Polaris Sportsman 500 EFI HO X2 Touring 2009-2012 ATV Service Repair Workshop Manual

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The Polaris Sportsman 500 EFI HO X2 Touring, produced from 2009 to 2012, represents a robust utility ATV designed for a variety of tasks and recreational activities. Known for its...

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Tipo: Atv

Proveedor:

SKU: 86773

Etiquetas: 2009 2010 2011 2012 ATV Misc Polaris Powersports Sportsman 500 EFI HO X2 Touring

Variantes de producto

Descripción

The Polaris Sportsman 500 EFI HO X2 Touring, produced from 2009 to 2012, represents a robust utility ATV designed for a variety of tasks and recreational activities. Known for its High Output (HO) engine and Electronic Fuel Injection (EFI) system, this model offers enhanced power, improved throttle response, and better fuel efficiency. The X2 Touring variant is distinguished by its versatile 2-up seating capability and a convertible cargo bed, making it suitable for recreational riders, farmers, hunters, and light utility users who require both passenger comfort and hauling capacity. Its liquid-cooled, 4-stroke SOHC engine, coupled with a Variable Transmission with engine braking, provides reliable performance across different terrains and demanding conditions. This comprehensive service and repair workshop manual provides detailed information for the maintenance and repair of the Polaris Sportsman 500 EFI HO X2 Touring. It covers all essential systems, including the engine, transmission, drivetrain, fuel system, electrical system, brakes, suspension, and steering. The manual includes step-by-step repair procedures, routine maintenance schedules, troubleshooting guides, and critical technical specifications, such as torque values and fluid requirements. With over 500 pages of content, this English-language manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, longevity, and safety of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 EFI HO X2 Touring

Model Variant:

X2 Touring

Production Years Covered:

2009, 2010, 2011, 2012

Codes

Engine Code Suffix:

HO (High Output)

Fuel Induction Code:

EFI (Electronic Fuel Injection)

👋 Introduction

Market Position

Segment:

Utility ATV

Target User:

Recreational riders, farmers, hunters, and light utility users.

Competitive Analysis

Key Competitors:

Can-Am Outlander 500, Arctic Cat 500, Honda Foreman/Rancher series, Yamaha Grizzly 550.

Key Features

Versatility:

The 'X2' designation typically implies a 2-up seating capability and a versatile cargo bed.

Engine Performance:

HO (High Output) engine designation suggests enhanced power and torque for its class.

Fuel Efficiency:

EFI system contributes to better fuel economy and throttle response compared to carbureted models.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, diagnostics, component testing, lubrication system, cooling system, intake and exhaust systems.

Transmission:

Automatic transmission service, removal and installation, torque converter, gearcase, oil and filter changes.

Drivetrain:

All-wheel drive (AWD) system, front and rear driveshafts, differential service, CV joints, final drive.

Fuel System:

EFI system, fuel pump, injectors, fuel pressure regulator, throttle body, ECM diagnostics.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting, wiring diagrams, fuses, relays.

Brakes:

Hydraulic brake system, brake lines, master cylinder, calipers, pads, rotors, bleeding procedures.

Suspension:

Front and rear suspension systems, shocks, springs, control arms, ball joints, bushings, alignment procedures.

Steering:

Steering column, tie rods, steering rack, power steering system (if applicable), alignment.

Body And Chassis:

Frame inspection, body panels, seats, racks, bumpers, fenders, removal and installation.

Cooling System:

Radiator, fan, coolant, thermostat, water pump, flushing and refilling.

Exhaust System:

Muffler, pipes, catalytic converter (if applicable), inspection and replacement.

Wheels And Tires:

Tire pressure, rotation, replacement, wheel torque specifications, lug nut patterns.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, battery maintenance, lubrication points.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, error code interpretation.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Overhaul Procedures:

Detailed instructions for complete engine, transmission, and differential rebuilds.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams with component identification.

Torque Specifications:

All critical torque values for fasteners and components.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Technical Depth

Depth Of Coverage:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds).

Diagnostic Capabilities:

Advanced diagnostics for EFI system, electrical faults, and mechanical issues.

📊 Manual Specifications

File Format

File Format:

Portable Document Format (PDF)

Print Quality

Image Resolution:

High-resolution for clear viewing of diagrams and photos.

Text Searchability:

Searchable text for quick information retrieval.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 3-valve

Displacement:

499 cc

Bore X Stroke:

92 mm x 76 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approximately 30-33 HP (manufacturer dependent, actual will vary slightly).

Torque:

Estimated at 30-33 lb-ft (manufacturer dependent, actual will vary slightly).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Fuel Tank Capacity:

4.25 US gallons (16.1 L)

🔧 Transmission

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission) with Engine Braking

Drive Modes:

High, Low, Neutral, Reverse, Park

Optional

Optional Features:

Not applicable for this model's core transmission.

Features

Gear Reduction:

Standard for low-speed torque and climbing.

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Oil or equivalent (refer to manual for exact specs and capacity).

📐 Dimensions

Exterior

Length:

Approx. 81 in. (205.7 cm)

Width:

Approx. 46 in. (116.8 cm)

Height:

Approx. 47 in. (119.4 cm)

Wheelbase:

Approx. 50.5 in. (128.3 cm)

Ground Clearance:

Approx. 11.25 in. (28.6 cm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (91 kg)

Weights

Dry Weight:

Approx. 665 lbs (301.6 kg)

Towing Capacity:

1,500 lbs (680 kg)

Payload Capacity:

N/A (but includes rider and cargo capacity)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI standards for recreational ATVs (where applicable for the era).

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Engine Braking:

Standard feature of the PVT transmission for downhill control.

Passive Features

Lighting:

Dual headlights, tail light, brake light.

Operator Station:

Handlebar design for control, comfortable seating for rider and passenger.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumental cluster (speedometer, odometer, fuel gauge, warning lights). No advanced infotainment system.

Driver Assistance

Driver Assistance Features:

None (standard ATV operation).

Connectivity

Connectivity Options:

None.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months (whichever comes first); refer to manual for severe usage intervals.

Air Filter Inspection:

Check every 25 hours or 1 month; clean/replace as needed.

Spark Plug Replacement:

Recommended at 200 hours or 12 months.

Transmission Fluid Change:

Every 100 hours or 6 months.

Fluid Specifications

Engine Oil Type:

SAE 5W-50 Synthetic Motorcycle Oil (API CI-4 or higher recommended for wet clutch compatibility, or Polaris 4-stroke engine oil).

Engine Oil Capacity:

Approx. 2.2 US quarts (2.1 L) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water).

Known Issues

Efi System Maintenance:

Periodic cleaning of throttle body and injectors can prevent performance issues.

Belt Wear:

Regular inspection of the CVT belt for wear and damage is crucial; premature wear can occur with aggressive riding or improper belt tension.

Suspension Bushings:

Like many ATVs of this era, suspension and steering bushings can wear over time, leading to looseness and premature tire wear.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Polaris Industries is a long-standing American manufacturer with a significant presence in ATVs, snowmobiles, and powersports vehicles.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV series, known for its durability, comfort, and capability. The 500cc platform has been a mainstay for many years, evolving with EFI and chassis updates.

X2 Variant:

The X2 designation specifically introduced the unique dual-seating configuration with a convertible cargo bed, offering enhanced versatility for carrying a passenger and gear.

Production

Production Location:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2009-2012 Sportsman 500 X2 Touring are not individually documented, the Polaris Sportsman line consistently receives positive reviews for its durability, capability, and value in the utility ATV segment.

Ratings

Consumer Ratings:

Generally rated highly by consumers for its robust performance and versatility, particularly the X2's unique seating and cargo configuration.