2012 – 2014 Polaris Sportsman 550 ATV Service Manual

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This 2012, 2013, 2014 Polaris Sportsman 550 Service Manual  provides service, repair and maintenance information for 2012-2014 Sportsman 550 ATVs (TR/X2/EPS).

Table of Contents


2012 – 2014 Polaris Sportsman 550 Service Manual Index of Topics

2012-2013 Rear Stabilizer Bar, Assembly View
2014 Rear Stabilizer Bar, Assembly View
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
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 Assembly
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 / 550 EPS / 55C 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
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
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, Installation
Cylinder Head, Removal
Cylinder Honing
Cylinder, Inspection
Cylinder, Installation
Cylinder, Removal
Daily Inspection
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostic Trouble Code Table
Diagnostic Trouble Codes
Diagnostics, Engine
Digital Wrench
Engine Controller Reprogramming
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software
Digital Wrench Versions
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Disassembly, Engine Lower End
Drive Belt, Break-In
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal (Base Models)
Drive Belt, Removal (X2 / TOURING Models)
Drive Clutch, Button to Tower Clearance
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 Inspection
Drive Coupler Removal / Installation
Drive Shaft / CV Joint, Handling Tips
Drive Shaft Boot Inspection
Driven Clutch, Assembly
Driven Clutch, Disassembly
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
ECM Relay
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI Relay
EFI System Break-Out Diagram
EFI, Component Locations
EFI, Diagnostic Trouble Codes
EFI, Exploded View
EFI, Service Notes
EFI, Special Tools
Electrical Breakout Diagrams
Electronic Control Unit (ECU)
Engine Assembly, Lower End
Engine Controller Reprogramming
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
Exploded View, Engine
Fan Relay
Flywheel Installation
Flywheel, Removal
Foot (Auxiliary) Brake Master Cylinder
Foot Master Cylinder, Operation (550 INT’L)
Footwell, Removal / Installation
Frame Supports (Base Models)
Frame Supports (X2 / TOURING 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 Replacement
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Fuel System Troubleshooting
Fuel Tank
Fuel Tank Installation
Fuel Tank Removal
Fuse Box, 2012-2013
Fuse Box, 2014
Fused Circuits, 2012-2013
Fused Circuits, 2014
Gear Position Switch
Gear Selector Removal
Guided Diagnostics
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
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Inner Plunging Joint / Boot Replacement
Installation, Water Pump Mechanical Seal
Instrument Cluster
Instrument Cluster (Base /X2 / TOURING
Instrument Cluster (Base EPS Models)
Key, Reprogramming Authorization
Keys, Replacement
Lash Adjustment, Valve
Lash, Valve, Adjustment
Leakdown Test
Lubrication Grease Points
Main Frame (Base Models)
Main Frame (X2 / TOURING Models)
Maintenance and Service Products
Maintenance Quick Reference Chart
Maintenance, Heavy Duty (HD) Components
Mechanical Seal, Installation
Mechanical Seal, Removal
Metric Bolt Torque Specification
Model Number
Model Specifications, 2012
Model Specifications, 2012 Sportsman 550
Model Specifications, 2012 Sportsman 550 EPS Model Specifications, 2012 Sportsman 550 Touring
Model Specifications, 2012 Sportsman 550 X2
Model Specifications, 2013
Model Specifications, 2013 Sportsman 550
Model Specifications, 2013 Sportsman 550 EPS Model Specifications, 2013 Sportsman 550 Touring
Model Specifications, 2013 Sportsman 550 X2
Model Specifications, 2014
Mud Guards
Oil Delivery Pipe Installation
Oil Flow Diagram
Oil Pressure Test
Oil Pump, Assembly
Oil Pump, Removal
Outer CV Joint / Boot Replacement
Periodic Maintenance Chart
Piston Identification
Piston Ring, Installation
Piston-to-Cylinder Clearance
Piston, Inspection
Piston, Installation
Piston, Removal
Piston, Ring Installed Gap
Power Steering Relay
Power Steering Unit Installation
Power Steering Unit Removal
Power Steering Unit, Cleaning
Pre-Filter Service
Pre-Ride Inspection
Propshaft, U-Joint Service
Publication Part Numbers
PVT System, Assembly
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
Radiator, Removal
Rear A-arm, Removal
Rear A-arms
Rear A-arms, Exploded View
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
Rear Gearcase, Assembly (X2 Models)
Rear Gearcase, Disassembly and Inspection
Rear Gearcase, Disassembly and Inspection (X2 Models)
Rear Gearcase, Exploded View
Rear Gearcase, Exploded View (X2 Models)
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
Reflash Authorization
Relays / Fuses
Relays, Overview
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
Seat, Operator Backrest Removal/Installation (X2 Models)
Seat, Passenger (TOURING Models)
Seat, Passenger (X2 Models)
Seat, Passenger, Suspension Removal/Adjustment
(TOURING Models)
Shift Linkage Inspection
Shift Weights
Shocks and Springs
Side Panels
Software Version
Solenoid, Rear Differential (X2 Models)
Spark Plug
Special Tools
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, 2014 Sportsman 550
Specifications, 2014 Sportsman 550 Touring
Specifications, 2014 Sportsman 550 X2
Specifications, Brake Disc Runout
Specifications, Brake Pad Thickness
Specifications, Brakes
Specifications, Cooling System
Specifications, Engine
Specifications, Final Drive Torque
Specifications, Wheel Nut Torque
Speed Sensor, Operation Overview
Standard Bolt Torque Specification
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 (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 Models)
Steering, Exploded View (Non-EPS Models)
Steering, Tie Rod Replacement
Suspension Inspection
Suspension Spring Preload Adjustment
T-MAP Sensor
Tap/Drill Sizes
Tensioner, Cam Chain, Installation
Thermostat, Installation
Thermostat, Removal
Throttle Cable Adjustment
Throttle Operation
Throttle Position Sensor (TPS)
Throttle Release Switch (TRS)
Tie Rod Ends
Timing, Balance Shaft
Timing, Camshaft
Tire Inspection
Tire Pressure
Toe Alignment
Toe Alignment Adjustment
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
Trouble Codes, Instrument Cluster Display
Troubleshooting, Brake Noise
Troubleshooting, Brakes
Troubleshooting, Clutching
Troubleshooting, Cooling System
Troubleshooting, Engine
Troubleshooting, Spark Plug Fouling
Troubleshooting, Transmission
Upper Steering Post Installation (EPS Models)
Upper Steering Post Removal (EPS Models)
Valve Clearance
Valve Clearance Adjustment
Valve Sealing Test
Valve Seat Reconditioning
Valve, Inspection
Vehicle Information
VIN Number
Vehicle Information Numbers
Vent Lines
Version, Software
VIN Location
VIN Number
Voltage Drop Test
Water Pump Seal Removal
Wheel Hubs
Wheel Removal / Installation

Additional information

Weight 2.75 lbs
Dimensions 11 × 8.5 × 1.25 in