The Polaris Sportsman 550, a stalwart in the ATV world, boasts a reputation for power and versatility. But like any machine, it’s not without its quirks. Owning one often means familiarizing yourself with some common issues that can crop up, from electrical gremlins to engine hiccups. Knowing what to look for – and how to address it – can save you time, money, and a whole lot of frustration out on the trail.

What are Sportsman 550 Owners Talking About? The Common Gripes

Let's dive into the issues that frequently surface in online forums, repair shops, and owner discussions. These aren't necessarily problems every Sportsman 550 owner will encounter, but they're prevalent enough to warrant attention.

1. The Dreaded EPS (Electronic Power Steering) Troubles:

One of the most talked-about issues revolves around the Electronic Power Steering (EPS) system. Many owners have reported intermittent or complete EPS failure. This can manifest as a sudden loss of power steering assistance, making the ATV significantly harder to handle, especially at lower speeds or in challenging terrain.

  • What causes it? Common culprits include a faulty EPS unit itself, wiring harness issues, or a failing torque sensor. Sometimes, the issue is as simple as a blown fuse, but often it requires more in-depth diagnosis.
  • How to fix it? Start by checking the EPS fuse. If that's not the problem, inspect the wiring harness for any signs of damage or corrosion. If the wiring looks good, the torque sensor or the EPS unit itself may need to be replaced. This is often best left to a qualified mechanic, as it can involve specialized tools and diagnostic equipment. Some owners have found success with aftermarket EPS units, which can sometimes offer improved reliability.

2. Electrical Gremlins: A Persistent Nuisance:

Polaris ATVs, including the Sportsman 550, have a reputation for electrical issues. These can range from minor annoyances to complete system failures.

  • What causes it? Corrosion in connectors, damaged wiring harnesses (often due to rubbing or animal damage), and faulty sensors are common causes. Battery issues and stator problems can also contribute to electrical problems.
  • How to fix it? Prevention is key here. Regularly inspect and clean all electrical connections, paying particular attention to ground connections. Use dielectric grease on connectors to prevent corrosion. If you're experiencing electrical problems, start by checking the battery voltage and the condition of the stator. A multimeter is your best friend here. If you suspect a wiring harness issue, carefully inspect the harness for any signs of damage. Replacing a damaged harness can be time-consuming but is often necessary to resolve persistent electrical problems.

3. Overheating: When Things Get Too Hot:

Overheating can be a serious issue, potentially leading to engine damage. The Sportsman 550, particularly when used for demanding tasks or in hot weather, can be prone to overheating.

  • What causes it? A clogged radiator, low coolant level, a faulty thermostat, or a malfunctioning cooling fan are the most common causes. Air pockets in the cooling system can also contribute to overheating.
  • How to fix it? Regularly check the coolant level and top it off as needed. Inspect the radiator for any signs of dirt, mud, or debris, and clean it thoroughly. Make sure the cooling fan is functioning correctly. If the engine is still overheating, the thermostat may need to be replaced. Burping the cooling system to remove air pockets is also crucial, especially after servicing the cooling system. Consider using a higher-quality coolant designed for ATVs.

4. Fuel System Foibles: Carburetor or EFI Headaches:

Depending on the year of your Sportsman 550, it might have a carburetor or Electronic Fuel Injection (EFI) system. Both systems can experience problems.

  • Carbureted Models: Issues often involve a dirty carburetor, clogged jets, or a malfunctioning fuel pump. Stale fuel can also cause problems.
  • EFI Models: Problems can stem from a faulty fuel pump, clogged fuel injectors, or a malfunctioning throttle position sensor (TPS).
  • How to fix it? For carbureted models, cleaning the carburetor is often the first step. Disassemble the carburetor and clean all jets and passages with carburetor cleaner. Replace the fuel filter regularly. For EFI models, check the fuel pressure and inspect the fuel injectors for clogs. A fuel injector cleaner can sometimes help clear minor clogs. A faulty TPS can cause erratic engine performance and may need to be replaced.

5. Suspension Woes: Bushings and Ball Joints:

The suspension system on the Sportsman 550 takes a beating, especially when used off-road. Bushings and ball joints are wear items and will eventually need to be replaced.

  • What causes it? Constant use, exposure to mud and water, and lack of lubrication accelerate wear and tear on suspension components.
  • How to fix it? Regularly inspect the bushings and ball joints for play or damage. Replace worn components as needed. Greasing the suspension components regularly will help extend their lifespan. Consider upgrading to aftermarket bushings made from more durable materials like polyurethane.

6. Transmission Troubles: Slipping or Grinding Gears:

The transmission is a critical component, and problems can lead to significant downtime. Slipping gears, grinding noises, or difficulty shifting can indicate transmission issues.

  • What causes it? Low transmission fluid, worn clutch plates (if applicable), or damaged gears can cause transmission problems.
  • How to fix it? Check the transmission fluid level and top it off as needed. If the fluid is dirty or contaminated, change it. If you're experiencing slipping gears, the clutch plates may need to be replaced. Damaged gears will require a more extensive repair, potentially involving a complete transmission rebuild.

7. Brakes That Bite Back: Squealing, Grinding, or Weak Stopping Power:

Brakes are essential for safety, and any brake problems should be addressed immediately. Squealing, grinding noises, or weak stopping power indicate brake issues.

  • What causes it? Worn brake pads, contaminated brake rotors, or air in the brake lines are common causes. A sticking caliper can also cause brake problems.
  • How to fix it? Inspect the brake pads for wear and replace them if they're worn down. Clean the brake rotors with brake cleaner. Bleed the brake lines to remove any air. If a caliper is sticking, it may need to be rebuilt or replaced.

Preventing Problems: A Stitch in Time Saves Nine

While some problems are inevitable, proactive maintenance can significantly reduce the likelihood of major issues.

  • Regular Servicing: Follow the manufacturer's recommended maintenance schedule. This includes changing fluids (engine oil, transmission fluid, coolant), lubricating grease fittings, and inspecting critical components.
  • Thorough Cleaning: Regularly wash your Sportsman 550, paying particular attention to removing mud and debris from the radiator, engine, and suspension components.
  • Proper Storage: If you're storing your ATV for an extended period, use a fuel stabilizer to prevent fuel degradation. Disconnect the battery or use a battery tender to prevent the battery from discharging. Store the ATV in a dry, covered location.
  • Careful Riding: Avoid excessive abuse and aggressive riding, which can put undue stress on the ATV's components.

Frequently Asked Questions

  • Why is my Sportsman 550 overheating? Overheating can be caused by a clogged radiator, low coolant, or a faulty thermostat. Check these components first.

  • My EPS light is on. What does that mean? The EPS light indicates a problem with the electronic power steering system. Check the fuse and wiring harness, or consult a mechanic.

  • How often should I change the oil in my Sportsman 550? Refer to your owner's manual, but typically every 25 hours of use or every six months, whichever comes first.

  • My Sportsman 550 is hard to start. What could be the problem? This could be due to a weak battery, a faulty fuel pump, or a dirty carburetor (on carbureted models). Check these components.

  • What kind of fuel should I use in my Sportsman 550? Use unleaded gasoline with an octane rating of 87 or higher. Avoid using fuel with ethanol if possible.

Final Thoughts

The Polaris Sportsman 550 is a capable ATV, but understanding its common problems can empower you to keep it running smoothly. By staying informed, performing regular maintenance, and addressing issues promptly, you can enjoy many years of reliable performance from your machine. Knowledge is power, especially when it comes to keeping your ATV on the trail.