Model Variant:
500 EFI X2, 500 EFI, 500 Touring EFI
Vehicle Type:
All-Terrain Vehicle (ATV)
Chassis Code:
A08CH50AA (Sportsman 500 EFI X2), A08CH50AX (Sportsman 500 EFI X2), A08CH50AZ (Sportsman 500 EFI X2), A08CH50AX (Sportsman 500 EFI X2), A08CH50AZ (Sportsman 500 EFI X2), A08CH50AJ (Sportsman 500 EFI), A08CH50AL (Sportsman 500 EFI), A08CH50AZ (Sportsman 500 EFI), A08CH50AU (Sportsman Touring EFI), A08CH50AZ (Sportsman Touring EFI)
Segment:
Heavy-duty utility ATV, known for versatility and off-road capability.
Target Audience:
Recreational riders, farmers, hunters, and utility users requiring robust performance and carrying capacity.
Key Competitors:
Honda Foreman/Rancher, Yamaha Grizzly, Suzuki KingQuad, Kawasaki Brute Force.
Engine Configuration:
Single-cylinder, liquid-cooled, SOHC engine with Electronic Fuel Injection (EFI).
Transmission Type:
Polaris Variable Transmission (PVT) automatic with engine braking, Hi/Lo range, Reverse.
Drive System:
On-Demand, True All-Wheel Drive (AWD) with Automatic Desmodromic Control (ADC) or Lock & Ride system variants. Some models may offer 2WD/4WD selectability.
Suspension Type:
MacPherson strut front suspension, Independent Rear Suspension (IRS) for enhanced ride comfort and traction.
Utility Features:
Front and rear steel racks for cargo, 2-up seating (Touring), versatile cargo bed (X2 model).
Engine Mechanical:
Engine disassembly, inspection, assembly, top-end overhaul, piston and cylinder service, crankshaft and connecting rod service, valve train, timing.
Engine Fuel System:
Electronic Fuel Injection (EFI) system diagnostics, fuel pump, injectors, throttle body, pressure regulator, fuel tank and lines.
Engine Ignition System:
Ignition system components, troubleshooting, ignition timing (if applicable to EFI control).
Cooling System:
Radiator, fan, thermostat, coolant flow, leaks, flushing and refilling.
Exhaust System:
Muffler, exhaust pipes, catalytic converter (if equipped), gasket replacement.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission) operation, belt inspection and replacement, clutch service (primary and secondary), gearcase service, differential maintenance, AWD system (if applicable).
Braking System:
Hydraulic brake system, caliper service, pad replacement, fluid bleeding, rotor inspection, parking brake.
Suspension Steering:
Front and rear suspension components, shocks, struts, control arms, ball joints, bushings, steering linkage, tie rods, wheel alignment.
Electrical System:
Battery, charging system (stator, rectifier/regulator), starter motor, lighting, wiring diagrams, fuses, relays, ECM diagnostics.
Body Chassis:
Frame inspection, body panels, fenders, racks, seat removal, storage compartments.
Accessories Special Features:
X2 specific features (e.g., tilt bed), Touring specific features, winch operation and maintenance (if factory-equipped).
Routine Maintenance:
Oil changes, filter replacements, lubrication points, chain/belt adjustments (if applicable), tire pressure checks, spark plug service.
Troubleshooting:
Diagnostic charts, symptom-based problem solving, error code interpretation for EFI system.
Repair Overhaul:
Step-by-step instructions for major component repairs and overhauls.
Disassembly Assembly:
Detailed procedures for removing and reinstalling all major components.
Wiring Diagrams:
Comprehensive electrical schematics for all systems.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed EFI diagnostics and electrical troubleshooting.
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if properly created, allowing quick navigation to specific topics.
Printability:
Designed for printing individual sections or the entire manual for workshop use.
Image Clarity:
High-resolution images, diagrams, and schematics ensuring clarity for repair procedures.
Binding:
N/A (Downloadable PDF, binding not applicable to the digital product itself)
Paper Quality:
N/A (Downloadable PDF, paper type not applicable)
Engine Type:
4-stroke, SOHC, 3-valve, single-cylinder
Bore X Stroke:
92mm x 76mm
Cooling System:
Liquid-cooled
Horsepower Est:
Approximately 30-35 HP (Varies slightly by specific model and tuning)
Torque Est:
Not officially specified in HP, but known for strong low-end torque.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane recommended
Fuel Tank Capacity:
4.1 gallons (15.5 L)
Transmission Type:
Polaris Variable Transmission (PVT) Automatic
Gear Selection:
High, Low, Neutral, Reverse, Park
Engine Braking:
Standard on PVT system for controlled downhill descents.
Drive Modes:
2WD / On-Demand AWD (ADC)
Gearcase Oil:
Polaris AGL (Advanced Gear Lube) or equivalent SAE 75W-90 synthetic gear oil
Pvt Belt Inspection:
Recommended every 100 hours or 1000 miles for wear and tension.
Atv Safety:
ATVs are not designed for on-road use and require proper safety gear (helmet, eye protection, gloves, etc.) and training.
Braking System:
Hydraulic disc brakes front and rear, parking brake.
Drive System:
On-Demand AWD with ADC for improved traction and control in challenging terrain.
Lighting:
Dual headlights, tail light, brake light for visibility.
Engine Braking:
Contributes to safer downhill operation.
Display Features:
Digital instrument cluster displaying speedometer, tachometer, odometer, trip meter, fuel level, gear indicator, AWD status, and diagnostic trouble codes (DTCs).
Efi Management:
Engine Control Module (ECM) manages fuel delivery, ignition timing, and other engine parameters for optimal performance and emissions.
Awt System:
Polaris' advanced AWD system automatically engages front wheels when rear wheels lose traction, providing superior grip.
Diagnostic Port:
On-board diagnostics port allowing connection to scan tools for detailed system analysis and DTC retrieval.
Engine Oil Change:
Every 100 hours or 1000 miles, whichever comes first. More frequently under severe use.
Oil Filter Change:
Replace with every oil change.
Air Filter Cleaning Replacement:
Inspect every 25 hours, clean or replace as needed. Replace every 100 hours or annually.
Spark Plug Replacement:
Inspect every 100 hours, replace as needed. Typical replacement interval around 1000 hours or 2 years.
Transmission Oil Change:
Every 200 hours or 2000 miles. Drain and refill the gearcase.
Brake Fluid Flush:
Recommended every 12-24 months, or as indicated by fluid condition.
Engine Oil:
Polaris Synthetic 2W-50 PS-4 (or equivalent SAE 5W-50 API SG or higher)
Engine Oil Capacity:
2.1 US quarts (2.0 Liters) with filter change
Transmission Gearcase Oil:
Polaris AGL (Advanced Gear Lube) or SAE 75W-90 synthetic gear oil
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Coolant:
50/50 mixture of ethylene glycol antifreeze and distilled water
Efi System:
Potential for sensor failures (e.g., throttle position sensor, crankshaft position sensor) leading to rough running or no-start conditions. Fuel pump issues can occur over time.
Pvtt Belt:
Belt wear and stretching are common, requiring periodic inspection and replacement. Premature failure can occur if subjected to excessive heat or abuse.
Suspension Bushings:
Wear on control arm and sway bar bushings can lead to looseness and noise, particularly after heavy use.
A-Arm Bushings:
Frequent lubrication or replacement of A-arm bushings is recommended, as they can wear quickly.
Manufacturer:
Polaris Industries, a long-standing American manufacturer of powersports vehicles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving over decades with improvements in engine technology, suspension, and features.
Efi Introduction:
The 500 EFI models represent Polaris' shift towards more efficient and responsive fuel injection systems, replacing carbureted versions for improved performance and emissions.
X2 Touring Variants:
The X2 and Touring variants were introduced to cater to specific user needs: the X2 offering a unique 2-seater with a tilt bed, and the Touring focusing on 2-up riding comfort.
Production Years Covered:
2008, 2009
