2010 Polaris Sportsman XP 550 ATV Service Manual

Description

This Official 2010 Polaris Sportsman XP 550 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for:

2010 Polaris Sportsman XP 550 ATVs

2010 Polaris Sportsman XP 550 International ATVs

2010 Polaris Sportsman XP EPS 550 ATVs

Table of Contents

General Information
Maintenance
Electronic Fuel Injection
Cooling System
Engine
Transmission Clutching (PVT)
Final Drive
Body/frame
Steering / Suspension
Brakes
Electrical

2010 Polaris Sportsman XP 550 ATV Service Manual Index of  Topics

A
Active Descent Control (ADC)
ADC Coil
ADC Fluid
ADC, Bleeding
ADC, Coil Resistance
ADC, Operation
Adjustment, Valve Clearance
Air Filter Service
All Wheel Drive (AWD) Coil
Authorization Key
Authorization, Reflash
Automatic Compression Release Inspection
AWD, Coil Resistance
AWD, Diagnosis
AWD, Operation
B
Balance Shaft Installation
Balance Shaft Removal / Inspection
Balance Shaft Timing
Ball Joint Service
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Battery Storage
Boring, Cylinder
Brake Bleeding
Brake Burnishing
Brake Caliper Assembly1
Brake Caliper Exploded View
Brake Caliper Inspection
Brake Caliper Installation
Brake Caliper Piston Bore ID
Brake Caliper Removal
Brake Disc Service
Brake Disc, Inspection
Brake Fitting Inspection
Brake Hose Inspection
Brake Pad Inspection
Brake Pad Installation
Brake Pads
Brake Pedal Inspection
Brake System Inspection
Brake System, Exploded View (550 / EPS / TOURING)
Brake System, Exploded View (550 INT’L)
Brake System, Exploded View (550 X2)
Brake System, Operation
Break-In Period
Breather Hose
Bumper Lights Relay
C
Cam Chain Tensioner Removal
Cam Chain Tensioner, Blade Installation
Cam Chain Tensioner, Inspection
Cam Chain Tensioner, Installation
Cam Sprocket Removal
Camshaft and Rocker Arm Support Installation
Camshaft Chain Installation
Camshaft Inspection
Camshaft Timing
Camshaft Timing Quick Reference
Camshaft, Inspection
Camshaft, Removal
Cargo Box, Removal/Installation (X2 Models)
Cargo Box, Tailgate Service (X2 Models)
Centralized Hilliard, Exploded View
Charging System
Chassis Relay
Clearance, Valve, Adjustment
Clutch, Starter One Way
Combustion Chamber
Communication Problems, Digital Wrench
Compression Release Inspection
Compression Test
Controls
Conversion Table
Coolant Level Inspection
Coolant Strength and Type
Cooling System
Cooling System Hoses
Cooling System, Bleeding Procedure
Cooling System, Specifications
Coupler, Drive, Removal / Installation
Crankcase Bearings
Crankcase, Assembly
Crankcase, Disassembly
Crankcase, Inspection
Crankcase, Separation
Crankshaft Inspection
Crankshaft Position Sensor (CPS)
Crankshaft, Removal
Cylinder Head Warp Inspection
Cylinder Head, Assembly
Cylinder Head, Disassembly
Cylinder Head, Inspection
Cylinder Head, Installation
Cylinder Head, Removal
Cylinder Honing
Cylinder, Inspection
Cylinder, Installation
Cylinder, Removal
D
Daily Inspection
Decal Replacement
Decimal Equivalent Chart
Diagnostic Code Table
Diagnostic Codes, Instrument Cluster
Diagnostics, Engine
Digital Wrench Engine Controller Reprogramming
Digital Wrench Updates
Digital Wrench Version and Update ID
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software
Digital Wrench Versions
Disassembly, Engine Lower End
Drive Belt, Break-In
Drive Belt, Inspection
Drive Belt, Installation (Base Models)
Drive Belt, Installation (X2 / TOURING Models)
Drive Belt, Removal (Base Models)
Drive Belt, Removal (X2 / TOURING Models)
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Button to Tower Clearance
Drive Clutch, Cover Bushing Removal/Installation
Drive Clutch, Disassembly
Drive Clutch, Exploded View
Drive Clutch, Moveable Sheave Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spider Removal
Drive Clutch, Spring
Drive Coupler Removal / Installation
Drive Shaft / CV Joint, Handling Tips
Drive Shaft Boot Inspection
Driven Clutch, Assembly
Driven Clutch, Bushing Service
Driven Clutch, Disassembly
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
E
ECM Relay
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI Relay
EFI System Break-Out Diagrams
EFI, Component Locations
EFI, Diagnostic Codes
EFI, Exploded View
EFI, Service Notes
EFI, Special Tools
Electrical Breakout Diagrams (550 Base / 550 EPS) Electrical Breakout Diagrams (550 INT’L)
Electrical Breakout Diagrams (550 TOURING / X2)
Electronic Control Unit (ECU)
Electronic Power Steering (Base / INT’L Models) Electronic Power Steering Touring Models)
Electronic Throttle Control (ETC)
Engine Assembly, Lower End
Engine Disassembly, Top End
Engine Installation Notes
Engine Model Number
Engine Removal
Engine Serial Number
Engine Service Data
Engine Service, General Information
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Oil and Filter Change
Engine, Oil Level
EPS, Cleaning
EPS, Operation
Exploded View, Engine
F
Fan Relay
Flywheel Installation
Flywheel, Removal
Foot (Auxiliary) Brake Master Cylinder
Foot Master Cylinder, Operation (550 INT’L)
Footwell, Removal / Installation
Footwells
Frame Supports (Base Models)
Frame Supports (TOURING Models)
Frame Supports (X2 Models)
Frame, Nuts, Bolts, Fasteners
Front A-arm, Removal / Replacement
Front A-arms
Front A-arms, Exploded View
Front Bearing Carrier
Front Bumper
Front Cab
Front Drive Shaft, Installation
Front Drive Shaft, Removal
Front Gearcase ADC Fluid
Front Gearcase Lubrication
Front Gearcase, Assembly
Front Gearcase, Disassembly / Inspection
Front Gearcase, Installation (EPS Models)
Front Gearcase, Installation (Non-EPS Models)
Front Gearcase, Removal (EPS Models)
Front Gearcase, Removal (Non-EPS Models)
Front Propshaft, Service
Front Rack
Front Storage Box
Fuel Filters
Fuel Injector
Fuel Line
Fuel Lines
Fuel Pressure Regulator
Fuel Pump Assembly
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Fuel System Troubleshooting
Fuel Tank
Fuel Tank Installation
Fuel Tank Removal
Fuse Box
Fuses
G
Gear Position Switch
Gear Selector Removal
General Specifications
Guided Diagnostics
H
Hand Brake Master Cylinder, Removal
Hand Master Cylinder, Exploded View
Hand Master Cylinder, Operation (550 INT’L)
Handlebar, Removal / Replacement
Head Lights
Headlight Pod
Honing, Cylinder
I
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Inner Plunging Joint / Boot Replacement
Installation, Water Pump Mechanical Seal
Instrument Cluster
K
Key, Reprogramming Authorization
Keys, Replacement
L
Lash Adjustment, Valve
Lash, Valve, Adjustment
Leak down Test
Lubrication Grease Points
M
Main Frame (Base Models)
Main Frame (TOURING Models)
Main Frame (X2 Models)
Maintenance and Service Products
Maintenance Quick Reference Chart
Maintenance Schedule
Mechanical Seal, Installation
Mechanical Seal, Removal
Model Number
Mud Guards
O
Oil Delivery Pipe Installation
Oil Flow Diagram
Oil Pressure Test
Oil Pump, Assembly
Oil Pump, Removal
Outer CV Joint / Boot Replacement
P
Periodic Maintenance Chart
Piston Identification
Piston Ring, Installation
Piston, Inspection
Piston, Installation
Piston, Removal
Piston, Ring Installed Gap
Piston-to-Cylinder Clearance
Power Steering Relay
Power Steering Unit Installation
Power Steering Unit Removal (Base Models)
Power Steering Unit Removal (X2 / TOURING Models)
Power Steering Unit, Cleaning
Pre-Filter Service
Pre-Ride Inspection
Propshaft, U-Joint Service
Publication Part Numbers
PVT System, Assembly (Base Models)
PVT System, Assembly (X2 / TOURING Models)
PVT System, Disassembly (Base Models)
PVT System, Disassembly (X2 / TOURING Models)
PVT System, Maintenance
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Drain Plug
PVT, Drying
R
Radiator
Radiator, Removal
Rear A-arm, Removal (Base Models)
Rear A-arm, Removal (X2 / TOURING Models)
Rear A-arm (Base Models)
Rear A-arm (X2 / TOURING Models)
Rear A-arm, Exploded View (Base Models)
Rear A-arm, Exploded View (X2 / TOURING Models)
Rear Bearing Carrier
Rear Bumper Covers (Base Models)
Rear Cab
Rear Cab, Removal / Installation (Base Models)
Rear Cab, Removal / Installation (TOURING Models)
Rear Cargo Box (X2 Models)
Rear Differential Solenoid Relay
Rear Drive Shaft, Installation
Rear Drive Shaft, Removal
Rear Fenders (X2 Models)
Rear Gearcase (Base / TOURING Models)
Rear Gearcase (X2 Models)
Rear Gearcase Lubrication
Rear Gearcase, Assembly (Base / TOURING Models)
Rear Gearcase, Assembly (X2 Models)
Rear Gearcase, Disassembly (Base / TOURING Models)
Rear Gearcase, Disassembly (X2 Models)
Rear Gearcase, Exploded View (Base / TOURING)
Rear Gearcase, Exploded View (X2)
Rear Gearcase, Installation (Base Models)
Rear Gearcase, Installation (TOURING Models)
Rear Gearcase, Installation (X2 Models)
Rear Gearcase, Removal (Base Models)
Rear Gearcase, Removal (TOURING Models)
Rear Gearcase, Removal (X2 Models)
Rear Propshaft, Service
Rear Rack
Rear Stabilizer Bar, Exploded View (Base)
Rear Stabilizer Bar, Exploded View (X2 / TOURING)
Reflash Authorization
Relays
Removal, Cam Chain Tensioner
Removal, Cam Sprocket
Replacement Keys
Reprogramming Authorization
Ring, Piston, Installation
Ring, Piston, Installed Gap Measurement
Rocker Arm Inspection
Rocker Arm Support Installation
Rocker Arm Support, Removal
Rocker Arm, Inspection
RPM Limit
S
Seat
Seat, Operator Backrest Removal/Installation (X2)
Seat, Passenger (TOURING)
Seat, Passenger (X2)
Seat, Passenger, Suspension (TOURING)
Shift Linkage Inspection
Shocks and Springs
Side Panels
Software Version
Solenoid, Rear Differential (X2)
Spark Plug
Special Tools, Body / Frame
Special Tools, Clutching
Special Tools, Cooling System
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Specification, Fuel Pressure
Specifications, Brake Disc Runout
Specifications, Brake Pad Thickness
Specifications, Brakes
Specifications, Clutching (550 / 550 EPS / 550 INT’L) Specifications, Clutching (550 X2 / 550 TOURING)
Specifications, Cooling System
Specifications, Engine
Specifications, Final Drive Torque
Specifications, Wheel Nut Torque
Speed Sensor, Operation Overview
Speedometer
Starter Drive
Starter Drive, Removal
Starter Motor, Assembly
Starter Motor, Disassembly
Starter Motor, Removal / Disassembly
Starter Solenoid, Test
Starter System
Starter System, Troubleshooting
Stator Housing Removal
Stator Installation
Stator Removal
Steering
Steering (Non-EPS Models)
Steering Inspection
Steering Post Installation (Non-EPS Models) Steering Post Removal (Non-EPS Models) Steering, Electronic Power Steering (EPS)
Steering, Exploded View (EPS)
Steering, Exploded View (Non-EPS Models)
Steering, Tie Rod Replacement
Suspension Inspection
Suspension Spring Preload Adjustment
T
Tap/Drill Sizes
Tensioner, Cam Chain, Installation
Thermostat, Installation
Thermostat, Removal
Throttle Cable Adjustment
Throttle Operation
Throttle Position Sensor (TPS)
Tie Rod Ends
Timing, Balance Shaft
Timing, Camshaft
Tire Inspection
Tire Pressure
T-MAP Sensor
Toe Alignment
Toe Alignment Adjustment
Torque Chart
Torque Patterns, Engine Fasteners
Torque Specifications, Body / Frame
Torque Specifications, Clutching
Torque Specifications, Cooling System
Torque Specifications, Engine
Torque Specifications, Steering / Suspension
Torque Specifications, Transmission
Torque Specifications, Wheel and Hub
TPS Adjustment
TPS Replacement
Transmission Lubrication
Transmission, Assembly
Transmission, Disassembly
Transmission, Exploded View
Transmission, Installation
Transmission, Lubrication
Transmission, Removal
Transmission, Shaft Service
Trouble Codes
Troubleshooting, Brake Noise
Troubleshooting, Brakes
Troubleshooting, Clutching
Troubleshooting, Cooling System
Troubleshooting, Engine
Troubleshooting, Spark Plug Fouling
Troubleshooting, Transmission
U
Upper Steering Post Installation (EPS Models)
Upper Steering Post Removal (EPS Models)
V
Valve Clearance
Valve Clearance Adjustment
Valve Sealing Test
Valve Seat Reconditioning
Valve, Inspection
Vehicle Identification Number (VIN)
Vehicle Identification Numbers
Vent Lines
Version, Software
VIN Location
Voltage Drop Test
W
Water Pump Seal Removal
Wheel Hubs
Wheel Removal / Installation