Market Segment:
Polaris Sportsman series is positioned as a premium, versatile All-Terrain Vehicle (ATV) suitable for utility, trail riding, and recreational purposes, with the Touring model specifically catering to two-up riding comfort and longer excursions.
Competitors:
Competes with other major ATV manufacturers in the 500cc-class utility/recreational segment, such as Can-Am Outlander 500, Arctic Cat 500 TRV, and Yamaha Grizzly 550.
Key Features Vehicle:
Dual-seat comfort, powerful 500cc EFI engine, Independent Rear Suspension (IRS), Active Descent Control (ADC) or Engine Braking System (EBS), On-Demand All-Wheel Drive (AWD), power steering (often optional on this trim), substantial towing and payload capacities.
Key Features Manual:
Comprehensive coverage, detailed diagrams and illustrations, step-by-step repair instructions, troubleshooting guides, maintenance schedules, and factory specifications.
Systems Covered:
Engine, Fuel System, Ignition System, Drivetrain, Transmission, Suspension, Steering, Brakes, Electrical System, Bodywork, Chassis, Cooling System, Lubrication System, Exhaust System, Frame, Drive Shafts, Axles, Wheels, Tires, Controls, Instruments, Lighting, Security Systems, and much more.
Estimated Page Count:
Approximately 300-450 pages (typical for a comprehensive service manual of this era and complexity).
Manual Type:
Workshop Repair and Service Manual
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly of the 500cc EFI engine, including top-end (cylinder head, valves, camshaft) and bottom-end (crankshaft, connecting rods, pistons) components.
Fuel And Ignition:
In-depth coverage of the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, throttle body, sensors (MAP, TPS, IAT, ECT), ECM/ECU, and ignition coil operation, diagnosis, and repair.
Drivetrain And Transmission
Drivetrain:
Comprehensive details on the Automatic PVT (Polaris Variable Transmission) including belt inspection, replacement, clutch service, and final drive assembly (gearcase, differentials, driveshafts, CV joints).
Maintenance Procedures:
Scheduled maintenance (oil changes, filter replacements, spark plug checks, valve adjustments if applicable), general inspections, lubrication points, and winterization/storage procedures.
Diagnostic Procedures:
Systematic troubleshooting guides, diagnostic trouble codes (DTCs) and their meanings, electrical system testing, component testing procedures, and symptom-based diagnostic flowcharts.
Repair Procedures:
Step-by-step instructions for component removal, repair, replacement, and installation, covering virtually all mechanical and electrical systems of the ATV.
Diagnostic Capabilities:
Advanced diagnostic capabilities, including electrical schematic interpretation, voltage/resistance testing of sensors and actuators, and EFI system parameter analysis.
Rebuild Information:
Complete rebuild procedures for major components such as the engine, transmission, and differentials, including torque specifications and critical clearances.
Troubleshooting Methodology:
Structured troubleshooting methodology, guiding technicians through logical steps to identify and resolve issues efficiently.
Print Quality:
High-resolution scans or digital original ensuring clear text, diagrams, and illustrations suitable for printing.
Binding Type:
N/A (PDF Download)
Paper Type:
N/A (PDF Download)
Searchability:
Likely searchable text (OCR'd) for quick information retrieval.
Digital Features:
Hyperlinked table of contents and index for easy navigation.
Engine Type:
Four-stroke, Liquid-cooled, SOHC, 4-valve
Bore X Stroke:
92 mm x 76 mm (approximate, verify with manual)
Horsepower:
Approximately 30-35 HP (peak, actual may vary slightly based on tuning and conditions - manual will have exact figures).
Torque:
Specific torque figures are not typically advertised but are available in detailed service manuals.
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body
Fuel Type:
Unleaded gasoline, minimum 87 octane
Cooling Method:
Liquid-cooled
Oil Capacity:
Approximately 2.0 - 2.5 US quarts (1.9 - 2.4 liters) with filter change (verify with manual).
Oil Type:
Polaris recommends specific synthetic or semi-synthetic ATV oil meeting JASO MA standards. Manual will specify SAE viscosity grade (e.g., 0W-40, 10W-40, 5W-50).
Transmission Type:
Automatic Polaris Variable Transmission (PVT) with Gearing: High, Low, Neutral, Reverse, Park.
Optional Transmission:
N/A for this model and year.
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/AWD selector and often features Electronic Descent Control (EDC) or Engine Braking System (EBS).
Clutch Type:
Primary and Secondary CVT clutches.
Length:
Approximately 85 inches (2159 mm).
Width:
Approximately 47.2 inches (1200 mm).
Height:
Approximately 48.3 inches (1227 mm).
Front Rack Capacity:
Approximately 100 lbs (45 kg).
Rear Rack Capacity:
Approximately 200 lbs (90 kg).
Dry Weight:
Approximately 640 lbs (290 kg) (varies by specific configuration).
Towing Capacity:
1500 lbs (680.4 kg).
Tongue Weight:
150 lbs (68 kg).
Safety Certifications:
Typically meets ANSI/SVIA standards for recreational ATVs. Specific crash test ratings are not applicable in the same way as passenger cars.
Braking System:
Hydraulic disc brakes front and rear. Often features engine braking (EBS).
Traction Control:
On-Demand AWD system provides enhanced traction.
Lighting:
Dual 50W halogen headlights, 25/80W dual-beam taillight/brake light.
Seatbelts Roll Over:
Not equipped with seatbelts or a roll cage; riders must wear appropriate protective gear.
Instrumentation:
Digital odometer, trip meter, tachometer, engine hour meter, speedometer, fuel gauge, gear indicator, AWD indicator, 4x4 indicator, oil pressure light, check engine light.
Electronic Features:
On-Demand AWD, Engine Braking System (EBS) or Active Descent Control (ADC) depending on exact sub-model/package.
Diagnostics Port:
Likely has a diagnostic connector for EFI system diagnostics, requiring specific tools or the manual for interpretation of codes.
Engine Oil Change:
Typically every 100 hours of operation or 6 months, whichever comes first. (Verify with manual for exact interval).
Air Filter Cleaning Replacement:
Inspect every 50 hours, clean or replace as needed. More frequent in dusty conditions. (Verify with manual).
Spark Plug Check Replacement:
Inspect every 100 hours or annually. Replace as needed. (Verify with manual).
Transmission Fluid Change:
Typically every 200 hours or 12 months. (Verify with manual).
Engine Oil Specification:
Polaris Synthetic 5W-50 PS-4 or equivalent SAE 5W-50 engine oil meeting API GL-4 standards. (Manual is definitive).
Gearcase Fluid Specification:
Polaris Demand Drive Fluid or equivalent SAE 75W-90 Synthetic Gear Oil. (Manual is definitive).
Coolant Specification:
Ethylene glycol-based antifreeze coolant (e.g., Polaris Brand Antifreeze/Coolant) mixed 50/50 with distilled water. (Manual is definitive).
Common Issues:
CV joint boot wear, differential seal leaks, starter solenoid issues, occasional drive belt wear beyond normal, fuel pump strainer clogging. The manual will provide specific diagnostic procedures for these.
Efi System Maintenance:
Periodic cleaning of throttle body and checking fuel filter/strainer integrity are recommended by the EFI system's nature. The manual will detail these procedures.
Polaris Atv History:
Polaris is a long-standing and innovative manufacturer of off-road vehicles, with the Sportsman line being a cornerstone of their ATV offerings since the early 1990s, known for utility, comfort, and performance.
Sportsman Touring Lineage:
The Touring models are an evolution of the core Sportsman platform, designed to provide enhanced comfort for two riders with a longer wheelbase, improved ergonomics, and often more premium features compared to single-rider models.
Production Years 500 Efi:
The 500 EFI engine was a prevalent powerplant for Polaris ATVs across multiple years, including 2009. The Touring 500 EFI variant specifically addresses the two-up market within this engine family.
