Category:
Utility ATV (All-Terrain Vehicle) for recreational and working purposes.
Target User:
Owners seeking to perform maintenance, repairs, and diagnostics on their Polaris Sportsman Touring 500 EFI.
Competitors:
Competes with models from brands like Can-Am Outlander, Yamaha Grizzly, Honda Foreman, and Arctic Cat in the utility ATV segment.
Feature Highlight:
The 'Touring' designation indicates a focus on comfort and extended ride capabilities, often with features like a passenger seat and a longer wheelbase.
Value Proposition:
Provides comprehensive factory information for DIY mechanics, reducing reliance on dealership service.
Engine:
Detailed diagnostics, repair, and overhaul procedures for the 499cc liquid-cooled, 4-stroke, SOHC, single-cylinder engine.
Fuel System:
EFI system (Electronic Fuel Injection) troubleshooting, component testing (injectors, throttle body, fuel pump), and calibration.
Ignition System:
CDI unit, spark plug analysis, coil testing, and timing procedures.
Transmission Drive:
Automatic PVT (Polaris Variable Transmission) clutch service (primary and secondary), belt inspection and replacement, roller maintenance, and gearbox overhaul.
Drivetrain:
All-Wheel Drive (AWD) system diagnostics, AWD lock actuator service, front differential maintenance, rear differential service, and driveshaft U-joint inspection.
Suspension:
Front and rear suspension component inspection, shock absorber adjustment and replacement, A-arm bushings, and steering linkage maintenance.
Brakes:
Hydraulic brake system service, caliper overhaul, brake pad replacement, rotor inspection, brake fluid flushing and bleeding, and parking brake adjustments.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor service, lighting system troubleshooting, and accessory wiring.
Cooling System:
Radiator service, fan operation, coolant type and capacity, thermostat testing, and hose inspection.
Exhaust System:
Muffler and pipe inspection, gasket replacement, and heat shield maintenance.
Frame Chassis:
Frame inspection for damage, steering column service, and rider controls (handlebars, levers).
Bodywork:
Plastic panel removal and installation, fender maintenance, and seat service.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain/belt adjustments, and general inspections.
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon issues across all major systems.
Component Overhaul:
Detailed rebuild procedures for engines, transmissions, differentials, and other major components.
Electrical Diagnostics:
Schematics, wiring harness troubleshooting, component testing using multimeters, and fault code interpretation (if applicable).
Suspension Alignment:
Procedures for checking and adjusting steering geometry and suspension settings.
Clutch Adjustment:
Specific instructions for maintaining optimal performance of the PVT system.
Fluid Changes:
Correct types, capacities, and intervals for engine oil, transmission oil, coolant, and brake fluid.
Torque Specifications:
Essential torque values for critical fasteners throughout the vehicle.
Depth:
Factory-level, in-depth technical information covering everything from routine maintenance to complete engine and transmission rebuilds.
Diagnostic Tools:
Information on diagnostic connectors and basic diagnostic procedures.
Special Tools:
Identification of any specialized tools required for specific repair procedures.
Engine Type:
4-stroke, SOHC, single-cylinder
Cooling System:
Liquid-cooled
Bore X Stroke:
Specifics available in manual, typically around 92mm x 75.2mm
Compression Ratio:
Specifics available in manual, typically around 10.2:1
Horsepower:
Approx. 39-40 HP at RPM (specifics in manual)
Torque:
Specifics available in manual, typically around 31 lb-ft at RPM
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body
Fuel Type:
Unleaded gasoline (Octane rating specified in manual, typically 87 or higher)
Fuel Pump Pressure:
Specific pressure readings for troubleshooting will be detailed in the manual.
Type:
Automatic Polaris Variable Transmission (PVT) with Engine Braking
Optional Types:
N/A for this model; PVT is standard.
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/AWD selector
Clutch Type:
Centrifugal primary clutch, roller secondary clutch
Transmission Fluid Type:
Polaris AGL Premium Gearcase Lubricant or equivalent SAE 30/40 Synthetic Gearcase Lubricant (refer to manual for exact specification).
Gearcase Capacity:
Specific capacity listed in manual, typically around 10-12 oz.
Atv Safety Standards:
Compliant with ANSI/SVIA standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear, sealed hydraulic rear braking system with left-handlebar lever and right-foot pedal.
Engine Braking:
PVT system provides effective engine braking for downhill control.
AWD System:
On-demand AWD for enhanced traction.
Lighting:
Dual 50W headlights, dual brakelights/taillights.
Ergonomics:
Designed for rider comfort and control, including passenger seating with backrest and floorboards.
Rollover Protection:
N/A - ATVs do not have built-in rollover protection systems like ROVs; emphasis on rider training and safe operation.
Engine Oil Change:
Every 100 hours or annually, whichever comes first. (Refer to manual for specific operating conditions).
Air Filter Cleaning:
Every 50 hours or annually; clean more frequently in dusty conditions.
Spark Plug Inspection:
Every 100 hours or annually.
Transmission Oil Check:
Every 100 hours or annually.
Brake Fluid Flush:
Every 2 years or as needed.
Engine Oil Type:
Polaris PS-4 Full Synthetic 5W-50 or equivalent API SG, JASO MA certified oil.
Engine Oil Capacity:
Approx. 2.1 U.S. quarts (2.0 liters) with filter change (refer to manual for exact capacity).
Coolant Type:
Polaris Premium 2-Stroke Coolant or equivalent ethylene glycol-based antifreeze.
Coolant Capacity:
Approx. 2.1 U.S. quarts (2.0 liters) (refer to manual for exact capacity).
Common Wear Items:
PVT belt wear, A-arm bushings, wheel bearings, and ball joints are common wear items in utility ATVs.
Efi System Checks:
Occasional need for throttle body cleaning and ensuring proper fuel quality for optimal EFI performance.
Drivetrain Maintenance:
Regular inspection of CV boots for tears and proper lubrication of AWD components is crucial.
Manufacturer:
Polaris Industries Inc. is a long-standing American manufacturer known for ATVs, snowmobiles, and powersports vehicles.
Lineage:
The Sportsman line is Polaris's flagship utility ATV series, continuously updated for performance and comfort.
Touring Variant:
The 'Touring' variants were introduced to cater to riders who frequently carry passengers or prioritize extended ride comfort.
Production Period:
The 500 EFI engine was a popular choice for Polaris in this era, with the Touring 500 EFI specifically produced from 2008 through the early 2010s.
Manufacturing Location:
Primarily manufactured in the United States.
