed, implying a high level of technical detail.
Oil Change:
Typically every 100 hours or 6 months, whichever comes first. Check manual for specific intervals and conditions.
Air Filter Check:
Check every 50 hours, clean or replace as needed. More frequent checks in dusty conditions.
Spark Plug Replacement:
Refer to manual for recommended interval, typically around 100-150 hours or annually.
Engine Oil:
Polaris recommends specific SAE viscosity grades (e.g., 0W-40 or 10W-50 Synthetic for optimal performance) and API service classifications. Consult manual for exact specifications.
Transmission Fluid:
Polaris AGL Synthetic Gearcase Oil or equivalent is typically recommended for the transmission and final drives. Consult manual for specific type and capacity.
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Consult manual for specific type and capacity.
Common Wear Items:
Brake pads, tires, drive belts (PVT system), wheel bearings are common wear items requiring periodic inspection and replacement.
Engine Performance:
Carburetor jetting can sometimes require adjustment depending on altitude and modifications. Ensure proper maintenance of the fuel and air intake systems.
Electrical Connections:
Check for corrosion or looseness in electrical connectors, especially in wet or dirty environments.
