Positioning:
The Polaris Sportsman 500 EFI Touring was a popular model in the utility ATV segment, known for its comfortable ride, storage capacity, and capable performance for both work and recreation.
Competitors:
Competed with models such as the Can-Am Outlander, Arctic Cat Prowler (though Prowler is side-by-side, comparable utility focus), and other 500cc class ATVs from Honda, Yamaha, and Suzuki.
Touring Features:
Designed for longer rides with features like comfortable seating for two, enhanced suspension, and ample storage capacity, distinguishing it from standard Sportsman models.
Value:
Essential for owners and technicians to maintain the complex EFI system and overall functionality, ensuring longevity and optimal performance of the ATV.
Primary Coverage:
Complete service, maintenance, repair, and troubleshooting for Polaris Sportsman 500 EFI Touring models.
Secondary Coverage:
Includes detailed diagrams, specifications, and procedures for all major systems.
Estimated Pages:
High (typically 500+ pages for comprehensive manuals of this nature, precise count not provided in product info but implied by scope)
Type:
Workshop Service Manual
Purpose:
Intended for mechanical technicians and advanced DIY users.
Engine:
Engine overhaul, disassembly, assembly, lubrication, cooling system, fuel system (EFI components), exhaust system, ignition system, starting system.
Drivetrain:
Transmission (PVT - Polaris Variable Transmission), clutches (primary and secondary), drive belts, final drive, AWD system (if applicable), driveshafts, U-joints.
Suspension:
Front and rear suspension systems, shock absorbers, control arms, bushings, wheel bearings, steering components.
Brakes:
Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, rotor service, bleeding procedure.
Electrical:
Battery, charging system (stator, regulator/rectifier), lighting (headlights, taillights, signals), ignition switch, starter motor, wiring diagrams, diagnostic codes, EFI sensors.
Chassis Body:
Frame inspection and repair, body panels, racks, seat assembly, fenders, graphics.
Fuel System Efi:
Fuel pump, fuel injectors, throttle body, MAP sensor, TPS sensor, O2 sensor (if applicable), ECU diagnostics.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, spark plug service, valve adjustments, clutch inspection and service, brake fluid flush, coolant checks and changes.
Repair:
Complete engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical system troubleshooting and repair, bodywork fixes.
Troubleshooting:
Diagnostic flowcharts for common problems, error code interpretation, specific component testing procedures.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine and transmission rebuilds, including electrical diagnostics for EFI systems.
Diagnostics:
Detailed diagnostic procedures for EFI system faults, including sensor testing and troubleshooting common starting or running issues.
Engine Type:
4-stroke, Single Cylinder, SOHC
Cooling System:
Liquid-Cooled
Horsepower:
Approx. 30-32 HP (varies slightly by year and tuning)
Torque:
Specific torque figures not readily available without detailed manual, but characterized by strong low-end grunt.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Ignition System:
CDI with Electronic Advance
Oil Type:
SAE 5W-50 Synthetic Motorcycle/ATV Oil recommended by Polaris for optimal performance and protection.
Transmission Type:
Polaris Variable Transmission (PVT) Automatic
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/4WD engagement
Clutch System:
CVT with Primary and Secondary Clutch, Belt Drive
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant is typically specified for the final drive and transmission.
Atv Safety Guidelines:
All ATVs require responsible operation, including wearing appropriate safety gear (helmet, eye protection, gloves, boots, long sleeves/pants). Always follow manufacturer's guidelines and local regulations.
Braking:
Hydraulic disc brakes on all wheels.
AWD System:
On-Demand AWD enhances traction and control in challenging terrain.
Ergonomics:
Ergonomic seating and controls for rider comfort and control during extended use.
Lighting:
Dual halogen headlights and a tail/brake light for visibility.
Infotainment System:
Basic; primarily focused on vehicle operation. Features typically include handlebar-mounted instrumentation with speedometer, odometer, trip meter, tachometer, fuel gauge, and indicator lights.
Assistance Features:
On-Demand AWD system is the primary driver assistance feature for traction control.
Connectivity Features:
No modern connectivity features such as Bluetooth or GPS navigation are standard on this model. Focus is on robust mechanical and EFI systems.
Efi Benefits:
Electronic Fuel Injection provides improved throttle response, easier cold starts, better fuel economy, and more consistent power delivery compared to carbureted models.
Oil Change:
Every 100 hours or 12 months (whichever comes first), or more frequently under severe use.
Air Filter:
Inspect every 25 hours, clean or replace as needed. Replace every 100 hours.
Spark Plug:
Replace every 100 hours or 12 months.
Drive Belt:
Inspect every 50 hours, replace as needed, typically every 2-3 years or 1000 hours of service (dependent on usage).
Valve Adjustment:
Check and adjust every 100 hours or 12 months.
Engine Oil Capacity:
Approx. 2.2 L (2.3 US qt) with filter change.
Coolant Type:
Polaris Premium All-Season Coolant or equivalent (50/50 mix of antifreeze and distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Problems:
Potential issues can include drive belt wear, starter solenoid failures, suspension component wear (bushings, ball joints), and occasional EFI sensor malfunctions (e.g., TPS, MAP) if not maintained or subjected to extreme conditions.
Efi Maintenance:
Proper fuel quality and regular use can help prevent issues with the EFI system; the manual will detail specific diagnostic steps for any fault codes.
Heritage:
Polaris has a long history in powersports, particularly with the Sportsman line, which has been a cornerstone of their ATV offerings for decades, evolving with new technologies and rider demands.
Evolution 500:
The 500cc engine platform has been a staple for Polaris, with the Sportsman 500 EFI Touring representing an evolution towards fuel-injected, more comfortable, and two-up capable utility ATVs.
Production Era:
The 2009-2010 models represent a specific iteration of the popular Sportsman 500 platform before further updates or model redesigns.
