Polaris Sportsman Touring 500 EFI 2009 Online Service Manual

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Mots clés: 2009 ATV Polaris Powersports Sportsman Series Sportsman Touring 500 EFI

Variantes de produits

Description

The 2009 Sportsman Touring 500 EFI is a versatile All-Terrain Vehicle (ATV) designed for recreational riding and utility tasks. This model features a robust single-cylinder, 4-stroke engine with Electronic Fuel Injection (EFI) for reliable power delivery. Key highlights include its Independent Rear Suspension (IRS) for a smoother ride, On-Demand All-Wheel Drive (AWD) for enhanced traction, and comfortable seating for two, making it ideal for longer excursions. With substantial cargo rack capacity and a towing capability of up to 1,500 lbs, the Sportsman Touring 500 EFI offers practical functionality alongside its recreational appeal. This comprehensive Service and Repair Manual provides detailed guidance for owners and technicians on maintaining and repairing the 2009 Sportsman Touring 500 EFI. It covers essential areas such as engine inspection and overhaul, transmission operation and maintenance, fuel system diagnostics including EFI components, as well as body, suspension, steering, brakes, and electrical systems. The manual includes step-by-step repair instructions, troubleshooting charts for common issues, and critical technical specifications like torque values and fluid capacities, ensuring the ATV remains in optimal condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Touring 500 EFI

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Engine Configuration:

Single-cylinder, 4-stroke

Fuel System:

Electronic Fuel Injection (EFI)

Codes

Vin Code Year:

👋 Introduction

Market Position

Positioning:

The Polaris Sportsman Touring 500 EFI (2009) was positioned as a capable and comfortable recreational and utility ATV, often favored for its independent rear suspension and touring capabilities.

Competitive Analysis

Competitors:

Competed against models from brands like Can-Am (Outlander), Yamaha (Grizzly), and Honda (Foreman/Rancher) in the mid-size utility/recreational ATV segment.

Key Features

Features:

Independent Rear Suspension (IRS), On-Demand All-Wheel Drive (AWD), powerful 500cc EFI engine, comfortable seating for two, extensive cargo rack capacity.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF / WinRAR

Delivery Method:

Instant Download

Compatibility:

Windows (95/98/ME/XP/Vista/7/8), Linux, MAC, iOS, Android

📖 Manual Coverage

Systems Covered

Engine:

Detailed inspection, overhaul, and component testing

Transmission:

Operation, maintenance, and repair of the CVT (Continuously Variable Transmission)

Fuel System:

EFI system diagnosis, injector cleaning, fuel pump testing

Body:

Frame, plastic components, seat, and storage

Suspension:

Front and rear suspension components, shock absorber service

Steering:

Handlebar, steering column, tie rods, and wheel alignment

Brakes:

Hydraulic brake system, caliper service, pad replacement, bleeding procedures

Electrical:

Wiring diagrams, component testing, battery, ignition system, lighting

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid changes, filter replacement

Troubleshooting:

Diagnostic charts for common problems and solutions

Repair:

Step-by-step repair instructions for all major components

Technical Specifications:

Torque values, clearances, fluid capacities, and electrical specifications

Technical Depth

Depth:

Comprehensive coverage from basic maintenance to full engine and transmission rebuilds

📊 Manual Specifications

File Format

Format Details:

Searchable PDF within a WinRAR archive for efficient download and extraction.

Print Quality

Quality:

High-resolution scans ensuring clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 4-valve, Single Cylinder

Displacement:

499cc

Bore X Stroke:

93.5mm x 72mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approximately 30 HP (estimated)

Torque:

Not officially published, but estimated to be in the range of 28-32 lb-ft

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with 40mm throttle body

Fuel Type:

Unleaded gasoline, 87 octane recommended

Lubrication

Oil Type:

Polaris Premium 4 Synthetic 0W-40 (or equivalent)

Oil Capacity:

Approximately 2.0 quarts (1.9 liters) with filter change

🔧 Transmission

Standard

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Drive System:

Shaft Drive with On-Demand AWD

Features

Gear Selection:

High, Low, Neutral, Reverse, Park

Clutch Type:

Primary and Secondary Clutch (Belt Driven)

Transmission Fluid:

Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 75W-90 synthetic gear oil)

Transmission Fluid Capacity:

Approximately 10.1 fl oz (300 ml)

📐 Dimensions

Exterior

Length:

81 in (205.7 cm)

Width:

46 in (116.8 cm)

Height:

47 in (119.4 cm)

Wheelbase:

56.5 in (143.5 cm)

Ground Clearance:

11.25 in (28.6 cm)

Weights

Dry Weight:

656 lbs (297.5 kg)

Payload Capacity:

450 lbs (204 kg)

Towing Capacity:

1,500 lbs (680 kg)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Fuel Capacity:

4.1 gal (15.5 L)

🛡️ Safety Features

Ratings

Safety Standards:

Meets ANSI standards for recreational ATVs.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Parking Brake:

Parking brake integrated into the transmission (lever on handlebars).

Passive Features

Lighting:

Dual 50W headlights, dual taillight/brake light.

Operator Protection:

Handlebar wind deflectors, integrated floorboards with heel guards.

💡 Technology Features

Infotainment

Display:

Digital instrumentation display including speedometer, odometer, trip meter, tachometer, fuel gauge, and gear indicator.

Driver Assistance

AWD System:

On-Demand All-Wheel Drive (AWD) engages front wheels automatically when rear wheels lose traction.

Connectivity

Charging System:

12V DC outlet (cigarette lighter style) for charging accessories.

🔧 Maintenance

Service Intervals

Initial Service:

Check oil, chain tension, and fasteners at 10 hours or 1 month.

Oil Change Interval:

Every 100 hours or 6 months, whichever comes first.

Air Filter Maintenance:

Clean every 25 hours; replace every 100 hours or as needed.

Spark Plug Replacement:

Replace every 100 hours or 12 months.

Transmission Fluid Change:

Change every 6 months or 100 hours.

Fluid Specifications

Engine Oil Spec:

SAE 0W-40 Synthetic, API SG or higher.

Gearcase Oil Spec:

SAE 75W-90 Synthetic Gear Oil.

Coolant Spec:

Polaris Premium Pre-mixed Antifreeze/Coolant (or equivalent ethylene glycol based, 50/50 mix).

Known Issues

Common Complaints:

CVT belt wear, potential starter issues, some fuel delivery concerns under heavy load or specific conditions (though EFI mitigates some carb issues).

Preventative Measures:

Regular inspection and cleaning of the CVT primary and secondary clutches, ensuring proper belt tension and condition. Keeping the air filter clean and fuel system free of debris.

📚 Vehicle History

Brand Heritage

Brand Origin:

Polaris Industries Inc. is an American manufacturer of motorcycles, ATVs, and snowmobiles, founded in 1954.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, evolving from basic utility models to more feature-rich recreational and touring machines. The 500cc engine has been a popular choice throughout its history.

Production

Manufacturing Location:

Primarily manufactured in the United States by Polaris Industries.