2009 Sportsman XP 550 - XP 550 EPS - SM.pdf - Quad service manual Polaris - wielebny111

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2009 SPORTSMAN XP 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2009 SPORTSMAN XP 550 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

DETAILED: 2009 SPORTSMAN XP 550 / XP 550 EPS. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

8 7 7 - 9 9 9 - 5 6 8 6

1.1

P a r t S h a r k . c o

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

A 0 9 Z N 5 5 A L

Year Designation

Basic Chassis

Designation

Emissions &

Model Option

Engine Designation

Engine Designation Number

ES550PLE .......................................................... Single Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start

P a r t S h a r k . c o

Vehicle Identification Number (VIN)

8 7 7 - 9 9 9 - 5 6 8 6

World

Mfg. ID

Vehicle Descriptor

Vehicle Identifier

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

4 X A Z N 5 5 A * 9 P 0 0 0 0 0 0

Body Style

Engine

Model

Year

Individual Serial Number

Emissions

Plant No

* This could be either

a number or a letter

Powertrain

Check Digit

Vehicle and Engine Serial Number Locations

Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and

the engine serial number.

The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1).

The engine serial number can be found on a decal applied to the recoil housing on the front side of the engine

(see Figure 1-2).

Figure 1-1

Figure 1-2

Engine Serial

Number

VIN

1.2

GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

YEAR

MODEL

MODEL NO.

OWNER’S MANUAL PN PARTS MANUAL PN

2009 SPORTSMAN XP 550

A09ZN55AL, AQ,

AS, AT, AX, FX

9921973

9922173 (INT’L)

9921855

9922387 (INT’L)

2009 SPORTSMAN XP 550 EPS

A09ZX55AC, AL,

AQ, AS, AX

9921973

9921974

NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from

www.purepolaris.com.

Replacement Keys

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key

and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch

assembly is necessary.

P a r t S h a r k . c o

8 7 7 - 9 9 9 - 5 6 8 6

KEY COVER

P/N 5533534

Key Series

Number

Series #

Part Number

4010278

4010321

4110141

4110148

4010278

Special Tools

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools

maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris

product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or

on-line at http://polaris.spx.com/ .

1.3

GENERAL INFORMATION

SPECIFICATIONS

MODEL: 2009 SPORTSMAN XP 550

MODEL NUMBER:. . . . . . . . . A09ZN55AL, AQ, AS, AT, AX, FX

ENGINE MODEL:. . . . . . . . . . ES550PLE

Category

Dimension

Length

83.25 in. / 211.5 cm

Width

47.6 in. / 121 cm

Height

50.75 in. / 129 cm

Wheel Base

53 in. / 135 cm

Ground Clearance

11.6 in. / 29.5 cm

Turning Radius

84 in. / 213 cm (unloaded)

Dry Weight

744 lbs. / 337.5 kg

Front Rack Capacity

120 lbs. / 54 kg

Rear Rack Capacity

240 lbs. / 109 kg

Max. Weight Capacity

575 lbs. / 261 kg

Towing Capacity

1500 lbs. / 680 kg

Hitch Tongue Weight

150 lbs. / 68 kg

1.4

GENERAL INFORMATION

2009 SPORTSMAN XP 550 / XP 550 EPS

Drivetrain

XP MODELS: A09ZN55AL,AQ,AS,AT,AX,FX

XP EPS MODELS: A09ZX55AC,AL,AQ,AS,AX

ENGINE MODEL: ES550PLE

Transmission Type

Automatic PVT

In-Line H-L-N-R-P

Transmission

Fluid Type / Fluid Capacity

Synthetic Sportsman XP

Transmission Fluid /

32 oz. (946 ml)

Engine

Platform

Fuji Single Cylinder, 4-Cycle

Front Gearcase

Fluid Type / Fluid Capacity

Premium LT Demand Drive

Fluid / 9.3 oz. (275 ml)

Engine Model Number

ES550PLE010

Engine Displacement

549 cc

Front Gearcase

ADC Reservoir Fluid Type

Premium ADC

Front Drive Fluid

Number of Cylinders

Rear Gearcase

Fluid Type / Fluid Capacity

ATV Angle Drive Fluid /

7.1 oz. (210 ml)

Bore & Stroke (mm)

96.6 x 75 mm

Compression Ratio

9.6:1

Clutch Type

PVT w/EBS

Compression Pressure

70 - 90 psi

Belt

3211123

Steering / Suspension

Engine Idle Speed

1650 RPM

P a r t S h a r k . c o

Cooling System / Cap.

Liquid Cooled / 2 qt. (1.9 l)

Toe Out

0-1/16 in. (0-.159 mm)

Overheat Warning

Instrument Cluster Indicator

Front Suspension

Dual A-arm

Lubrication

Pressurized Wet Sump

Front Travel

9.2 in. / 23.4 cm

8 7 7 - 9 9 9 - 5 6 8 6

Engine Oil Requirement

PS-4 Plus / 2 qt. (1.9 l)

Rear Suspension

Dual A-arm w/Rolled IRS

Stainless Steel Header Pipe

w/ Single Outlet Silencer

Fuel System

Exhaust System

Rear Travel

10.2 in. / 25.9 cm

Shock Preload Adjustment

Front / Rear

Cam Adjustable

Visteon

Electronic Fuel Injection

Fuel System Type

Wheels / Brakes

Front Wheel Size / Bolt Pattern

Tire Model / Size

14 x 6 / 4-156

Carlisle Terrathon / 26 x 8 - 14

Throttle Body / Size

Mikuni / 42 mm

Electronic Fuel Pump

(in tank)

Fuel Delivery

Rear Wheel Size / Bolt Pattern

Tire Model / Size

14 x 8 / 4-156

Carlisle Terrathon / 26 x 10 - 14

Fuel Pressure

43 psi

Front: 7 psi (48 kPa)

Rear: 5 psi (34.5kPa)

Fuel Capacity

XP: 5.25 gal. (20 l)

XP EPS: 4.5 gal. (17 l)

Tire Air Pressure

Single Control

Hydraulic 3-Wheel Disc

Fuel Requirements

87 Octane (minimum)

Electrical

Brakes - Front & Rear

Brake Fluid

Polaris DOT 4 Brake Fluid

Alternator Output

490 W @1350 RPM / Peak: 630 W

Voltage Regulator

3-Phase / 32 Amp

CLUTCH CHART

Pod: 12V / 50 Watts

Bumper: 12V / 50 Watts x 2

Brake Light 12V / 27 Watts

Tail Light 12V / 7 Watts

Starting System Electric

Ignition System Visteon EFI (ECU Controlled)

Ignition Timing 13° ± 3° BTDC @ 1650 RPM

Spark plug / Gap NGK BKR6E / .035 in. (.9 mm)

Battery / Model / AH / CCA YUASA / YTX20HL / 18 AH / 310

Instrumentation

Altitude

Shift

Weight

Drive

Spring

Driven

Spring

Meters

(Feet)

0-1800

(0-6000)

23-58

5632218

Red / Blk

7043500

Red / Wht

3235621

1800-3700

(6000 - 12000)

23-54

5632219

Red / Blk

7043500

Red / Wht

3235621

Multifunction Instrument Cluster

DC Outlet

Standard

Relays

(Located in Relay/Fuse Box)

Chassis / ECU / Fan / EFI /

Bumper Lights

Circuit Breaker

Fan Motor: 10A

Fuses

(Located in Relay/Fuse Box)

Lights: 20A / Drive: 20A /

Accessory: 20A / EFI: 20A /

Unswitched: 10A / EPS: 30A

1.5

Head Lights

2009 Sportsman XP 550 - XP 550 EPS - SM.pdf

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