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.

More Info : http://www.sitelux.com

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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 / 4x4 / 2x4 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
    
    -