Polaris SPORTSMAN XP 550 and SPORTSMAN XP 550 EPS Complete OFFICIAL Factory Service / Repair / Full Workshop Manual

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Unlock the full potential of your 2009 Polaris Sportsman XP 550 / XP 550 EPS with the definitive factory-authorized service manual. This 372-page PDF delivers professional-grade repair procedures, maintenance schedules,...

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Type: Atv

Vendor:

Sku: 39048

Tags: 550 Atv CASE Construction Crawler Dozers Featured Polaris SPORTSMAN XP 550 SPORTSMAN XP 550 EPS

Product variants

Description

Unlock the full potential of your 2009 Polaris Sportsman XP 550 / XP 550 EPS with the definitive factory-authorized service manual. This 372-page PDF delivers professional-grade repair procedures, maintenance schedules, and troubleshooting guides—exactly as used by Polaris technicians. Whether you're performing routine upkeep or complex engine work, this manual is your essential partner for keeping your ATV in peak condition.

Factory Precision: Step-by-step instructions with torque specs and diagrams for every system
Complete Coverage: From oil changes to full engine rebuilds and electrical diagnostics
Instant Access: Download your manual immediately—no shipping delays or physical storage needed
Money-Back Guarantee: Risk-free purchase with our satisfaction promise

This digital manual provides zoomable diagrams and printable pages, making it easier than ever to service your ATV's:

Liquid-cooled 549cc engine with detailed overhaul procedures
PVT transmission and on-demand AWD system maintenance
Electronic Power Steering (EPS) diagnostics (where equipped)
Hydraulic disc brakes and independent suspension service

Designed for both DIY enthusiasts and professional mechanics, this manual delivers factory-correct specifications that protect your investment and ensure optimal performance across all terrains. The included troubleshooting flowcharts can save hours of diagnostic time, while proper maintenance schedules help prevent costly repairs.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman XP 550 / XP 550 EPS

Model Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Chassis Code:

Not specified in product data

Engine Code:

Not specified in product data

👋 Introduction

Market Position

Category:

High-performance utility ATV

Target Audience:

Outdoor enthusiasts, hunters, farmers, recreational riders requiring robust and capable off-road performance.

Competitive Analysis

Competitors 2009:

Can-Am Outlander, Arctic Cat 500/700 series, Honda Foreman/Rubicon, Yamaha Grizzly.

Key Features

Powertrain:

Powerful 550cc engine, known for strong torque and all-around performance.

Suspension:

Independent suspension for enhanced ride comfort and handling over rough terrain.

Eps Variant:

Electronic Power Steering (EPS) option reduces steering effort, particularly at low speeds and over obstacles.

Durability:

Polaris reputation for rugged construction and off-road capability.

📋 Manual Details

Coverage Areas

Primary Coverage:

Polaris Sportsman XP 550 and Sportsman XP 550 EPS models

Secondary Coverage:

All components, systems, and procedures related to maintenance, repair, and diagnostics for the specified models.

Page Count

Total Pages:

Manual Type

Type:

Complete Official Factory Service / Repair / Full Workshop Manual

Language

Language:

English

Format

File Format:

Delivery Format:

PDF Download

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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.

Technical Depth

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.

📊 Manual Specifications

File Format

Readability:

Zoom In/Out functionality enabled

Print Quality

Printability:

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

Quality

Manual Quality:

Factory Original

Features

Instant Download:

Shipping:

No Shipping Cost

Delivery Method:

Instant Download (No CD-ROM wait)

Guarantee:

Full Money Back Guarantee

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, SOHC, 4-stroke, 3-valve, single cylinder.

Engine Displacement:

549 cc (33.5 cubic inches)

Bore X Stroke:

Not specified in product data (typical for this engine class: approx. 93mm x 79.4mm)

Performance

Horsepower:

Approximately 40-45 HP (est. for 2009 model).

Torque:

Strong mid-range torque for pulling and climbing.

Fuel System

Carburetor:

Mikuni (specific model not listed in product data, but commonly a 40mm or 42mm BST series for this displacement).

Fuel Type:

Unleaded gasoline

Fuel Capacity:

Typically 4.1 gallons (15.5 liters) for this model range.

🔧 Transmission

Standard

Type:

Automatic with Engine Braking

Transmission Model:

PVT (Polaris Variable Transmission)

Gear Selection:

High, Low, Neutral, Reverse, Park

Optional

Optional Features:

Not applicable for this model year's powertrain as per standard offerings.

Features

Drive System:

Shaft Drive with On-Demand AWD/2WD

Clutch Type:

Dual clutch, centrifugal engagement

📐 Dimensions

Exterior

Length:

Approx. 83.2 inches (211.3 cm)

Width:

Approx. 46 inches (116.8 cm)

Height:

Approx. 47 inches (119.4 cm)

Weights

Dry Weight:

Approx. 666 lbs (302 kg)

Ground Clearance:

Approx. 11.25 inches (28.6 cm)

Cargo

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

Towing

Towing Capacity:

1500 lbs (680.4 kg)

Payload Capacity:

Not explicitly stated in product data, but typically around 200-300 lbs for this class.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (ATVs are not subject to automotive crash testing standards like NHTSA or Euro NCAP).

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Drive Mode:

On-Demand All-Wheel Drive (AWD) for enhanced traction.

Passive Features

Hand Guards:

Often standard or available to protect hands from trail debris.

Seat Belt:

N/A (ATVs typically do not have seat belts; riders use helmets and protective gear).

💡 Technology Features

Infotainment

Audio System:

Base models typically do not include integrated infotainment systems. Aftermarket audio solutions may be available.

Driver Assistance

Electronic Power Steering:

The 'EPS' designation signifies the presence of Electronic Power Steering, a significant technology feature for rider comfort and control.

Connectivity

Accessories:

Provisions for accessory lighting, winches, and storage solutions are common.

Instrumentation

Display:

Digital instrument cluster typically includes speedometer, odometer, trip meter, engine hour meter, fuel gauge, gear indicator, and AWD status.

🔧 Maintenance

Service Intervals

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.

Fluid Specifications

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.

Known Issues

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.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc. is a long-standing American manufacturer of powersports vehicles, known for its innovation in ATVs, snowmobiles, and side-by-sides.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving over decades to incorporate advanced features and improved performance, with the XP models representing a higher-performance tier.

Production

Manufacturing Location:

Primarily manufactured in the USA (e.g., Roseau, Minnesota).