Positioning:
The Polaris Sportsman Touring 500 H.O. is positioned as a capable and comfortable multi-purpose ATV for recreational riding, utility tasks, and light trailering.
Competitors:
Competes with similar offerings from Can-Am (Outlander), Yamaha (Grizzly), Arctic Cat (Prowler), and Honda (FourTrax Foreman/Rubicon).
Touring Design:
Emphasis on rider comfort, storage, and capability for longer excursions, often including features like a passenger seat and upgraded suspension.
Manual Value:
This manual provides the essential technical data and procedures required for owners and technicians to maintain, diagnose, and repair the specific model years, ensuring optimal performance and longevity.
Primary Coverage:
Complete Factory Service, Repair, and Workshop Procedures
Secondary Coverage:
Servicing, Diagnostics, Troubleshooting, Component Replacement, Assembly/Disassembly
Estimated Page Count:
Comprehensive, exceeding 500 pages (typical for full service manuals)
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Download Access:
Instant download, no expiry dates
Engine:
Complete engine disassembly, assembly, tuning, diagnostics, and component overhauls
Fuel System:
Fuel pump, injectors, fuel lines, fuel tank, carburetor/EFI system diagnostics and repair
Cooling System:
Radiator, fan, water pump, thermostat, coolant flow, and leak detection
Ignition System:
CDI unit, ignition coil, spark plugs, wiring, timing
Transmission:
CVT system, drive clutch, driven clutch, belt inspection/replacement, gearcase service
Drivetrain:
Front and rear differentials, driveshafts, universal joints, wheel hubs
Suspension:
Front and rear A-arms, shocks, springs, bushings, wheel bearings, adjustment procedures
Brakes:
Hydraulic brake system, calipers, master cylinders, brake lines, pads, rotors, bleeding procedures
Steering:
Handlebar assembly, steering shaft, tie rods, steering linkage, geometry
Electrical System:
Battery, charging system (stator, regulator/rectifier), lighting, starting system, instrumentation, wiring diagrams
Frame And Bodywork:
Frame inspection, body panel removal/installation, seat, racks, fenders
Exhaust System:
Muffler, head pipe, heat shields, emissions control components
Maintenance:
Regular servicing, oil changes, filter replacements, lubrication, pre-ride inspections
Troubleshooting:
Diagnostic flowcharts, symptom-based problem solving for various systems
Repair:
Component repair, replacement, and adjustment for all covered systems
Overhaul:
Detailed procedures for engine, transmission, and differential rebuilds
Diagnostics:
Electrical system diagnostics, fuel system testing, ignition system analysis
Assembly Disassembly:
Step-by-step guides for dismantling and reassembling all major components and sub-assemblies
Depth:
Factory-level detail, covering everything from routine maintenance to complete engine and transmission rebuilds
Detail Level:
Includes torque specifications, clearances, special tool requirements, and detailed diagnostic procedures
Engine Type:
4-Stroke, SOHC, 4-Valve
Engine Displacement:
499cc
Engine Cooling:
Liquid-Cooled
Bore X Stroke:
Refer to manual for precise figures (typical for 500cc class)
Compression Ratio:
Refer to manual for precise figures
Horsepower:
Approx. 32 HP (actual figures vary by year and specific tune)
Torque:
Refer to manual for precise figures
Fuel Delivery:
Electronic Fuel Injection (EFI) or Carburetor (depending on specific sub-model/year variance, manual will detail)
Fuel Type:
Unleaded Gasoline (minimum Octane rating specified in manual)
Fuel Tank Capacity:
Approx. 4.0 US gal (15.1 L)
Atv Safety Standards:
Adheres to ANSI/SVIA standard 1-2010 for ATVs. Manual will detail specific safety warnings.
Braking System:
Hydraulic disc brakes front and rear, often with a linked braking system controlled by levers.
All Wheel Drive:
On-Demand AWD for improved traction in challenging terrain.
Roll Over Protection:
None inherently provided (ATVs require safe operating practices).
Seat Belt:
Not equipped (ATVs are operated standing or seated without seat belts).
Hand Guards:
Often standard or optional for lever protection and debris deflection.
Oil Change Interval:
Typically every 100 hours or 6 months, whichever comes first. Refer to manual for exact specification.
Belt Inspection Interval:
Regular inspection for wear and tear, recommended at ~50-100 hour intervals. Manual will detail.
Air Filter Cleaning:
Frequent cleaning/replacement depending on operating conditions, crucial for engine health.
Engine Oil Type:
Refer to manual. Typically SAE 5W-50 Synthetic or 0W-40 Synthetic for extreme cold.
Engine Oil Capacity:
Approx. 2.2 US qts (2.1 L) with filter change. Refer to manual.
Coolant Type:
Ethylene Glycol-based Antifreeze (e.g., Polaris Premium Pre-Mix)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid. Refer to manual.
Cv Boot Wear:
CV boot tears can occur from debris; regular inspection and replacement are vital.
Belt Slippage:
CVT belt wear or damage can lead to slippage and reduced performance. Manual details diagnosis and replacement.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues. Manual provides wiring diagrams for troubleshooting.
