Polaris Touring 500 EFI Sportsman 2009 Workshop Manual

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Stichworte: 2009 ATV Polaris Powersports Sportsman Series Touring 500 EFI Sportsman

Produktvarianten

Beschreibung

The Polaris Sportsman Touring 500 EFI is a versatile utility all-terrain vehicle from 2009, designed for enthusiasts and utility users seeking comfortable, extended-range off-road capabilities. This model, part of Polaris's well-regarded Sportsman line, features tandem seating and an extended chassis for enhanced passenger comfort, blending utility features with a focus on rider and passenger experience. Its 499cc liquid-cooled, 4-stroke engine with Electronic Fuel Injection (EFI) provides reliable power for various terrains, supported by an On-Demand All-Wheel Drive system for optimal traction. Known for its independent rear suspension and robust build, the Sportsman Touring 500 EFI offers a comfortable and capable platform for both recreational riding and demanding tasks. This comprehensive workshop manual serves as an essential resource for owners and mechanics, covering all aspects of repair and maintenance for the 2009 Polaris Sportsman Touring 500 EFI. It details procedures for the powertrain, chassis, body, and electrical systems, including engine diagnostics, transmission servicing, suspension adjustments, and brake system maintenance. The manual provides step-by-step instructions for routine maintenance, troubleshooting common and uncommon issues, and mechanical repairs, complete with detailed diagrams and torque specifications. Its scope is designed to empower users, from beginners to experienced technicians, to effectively diagnose problems and perform necessary upkeep, ensuring the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Touring 500 EFI

Year:

Product Name:

Polaris Touring 500 EFI Sportsman 2009 Workshop Manual PDF Download

👋 Introduction

Market Position

Segment:

Utility All-Terrain Vehicle (ATV) - Touring Variant

Target User:

Enthusiasts and utility users requiring comfortable, extended-range off-road capabilities

Competitive Analysis

Key Competitors Segment:

Other major ATV manufacturers (e.g., Arctic Cat, Can-Am, Honda, Yamaha) offering similar displacement touring or utility models.

Key Features

Vehicle Focus:

Tandem seating, extended chassis for passenger comfort, utility features combined with comfortable touring.

Manual Value:

Empowers owners with comprehensive knowledge for self-sufficiency in maintenance and repair, reducing reliance on service centers.

📋 Manual Details

Coverage Areas

Primary Focus:

Workshop repair and maintenance

Intended Audience:

Owners, beginners to experienced mechanics

Diagnostic Scope:

Determining cause of vehicle-related problems

Procedural Scope:

Recommended repair and maintenance procedures

Page Count

Estimated Pages:

Likely 300-500 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Manual / Service Manual / Repair Manual

Language

Language:

English

Format

Delivery Method:

Instant PDF Download

File Type:

PDF / WINZIP

Compatibility

Device Compatibility:

All devices with a PDF reader (desktops, laptops, tablets, smartphones)

Os Compatibility:

All versions of operating systems

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission (CVT/Transmission), Fuel System

Chassis:

Suspension, Steering, Brakes

Body:

Body and related components

Electrical:

Electrical system, Wire Diagrams

Specific Components:

Engine internals (pistons, rings, valves, crankshaft), CVT clutch components, drive axles, differentials, steering rack, suspension arms, shock absorbers, brake calipers, master cylinders.

Procedures Included

Routine Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements

Troubleshooting:

Diagnostic procedures for common and uncommon issues

Mechanical Repair:

Disassembly, inspection of parts for reuse, rebuilding, and assembly of components

Assembly Disassembly:

Detailed step-by-step instructions with torque specifications for major component removal and reinstallation.

Technical Depth

Depth Level:

Comprehensive, covering basic to advanced repair procedures, suitable for DIY and professional mechanics

Diagnostic Charts:

Includes symptom-based troubleshooting guides, often presented in a flow-chart format.

Electrical Diagnostics:

Comprehensive wiring diagrams for all electrical systems, component testing procedures, and troubleshooting related to shorts, opens, and circuit faults.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Compression:

WINZIP (indicating potential for multiple files or archival)

Searchability:

PDF format allows for keyword searching within the document for quick access to specific information.

Print Quality

Scalability:

Scalable vector graphics for diagrams and illustrations, sharp text for readability

Illustration Quality:

High-quality diagrams, schematics, and exploded views to aid in understanding assembly and repair processes.

Binding Type

Digital Binding:

Non-applicable for PDF, but implies structured content with navigable sections

Paper Type

Digital Paper Equivalent:

High-resolution digital pages, optimized for screen viewing and optional printing

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-Cooled, 4-Stroke, SOHC, Single Cylinder

Displacement:

499cc

Bore X Stroke:

Typically around 92mm x 75mm (specifics in manual)

Valve Train:

SOHC (Single Overhead Camshaft), 4 Valves per cylinder

Cooling System:

Liquid-Cooled with fan assist

Performance

Horsepower Estimated:

Approx. 30-35 HP (specific to manual)

Torque Estimated:

Around 30-35 lb-ft (specific to manual)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Ignition System:

CDI (Capacitor Discharge Ignition) with electronic spark advance

Fuel Type:

Unleaded Gasoline, 87 Octane minimum

🔧 Transmission

Standard

Type:

Automatic (CVT)

Drive Modes:

High, Low, Neutral, Reverse, Park

Features

Engagement:

On-Demand All-Wheel Drive (AWD)

Braking Aid:

Engine Braking (via CVT)

📐 Dimensions

Exterior

Length:

Approx. 85.0 inches (215.9 cm)

Width:

Approx. 46.0 inches (116.8 cm)

Height:

Approx. 48.0 inches (121.9 cm)

Weights

Dry Weight:

Approx. 675 lbs (306 kg)

Ground Clearance:

Approx. 10.5 inches (26.7 cm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Towing

Towing Capacity:

1500 lbs (680 kg)

Hitch Type:

2-inch Receiver

🛡️ Safety Features

Ratings

Rollover Resistance:

N/A (ATVs are not rated by government agencies like cars; owner responsibility for safe operation)

Active Features

Braking System:

Hydraulic Disc Brakes (front and rear), often with a single-lever front and rear application, and right-foot rear brake.

Throttle Limiter:

Potentially adjustable throttle limiter for new riders (check manual for details).

Passive Features

Lighting:

Dual Halogen Headlights, Taillight/Brake Light

Operator Station:

Ergonomic handlebar, handguards, comfortable seating for two.

💡 Technology Features

Infotainment

Features:

Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, engine hour meter, AWD indicator, high beam indicator. No advanced infotainment typically found in modern ATVs.

Driver Assistance

Features:

On-Demand AWD system which automatically engages front wheels when rear wheels lose traction. Engine braking via CVT.

Connectivity

Features:

None (not applicable to this vehicle type and era).

🔧 Maintenance

Service Intervals

Oil Change:

Every 100 hours or 1 year (specifics detailed in the manual, engine hours are primary for ATVs).

Air Filter Cleaning:

Every 25 hours or as needed in dusty conditions.

Spark Plug Check:

Every 100 hours or 1 year.

Fluid Specifications

Engine Oil Type:

SAE 5W-50 Synthetic (Polaris Premium 4 or equivalent API SG or higher rating)

Engine Oil Capacity:

Approx. 2.2 quarts (2.1 liters) with filter change.

Transmission Fluid:

Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent.

Coolant Type:

Ethylene Glycol based antifreeze with corrosion inhibitors, typically 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (check manual for specific recommendation)

Known Issues

Common Wear Items:

CV boots, tie rod ends, wheel bearings, brake pads, drive belt (CVT).

Efi System:

EFI systems can be sensitive to fuel quality and cleanliness; potential issues with fuel pump, injectors, or sensors. Manual will cover diagnostics.

Charging System:

Potential issues with stator or voltage regulator; manual will provide testing procedures.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship ATV series, known for its independent rear suspension (IRS) and utility/comfort features. The Touring models are an extension of this, prioritizing rider and passenger comfort for longer rides.

Production

Production Period:

The 500cc engine platform has been a staple for Polaris for many years, with the Touring 500 EFI being a specific iteration in their lineup.

🏆 Awards & Recognition

Recognitions

General Recognition:

Polaris Sportsman models have historically been well-regarded for their ride comfort, independent suspension, and utility capabilities, often receiving positive reviews in powersports media.