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2011 Polaris Sportsman 550 ATV Repair Manual

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Basic Information Identification Make: Polaris Model: Sportsman 550 Year: 2011 Vehicle Type: ATV (All-Terrain Vehicle) Trim Levels Covered: Sportsman 550, Sportsman 550 EPS, Sportsman 550 X2, Sportsman 550 Touring Introduction Market Position Market Segment: High-performance utility and recreational ATV segment. Competitive Analysis Competitors 2011: Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rancher, Suzuki KingQuad. Key Features Vehicle Key Features: Powerful 550cc engine, Polaris Variable Transmission (PVT) with engine braking, On-Demand True All-Wheel Drive (AWD), independent suspension, comfortable rider ergonomics, optional EPS. Key Features Manual Manual Benefits: Enables DIY repairs and maintenance, reduces service costs, provides in-depth technical knowledge, aids in diagnosing issues quickly, printable pages for workshop use. Manual Details Coverage Areas Primary Coverage: 2011 Polaris Sportsman 550 Series ATVs Specific Models Covered: Sportsman 550, Sportsman 550 EPS (Electronic Power Steering), Sportsman 550 X2, Sportsman 550 Touring Page Count Estimated Page Count: 400-600 pages (typical for comprehensive ATV service manuals) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, overhaul, torque specifications, timing, valve adjustments, piston and cylinder specifications. Fuel System: Carburetor (if applicable) or EFI system diagnostics, fuel pump, fuel filter, fuel lines, injectors, fuel tank maintenance. Lubrication And Cooling: Oil pump, oil filter, oil cooler, coolant system, radiator, thermostat, water pump, fluid types and capacities. Transmission And Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission), clutches (primary and secondary), belt inspection and replacement, gearcase lubrication, drive shafts, U-joints, differentials (front and rear), AWD system. Suspension And Steering: Front and rear shocks (gas, oil), springs, bushings, control arms, tie rods, steering column, EPS system components (if applicable), alignment procedures. Brakes: Hydraulic brake system, master cylinder, calipers, brake pads, brake rotors, brake lines, bleeding procedure, parking brake. Electrical System: Ignition system, starter motor, alternator/stator, battery, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays, ECU/ECM diagnostics, sensor testing. Bodywork And Chassis: Frame inspection, plastic body panels, seat, racks, fenders, skid plates, bumpers, installation and removal procedures. Intake And Exhaust: Air filter, air box, intake manifold, exhaust system components, mufflers, heat shields. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, tire pressure, chain adjustment (if applicable), clutch maintenance, battery care. Troubleshooting: Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides for all major systems. Component Repair And Rebuild: Detailed step-by-step instructions for repairing or rebuilding major components like engines, transmissions, differentials, and brake calipers. Part Replacement: Specific instructions for removing and installing virtually all replaceable parts on the ATV. Diagnostic Testing: Procedures for testing electrical components, sensors, fuel system pressure, and other diagnostic checks. Technical Depth Depth: Comprehensive; covers basic maintenance to complete engine and transmission overhauls. Includes detailed specifications, diagrams, and troubleshooting. Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, ensuring clarity of text and diagrams for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, Single Cylinder Displacement: 549cc (approximate) Bore X Stroke: To be detailed in the manual (typical for 550cc class) Cooling System: Liquid-cooled Fuel Delivery: Electronic Fuel Injection (EFI) Performance Horsepower: Approx. 40-45 HP (will be specified in manual) Torque: Will be specified in manual Fuel System Fuel Type: Unleaded gasoline (91 octane recommended) Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: Shaft Drive with On-Demand True All-Wheel Drive (AWD) and 2WD selectable Clutch Type: Primary and Secondary CVTech (or similar) centrifugal clutches Dimensions Exterior Length: Varies by model (e.g., Sportsman 550 Touring likely longer than base 550). Specifics in manual. Width: Varies by model. Specifics in manual. Height: Varies by model. Specifics in manual. Weights Dry Weight: Approximately 670-750 lbs depending on model (e.g., X2 and Touring will be heavier). Towing Capacity: 1500 lbs (680.4 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (91 kg) Safety Features Ratings Safety Features General: ATV safety regulations compliance, OSHA guidelines (if used for work). Active Features Active Safety: On-Demand True AWD, engine braking, responsive braking system, integrated handguards (may vary). Passive Features Passive Safety: Ergonomic seating, footwells, handlebar design for control. Technology Features Infotainment Infotainment Features: N/A (Focus on functionality, not infotainment) Driver Assistance Driver Assistance Features: Electronic Power Steering (EPS) on applicable models for reduced steering effort and vibration damping. Connectivity Connectivity Features: N/A Maintenance Service Intervals Oil Change Interval: Typically every 100 hours or 6 months (refer to manual for precise intervals and conditions). Air Filter Inspection: Inspect every 25 hours, clean or replace as needed. More frequent in dusty conditions. Spark Plug Replacement: Typically at 100 hours or annually. Clutch Belt Inspection: Inspect every 50 hours or annually. Replace as needed based on wear. Fluid Specifications Engine Oil Type: Polaris...
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2011 Polaris Sportsman 550 ATV Repair Manual
Basic Information
Identification
Make: Polaris
Model: Sportsman 550
Year: 2011
Vehicle Type: ATV (All-Terrain Vehicle)
Trim Levels Covered: Sportsman 550, Sportsman 550 EPS, Sportsman 550 X2, Sportsman 550 Touring
Introduction
Market Position
Market Segment: High-performance utility and recreational ATV segment.
Competitive Analysis
Competitors 2011: Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rancher, Suzuki KingQuad.
Key Features Vehicle
Key Features: Powerful 550cc engine, Polaris Variable Transmission (PVT) with engine braking, On-Demand True All-Wheel Drive (AWD), independent suspension, comfortable rider ergonomics, optional EPS.
Key Features Manual
Manual Benefits: Enables DIY repairs and maintenance, reduces service costs, provides in-depth technical knowledge, aids in diagnosing issues quickly, printable pages for workshop use.
Manual Details
Coverage Areas
Primary Coverage: 2011 Polaris Sportsman 550 Series ATVs
Specific Models Covered: Sportsman 550, Sportsman 550 EPS (Electronic Power Steering), Sportsman 550 X2, Sportsman 550 Touring
Page Count
Estimated Page Count: 400-600 pages (typical for comprehensive ATV service manuals)
Manual Type
Manual Type: Factory Service Manual / Repair Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Engine Mechanical: Complete engine disassembly, assembly, overhaul, torque specifications, timing, valve adjustments, piston and cylinder specifications.
Fuel System: Carburetor (if applicable) or EFI system diagnostics, fuel pump, fuel filter, fuel lines, injectors, fuel tank maintenance.
Lubrication And Cooling: Oil pump, oil filter, oil cooler, coolant system, radiator, thermostat, water pump, fluid types and capacities.
Transmission And Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission), clutches (primary and secondary), belt inspection and replacement, gearcase lubrication, drive shafts, U-joints, differentials (front and rear), AWD system.
Suspension And Steering: Front and rear shocks (gas, oil), springs, bushings, control arms, tie rods, steering column, EPS system components (if applicable), alignment procedures.
Brakes: Hydraulic brake system, master cylinder, calipers, brake pads, brake rotors, brake lines, bleeding procedure, parking brake.
Electrical System: Ignition system, starter motor, alternator/stator, battery, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays, ECU/ECM diagnostics, sensor testing.
Bodywork And Chassis: Frame inspection, plastic body panels, seat, racks, fenders, skid plates, bumpers, installation and removal procedures.
Intake And Exhaust: Air filter, air box, intake manifold, exhaust system components, mufflers, heat shields.
Procedures Included
Routine Maintenance: Oil changes, filter replacements, spark plug checks, tire pressure, chain adjustment (if applicable), clutch maintenance, battery care.
Troubleshooting: Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides for all major systems.
Component Repair And Rebuild: Detailed step-by-step instructions for repairing or rebuilding major components like engines, transmissions, differentials, and brake calipers.
Part Replacement: Specific instructions for removing and installing virtually all replaceable parts on the ATV.
Diagnostic Testing: Procedures for testing electrical components, sensors, fuel system pressure, and other diagnostic checks.
Technical Depth
Depth: Comprehensive; covers basic maintenance to complete engine and transmission overhauls. Includes detailed specifications, diagrams, and troubleshooting.
Manual Specifications
File Format
File Format: PDF
Print Quality
Print Quality: High-resolution, ensuring clarity of text and diagrams for printing.
Binding Type
Binding Type: N/A (Digital Download)
Paper Type
Paper Type: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Type: 4-stroke, SOHC, 4-valve, Single Cylinder
Displacement: 549cc (approximate)
Bore X Stroke: To be detailed in the manual (typical for 550cc class)
Cooling System: Liquid-cooled
Fuel Delivery: Electronic Fuel Injection (EFI)
Performance
Horsepower: Approx. 40-45 HP (will be specified in manual)
Torque: Will be specified in manual
Fuel System
Fuel Type: Unleaded gasoline (91 octane recommended)
Transmission
Standard
Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking
Gear Selection: High, Low, Neutral, Reverse, Park
Features
Drive System: Shaft Drive with On-Demand True All-Wheel Drive (AWD) and 2WD selectable
Clutch Type: Primary and Secondary CVTech (or similar) centrifugal clutches
Dimensions
Exterior
Length: Varies by model (e.g., Sportsman 550 Touring likely longer than base 550). Specifics in manual.
Width: Varies by model. Specifics in manual.
Height: Varies by model. Specifics in manual.
Weights
Dry Weight: Approximately 670-750 lbs depending on model (e.g., X2 and Touring will be heavier).
Towing Capacity: 1500 lbs (680.4 kg)
Rack Capacity Front: 100 lbs (45 kg)
Rack Capacity Rear: 200 lbs (91 kg)
Safety Features
Ratings
Safety Features General: ATV safety regulations compliance, OSHA guidelines (if used for work).
Active Features
Active Safety: On-Demand True AWD, engine braking, responsive braking system, integrated handguards (may vary).
Passive Features
Passive Safety: Ergonomic seating, footwells, handlebar design for control.
Technology Features
Infotainment
Infotainment Features: N/A (Focus on functionality, not infotainment)
Driver Assistance
Driver Assistance Features: Electronic Power Steering (EPS) on applicable models for reduced steering effort and vibration damping.
Connectivity
Connectivity Features: N/A
Maintenance
Service Intervals
Oil Change Interval: Typically every 100 hours or 6 months (refer to manual for precise intervals and conditions).
Air Filter Inspection: Inspect every 25 hours, clean or replace as needed. More frequent in dusty conditions.
Spark Plug Replacement: Typically at 100 hours or annually.
Clutch Belt Inspection: Inspect every 50 hours or annually. Replace as needed based on wear.
Fluid Specifications
Engine Oil Type: Polaris PS-4 Full Synthetic 5W-50 (or equivalent API SG, JASO MA certified)
Engine Oil Capacity: Approximately 2.1 US quarts (2.0 liters) with filter change (refer to manual for exact capacity).
Coolant Type: Polaris Premium Long Life Antifreeze/Coolant (or ethylene glycol based coolant with corrosion inhibitors)
Gearcase Oil Type: Polaris Demand Drive Fluid (front differential) and Polaris AGL Gearcase Lubricant (rear differential/gearcase)
Known Issues
Common Issues Potential: Belt wear/slippage (normal maintenance item), occasional electrical connector issues, potential for water intrusion in extreme conditions (proper maintenance is key), EPS unit performance checks.
Vehicle History
Brand Heritage
Brand Origins: Polaris Industries Inc., founded in 1954, a pioneer in snowmobiles and later ATVs.
Model Evolution
Sportsman Lineage: The Sportsman line has a long history of being a benchmark for comfort, capability, and all-around utility in the ATV market.
Production
Manufacturing Location: Primarily manufactured in the United States (e.g., Roseau, Minnesota).
Awards & Recognition
Recognitions
Industry Awards: Polaris Sportsman line has consistently received praise and awards for its performance, comfort, and utility from various ATV publications and organizations over the years. Specific awards for the 2011 model may be found in historical reviews.
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