Polaris Sportsman 550 (2009) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 550 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 550 (2009).

 
CONTENTS:

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
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
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)
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
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
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
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
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
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
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
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
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


WIRING 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
- 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