Polaris Sportsman XP 550 /EPS Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Sportsman XP 550 /EPS has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL: 2009 SPORTSMAN XP 550
MODEL NUMBER: A09ZN55AL, AQ, AS, AT, AX, FX
ENGINE MODEL: ES550PLE

MODEL: 2009 SPORTSMAN XP 550 EPS
MODEL NUMBER: A09ZX55AC, AL, AQ, AS, AX
ENGINE MODEL: ES550PLE

TABLE OF CONTENTS :

Chapter_01-GENERAL INFORMATION
Chapter_02-MAINTENANCE
Chapter_03-ELECTRONIC FUEL INJECTION
Chapter_04-COOLING SYSTEM
Chapter_05-ENGINE
Chapter_06-TRANSMISSION
Chapter_07-CLUTCHING (PVT)
Chapter_08-FINAL DRIVE
Chapter_09-BODY / FRAME
Chapter_10-STEERING / SUSPENSION
Chapter_11-BRAKES
Chapter_12-ELECTRICAL
WIRE DIAGRAMS
WIRE DIAGRAMS_Intl

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921830
Total Pages : 372

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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9921830_Chapter_01-GENERAL INFORMATION
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Identification
Engine Designation Number
Vehicle Identification Number (VIN)
Vehicle and Engine Serial Number Locations
VEHICLE INFORMATION
Publication Numbers
Replacement Keys
Special Tools
SPECIFICATIONS
MODEL: 2009 SPORTSMAN XP 550
MODEL: 2009 SPORTSMAN XP 550 EPS
2009 SPORTSMAN XP 550 / XP 550 EPS
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Glossary of Terms
9921830_Chapter_02-MAINTENANCE
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Break-In Period
Maintenance Chart Key
Maintenance Intervals
Grease Lubrication Points
Maintenance Quick Reference
Maintenance Quick Reference, Continued…..
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants,Maintenance and Service Products
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-ride / Daily Inspection
Frame, Nuts, Bolts, Fasteners
Controls
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Lines
Fuel Filters
Vent Line
Throttle Operation
Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment
Air Filter / Pre-Filter Service
ENGINE
Engine Oil Level
Engine Oil and Filter Change
Engine Breather Hoses
Compression and Leakdown Tests
Valve Clearance Adjustment
Exhaust Silencer Cleaning
Engine Mount Fastener Torque
TRANSMISSION AND GEARCASES
Transmission Lubrication
Front Gearcase Lubrication
Front Gearcase ADC Fluid
Rear Gearcase Lubrication
COOLING SYSTEM
Cooling System Overview
Coolant Level Inspection
Cooling System Hoses
Coolant Strength / Type
PVT / FINAL DRIVE / WHEEL AND TIRE
PVT Drying
Drive Belt Removal
Drive Shaft Boot Inspection
Wheel and Hub Torque Table
Wheel Removal
Wheel Installation
Tire Pressure
Tire Inspection
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Removal
Battery Installation
Spark Plug Service
Engine / Chassis Ground
STEERING
Steering Inspection
Power Steering Unit (EPS Models)
Tie Rod End / Steering Inspection
Toe Alignment
Toe Alignment Adjustment
SUSPENSION
Suspension Inspection
Suspension Spring Pre-Load Adjustment
BRAKE SYSTEM
Brake Fluid Inspection
Brake Pad Inspection
Hose / Fitting Inspection
Auxiliary Brake Pedal
MAINTENANCE LOG
9921830_Chapter_03-ELECTRONIC FUEL INJECTION
ELECTRONIC FUEL INJECTION
SPECIAL TOOLS
Part Numbers / Descriptions
Fuel Pressure Gauge Kit – PU-43506-A
Fuel Pressure Gauge Adaptor – PV-48656
Throttle Position Sensor Tester Kit – 2201519
Digital Wrench™ Diagnostic Software PU-47063
Digital Wrench™ SmartLink Module Kit – PU-47471
Digital Wrench™ – Diagnostic Connector
Digital Wrench™ – Download Website
FUEL TANK
Exploded View
FUEL LINE
Quick Connect Removal / Installation
EFI SERVICE NOTES
EFI SYSTEM LAYOUT
Exploded View
EFI COMPONENTS
Identification / Location
ELECTRONIC FUEL INJECTION
General Information
EFI Operation Overview
Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
ECU Service
ECU Removal / Replacement
FUEL PUMP ASSEMBLY
Operation
Fuel Sender Test
Fuel Pump Test
Fuel Pump / Fuel Tank Removal
Fuel Pump / Fuel Tank Installation
FUEL PRESSURE REGULATOR
Operation Overview
FUEL INJECTOR
Operation Overview
Fuel Injector Service
Fuel Injector Test
Fuel Injector Replacement
CRANKSHAFT POSITION SENSOR (CPS)
Operation Overview
CPS Test
CPS Replacement
TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
Operation Overview
T-MAP Sensor Test
T-MAP Sensor Replacement
IDLE AIR CONTROL (IAC)
Operation Overview
IAC Test
IAC Replacement
THROTTLE POSITION SENSOR (TPS)
Operation Overview
TPS Resistance Tests
TPS Tester Kit
Checking TPS Reading
TPS Adjustment
TPS Replacement
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Operation Overview
ECT Sensor Test
ECT Sensor Replacement
IGNITION COIL
Operation Overview
Ignition Coil Tests
Ignition Coil and HT Lead Replacement
FUEL SYSTEM TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Poor Idle
EFI DIAGNOSTICS
Instrument Cluster Trouble Code Display
EFI SYSTEM BREAK-OUT DIAGRAMS
EFI Sensor Circuits
Fuel Injector Circuit
Crankshaft Position Sensor (CPS) Circuit
Fuel Pump / Fuel Level Sensor Circuit
Fuel Pump Circuit
Ignition Coil Circuit
Idle Air Control (IAC) Circuit
Throttle Position Sensor (TPS) Circuit
Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
Engine Coolant Temperature Sensor (ECT) Circuit
Diagnostic Connector Circuit
Diagnostic Connector Circuit (EPS Models)
9921830_Chapter_04-COOLING SYSTEM
COOLING SYSTEM
SPECIAL TOOLS
TORQUE SPECIFICATIONS
COOLING SYSTEM
Cooling System Layout and Testing
Cooling System Specifications
Cooling System Bleeding Procedure
RADIATOR
Radiator Cleaning
Coolant Drain / Radiator Removal
WATER PUMP SERVICE
Water Pump Mechanical Seal Removal
Water Pump Shaft Oil Seal Removal / Installation
Water Pump Mechanical Seal Installation
THERMOSTAT
Removal (Engine Installed)
Removal (Engine Removed)
Installation
TROUBLESHOOTING
Cooling System
9921830_Chapter_05-ENGINE
ENGINE
SPECIAL TOOLS
Engine
SPECIFICATIONS
Torque Specifications
Engine Service Data
Engine Service Data
Engine Fastener Torque Patterns
GENERAL ENGINE SERVICE
Piston Identification
Accessible Engine Components
Top-End Service (Engine in Chassis)
Engine Removal
Engine Installation Notes
Engine Lubrication – ES55PLE
Oil Pressure Test – ES55PLE
Oil Flow Diagram – ES55PLE Engine
Exploded Views – ES55PLE Engine
ENGINE DISASSEMBLY – TOP END
Cam Chain Tensioner / Cam Sprocket Removal
Camshaft Sprocket Inspection
Cam Chain Tensioner Inspection
Rocker Support Removal
Camshaft / Rocker Arm Inspection
Automatic Compression Release Inspection
Automatic Compression Release Installation
Cylinder Head Removal
Cylinder Head Inspection
Cylinder Head Warpage
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Cylinder Removal
Cylinder Inspection
Piston Removal
Piston-to-Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Honing to Oversize
Cylinder Hone Selection / Honing Procedure
Cleaning the Cylinder After Honing
ENGINE DISASSEMBLY – LOWER END
Crankcase Disassembly
Drive Coupler Removal / Inspection
Drive Coupler Installation
Flywheel / Stator Housing Removal
Starter One-Way Clutch Inspection
Starter One-Way Clutch Installation
Flywheel Installation
Stator Removal
Stator / Stator Cover Installation
Cam Chain / Tensioner Blade
Oil Pump Removal
Oil Pump Assembly
Crankcase Separation
Balance Shaft Removal / Inspection
Crankshaft Removal
Crankshaft Inspection
Crankcase Bearing Inspection / Removal
Crankcase Inspection
Bearing Installation
Water Pump Mechanical Seal Replacement
Water Pump Shaft Oil Seal Replacement
ENGINE ASSEMBLY – LOWER END
Crankcase Assembly – PTO Side
Balance Shaft Installation / Timing
ENGINE ASSEMBLY – TOP END
Piston Ring Installation
Piston Installation
Cylinder Installation
Camshaft Chain Installation
Cylinder Head Installation
Camshaft / Rocker Support Installation
Camshaft Timing
Cam Chain Tensioner Installation
Camshaft Timing Quick Reference
Valve Clearance Adjustment.
Oil Delivery Pipe Installation
Thermostat Installation
TROUBLESHOOTING
Engine
Spark Plug Fouling
9921830_Chapter_06-TRANSMISSION
TRANSMISSION
TRANSMISSION SPECIFICATIONS
Torque Specifications
Lubrication Specifications
SHIFT LINKAGE / GEAR SELECTOR
Shift Linkage Inspection
Gear Selector Removal
TRANSMISSION SERVICE
Transmission Removal
Transmission Disassembly
Transmission Shaft Service
Transmission Assembly
Transmission Installation
Transmission Exploded View
TROUBLESHOOTING
Troubleshooting Checklist
9921830_Chapter_07-CLUTCHING (PVT)
CLUTCHING (PVT)
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
Drive Clutch Operation
Shift Weights
Driven Clutch Operation
PVT Break-In (Drive Belt / Clutches)
Maintenance / Inspection
Overheating / Diagnosis
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
Disassembly
Assembly
DRIVE BELT
Belt Removal
Belt Inspection
Belt Installation
PVT Break-In (Drive Belt / Clutches)
DRIVE CLUTCH SERVICE
Spring Specifications
Exploded View
Clutch Disassembly
Spider Removal
Roller, Pin, and Thrust Washer Inspection
Button To Tower Clearance Inspection
Shift Weight Inspection
Bearing Inspection
Clutch Inspection
Moveable Sheave Bushing Inspection
Bushing Service
Clutch Assembly
DRIVEN CLUTCH SERVICE
Clutch Disassembly
Bushing Service
Clutch Assembly
Exploded View
TROUBLESHOOTING
9921830_Chapter_08-FINAL DRIVE
FINAL DRIVE
GENERAL SPECIFICATIONS
Torque Specifications
Special Tools
WHEELS
Removal
Installation
WHEEL HUBS
Front Hub Exploded View
Rear Hub Exploded View
FRONT BEARING CARRIER
Inspection / Removal
Bearing Replacement
Installation
FRONT DRIVE SHAFT
Removal
Installation
FRONT PROPSHAFT
Removal
Installation
PROPSHAFT U-JOINT SERVICE
Disassembly
Assembly
FRONT GEARCASE – CENTRALIZED HILLIARD
Exploded View
AWD Operation
ADC Operation
AWD Diagnosis
Gearcase Removal
Gearcase Disassembly / Inspection
Gearcase Assembly
Setting Ring Gear Backlash
Gearcase Installation
ADC System Fluid Bleeding
REAR BEARING CARRIER
Inspection / Removal
Bearing Replacement
Bushing Replacement
Installation
REAR DRIVE SHAFT
Removal
Installation
DRIVE SHAFT SERVICE
Drive Shaft / CV Joint Handling Tips
Outer CV Joint / Boot Replacement
Inner Plunging Joint / Boot Replacement
Drive Shaft Exploded View
REAR PROPSHAFT
Removal
Installation
REAR GEARCASE
Gearcase Removal
Gearcase Disassembly and Inspection
Gearcase Bearing and Seal Replacement
Gearcase Assembly
Gearcase Installation
Gearcase Exploded View
9921830_Chapter_09-BODY / FRAME
BODY / FRAME
TORQUE SPECIFICATIONS
DECAL REPLACEMENT
SPECIAL TOOLS
Plastic Push Rivet Removal
Multi-Function Pliers
SEAT AND SIDE PANELS
Removal / Installation
FRONT RACK
Removal / Installation
FRONT BUMPER
Removal / Installation
MUD GUARDS
Removal / Installation
FOOTWELLS
Removal / Installation
FRONT CAB
Removal
Installation
REAR RACK
Removal / Installation
REAR BUMPER COVERS
Removal / Installation
REAR CAB
Removal / Installation
HEADLIGHT POD
Disassembly / Removal
Assembly / Installation
MAIN FRAME
Frame Support Exploded View
9921830_Chapter_10-STEERING / SUSPENSION
STEERING / SUSPENSION
GENERAL SPECIFICATIONS
Torque Specifications
HANDLEBAR
Removal / Replacement
Installation
STEERING
Steering Post Removal
Steering Post Installation
Steering Exploded View
STEERING (EPS MODELS)
Upper Steering Post Removal
Upper Steering Post Installation
Power Steering Unit Removal
Power Steering Unit Installation
Steering Exploded View (EPS Models)
STEERING TIE ROD
Tie Rod / Tie Rod End Replacement
FRONT A-ARMS
Exploded View
Removal / Replacement
BALL JOINT SERVICE
Removal
Installation
REAR A-ARMS
Exploded View
Removal
Installation
REAR STABILIZER BAR
Exploded View
Linkage Removal / Installation
Stabilizer Bar Removal / Installation
SHOCKS / SPRINGS
Exploded View
Shock Removal / Installation
Shock / Spring Replacement
9921830_Chapter_11-BRAKES
BRAKES
SPECIFICATIONS
General Brake Specifications
General Torque Specifications
Special Tools / Brake Fluid
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
Brake Caliper Exploded View
Hand Master Cylinder Exploded View
BRAKE BLEEDING
Fluid Replacement
Bleeding Procedure
HAND BRAKE MASTER CYLINDER
Removal
Disassembly
Installation
Brake Switch Replacement
FOOT BRAKE MASTER CYLINDER
Operation Overview
Foot Master Cylinder Removal / Installation
Brake Pedal Removal / Installation
BRAKE PADS
Pad Removal
Pad Inspection
Pad Installation
Brake Burnishing Procedure
CALIPER SERVICE
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Reassembly
Caliper Installation
BRAKE DISC SERVICE
Disc Inspection
Disc Removal / Replacement
TROUBLESHOOTING
Brake Squeal
9921830_Chapter_12-ELECTRICAL
ELECTRICAL
General Information
Special Tools
Electrical Service Notes
Component Locations
Instrument Cluster
Overview
Rider Information Display
Speed Information
Information Display Area
Diagnostic Mode
Instrument Cluster Pinouts
Ignition Switch
Function Test
ADC / 4×4 / 2×4 Switch
Function Test
Off / Run LH Switch
Function Test
Reverse Override / Mode Button
Function Test
Head Lamp Switch
Function Test
Electronic Throttle Control (ETC) Switch
Electronic Throttle Control (ETC) Switch
Gear Selector Switch
Selector Switch Function Test
Resistor Module Function Test
Speed Sensor
Vehicle Speed Sensor
Brake Switch
Function Test
AWD / ADC Coils
Operation Overview
Diagnosing System Failures
Relays
Relay Overview
Chassis Relay
Fan Relay
EFI Relay
Bumper Lights Relay
ECU Relay
Power Steering Relay
Fuses
Protected Circuits
Fuse Box Layout
Lights
Headlight Adjustment
Bumper Lamp Adjustment
Headlight Replacement
Bumper Lamp Replacement
Tail / Brake Bulb Replacement
Charging System
Charging System Diagram
Charging System Testing
Current Draw – Key Off
Battery Charge Test
Stator / Alternator Tests
Stator / Alternator Replacement
Battery Service
Battery Specifications
General Battery Information
Battery Removal / Installation
Battery Off Season Storage
Battery Testing
OCV – Open Circuit Voltage Test
Load Test
Charging Procedure
Starter Motor
Starter / Starter Lockout System Diagram
Troubleshooting
Voltage Drop Testing
Starter Motor Removal / Replacement
Starter Motor Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Motor Reassembly
Starter Motor Installation
Starter Drive Service
Starter Solenoid Bench Test
Instrument Cluster Troubleshooting
Instrument Cluster – Key OFF / No Power
Instrument Cluster – Key ON / No Power
Instrument Cluster – No High Beam Indicator
Instrument Cluster – No / Incorrect Fuel Level
Instrument Cluster Circuit
Electronic Power Steering (EPS)
Electronic Power Steering (EPS) Circuits
EPS Operation
EPS 8-Way Wire Harness Connector
EPS Troubleshooting
Electrical Break Out Diagrams
Battery Charging Circuits
Constant Power Circuits
Key-On Power Circuits
Chassis Power Circuits
Head Lamp Circuits
Brake Lamp Circuits
Engine Start Command Circuits
ECM / IAC Power Circuits
ECM Wake-Up Command Circuits
AWD / ADC Circuits (Early Build Units)
AWD / ADC Circuits (Late Build Units)
AWD / ADC Function Tests (Late-Build)
Reverse Override Circuit
Radiator Fan Circuit
Gear Selector Switch Circuit
Ground Speed Sensor Circuit
Controller Area Network (CAN)
Overview
CAN Troubleshooting
9921830_WIRE DIAGRAMS
SPORTSMAN XP 550 (PAGE 1 OF 2)
SPORTSMAN XP 550 (PAGE 2 OF 2)
AWD / ADC
BATTERY CHARGING
BATTERY PLUS
BRAKE LAMPS – START
CHASSIS POWER
COOLING FAN
ECM POWER
ECM WAKE-UP
EFI
ENGINE CRANK
FUEL PUMP & LEVEL
GEAR SENSOR
GROUND SPEED SENSOR
KEY ON POWER
HEADLAMPS
EPS
9921830_WIRE DIAGRAMS_Intl
SPORTSMAN XP 550 INTL (PAGE 1 OF 2)
SPORTSMAN XP 550 INTL (PAGE 2 OF 2)
AWD / ADC
BATTERY CHARGING
BATTERY PLUS
BRAKE LAMPS – START
CHASSIS POWER
COOLING FAN
ECM POWER
ECM WAKE-UP
EFI
ENGINE CRANK
FUEL PUMP & LEVEL
GEAR SENSOR
GROUND SPEED SENSOR
KEY ON POWER
LIGHTS
HAZARD LIGHTS

 

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Polaris Sportsman XP 550 /EPS Repair Service Manual 2009.pdf

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