This workshop service repair manual covers the Polaris Sportsman 550 platform, including the Sportsman 550, Sportsman X2 550, Sportsman 550 EPS, and Sportsman Touring 550 EPS models produced from 2010 through 2012. These versatile all-terrain vehicles are known for their robust engineering, reliable performance, and off-road capabilities, powered by a liquid-cooled, 549 cc 1-cylinder, 4-stroke Fuji ES550PLE engine with Electronic Fuel Injection (EFI). The Sportsman line is celebrated for its balance of power, utility, and rider comfort, further enhanced by features like Electronic Power Steering (EPS) on applicable variants. This comprehensive factory workshop service and repair manual provides essential information for the maintenance and repair of your Polaris Sportsman 550. It details procedures for all major systems, including the engine, powertrain, chassis, body, electrical, and braking systems. The manual offers step-by-step instructions, detailed illustrations, diagrams, and troubleshooting guides to assist both DIY enthusiasts and professional mechanics. Coverage includes periodic maintenance, fluid changes, component replacement, advanced EFI diagnostics, and repair procedures for everything from routine servicing to complete overhauls, ensuring the longevity and optimal performance of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 550 / Sportsman X2 550 / Sportsman 550 EPS / Sportsman Touring 550 EPS Product Type: Workshop Service Repair Manual Codes Model Years Covered: 2010, 2011, 2012 Generation Platform Identifier: Polaris Sportsman 550 platform 👋 Introduction Market Position Target User: DIY enthusiasts and professional mechanics worldwide. Utility For Owners: Essential resource for efficient and correct vehicle maintenance and repair. Competitive Analysis Value Proposition: Inexpensive method to maintain and repair the vehicle, leveraging factory-level information. Key Features Content Highlight: Detailed illustrations, step-by-step instructions, necessary diagrams and pictures for all service and repair procedures. 📋 Manual Details Coverage Areas Vehicle Variants Covered: Sportsman 550, Sportsman X2 550, Sportsman 550 EPS/INTL, Sportsman Touring 550 EPS, Sportsman 550/550 EPS/INTL, Sportsman X2 550/Tour 550 EPS Page Count Estimated Page Count: N/A (PDF format, page count varies with print settings) Manual Type Manual Classification: Factory Workshop Service and Repair Manual Language Primary Language: English Format Digital Format: PDF (Portable Document Format) Delivery Method: Digital Download File Compression: ZIP File Size Digital File Size: 27 MB 📖 Manual Coverage Systems Covered Powertrain: Engine Service, Transmission System, Clutching (PVT) System, Drive Belt System, Drive Clutch Service, Final Drive System, Gearcase - Centralized Hilliard, Bearing Carrier System, Differential Gearcase Chassis And Body: Body/Frame System, Steering System, Suspension System, Ball Joint Service, Stabilizer Bar, Shocks/Springs System, Wheels-Wheel Hubs Electrical And Fuel: Electronic Fuel Injection (EFI), Electronic Control Unit (ECU), Fuel Pressure Regulator, Idle Air Control, Throttle Position Sensor, Fuel System, EFI Diagnostics, Cooling System, Radiator-Thermostat, Electrical System, Instrument Cluster, Ignition System, Lighting System, Fuse & Relay, Charging System, Battery System, Starter Motor System Brakes: Brakes System, Hydraulic Brake System Engine Management: Covers the entire EFI system, ECU, sensors, and actuators for precise engine control. Procedures Included Maintenance Procedures: Periodic Maintenance, Fluid Checks and Changes, Filter Replacements, Spark Plug Service, Belt Inspection and Replacement Repair Procedures: Engine Disassembly and Assembly, Transmission Overhaul, Clutch Adjustment and Replacement, Suspension Component Replacement, Brake System Bleeding and Repair, Electrical Component Testing and Replacement Diagnostics And Troubleshooting: EFI Diagnostics, General Troubleshooting, Wiring Diagram Interpretation Troubleshooting Guides: Dedicated troubleshooting section with systematic approaches to diagnose common and uncommon problems. Technical Depth Diagnostic Capabilities: Advanced EFI diagnostics, component testing, fault code interpretation (implied by ECU and EFI sections) Repair Scope: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Instructional Style: Step-by-step written instructions with detailed illustrations, diagrams, and pictures. Special Tools Included: Manual lists special tools required for specific procedures, essential for accurate repairs. 📊 Manual Specifications File Format Document Type: PDF Print Quality Print Suitability: Printable on demand, allowing users to print only necessary pages. Binding Type Physical Binding: N/A (Digital Download) Paper Type Physical Paper: N/A (Digital Download) Software Requirements PDF Reader: Adobe Acrobat Reader (Free download from Adobe) Zip Utility: WinZip or WinRAR (Free download available) ⚙️ Engine Specifications Primary Engine Engine Model: Fuji ES550PLE Engine Configuration: 1-Cylinder, 4-Stroke Engine Cooling System: Liquid-Cooled Engine Displacement: 549 cc Performance Horsepower Estimate: Typically in the range of 40-45 HP (exact figure requires model-specific verification, manual covers this) Torque Estimate: Estimated around 40-45 lb-ft (exact figure requires model-specific verification, manual covers this) Fuel System Fuel Delivery System: Electronic Fuel Injection (EFI) Efi Components Covered: Fuel Pressure Regulator, Idle Air Control, Throttle Position Sensor 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Optional Gear Selection: Selectable 2WD/4WD, often with locking front differential on EPS models. Manual covers gear selector and linkage. Features Clutching System: Primary and Secondary Clutch (PVT) service, including drive belt inspection and replacement. Drive Systems Covered: Front and Rear Drive Shafts, Propshaft & U-Joint Service, Centralized Hilliard Gearcase, Differential Gearcase 📐 Dimensions Exterior Wheelbase Typical: Approximately 50-55 inches (varies by model variant, consult manual...