🏷️ Basic Information

Make:

Polaris

Model:

Sportsman Touring 500 EFI

Product Name:

POLARIS SPORTSMAN TOURING 500 EFI Digital Workshop Repair Manual 2009-2010 PDF Download

Generation Designation:

Not explicitly defined in product info, but covers 2009-2010 model years.

Chassis Code:

Not specified in product information.

👋 Introduction

Vehicle Segment:

The Polaris Sportsman Touring 500 EFI is positioned as a capable and comfortable utility ATV designed for recreational riding, work, and touring, offering enhanced passenger capacity.

Key Competitors:

Competes with other major ATV manufacturers like Can-Am (Outlander series), Honda (FourTrax Foreman/Rubicon), Yamaha (Grizzly), and Arctic Cat (Prowler/Wildcat) in the utility and touring ATV segment.

Unique Selling Points:

Emphasis on 'Touring' indicates a design prioritizing comfort for two riders, likely with a comfortable rear seat and passenger footrests. EFI ensures reliable starting and performance in varying conditions.

Manual Value Proposition:

This manual serves as an indispensable resource for owners and technicians, enabling them to maintain, diagnose, and repair the Sportsman Touring 500 EFI with precision and efficiency, thus extending its lifespan and performance.

📋 Manual Details

Coverage Years:

2009-2010

Coverage Models:

Polaris Sportsman Touring 500 EFI

Estimated Page Count:

Not explicitly stated, but described as 'highly detailed' and containing 'everything'.

Type:

Digital Workshop Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine overhaul, diagnosis, repair, tuning, fuel injection system (EFI), ignition system, lubrication system, cooling system.

Transmission:

All-Wheel Drive (AWD) system, automatic transmission (CVT), clutch system, drive shafts, differentials.

Brakes:

Hydraulic braking system, brake lines, calipers, master cylinder, parking brake.

Electrical:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting system, instrumentation, sensors, EFI ECU.

Chassis And Suspension:

Frame, front and rear suspension components (shocks, springs, A-arms), steering system, wheel bearings.

Bodywork And Trim:

Body panels, fenders, seat, handlebars, racks, plastics, decals.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, lubrication points, valve adjustments (if applicable).

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault code interpretation (for EFI systems), symptom-based troubleshooting charts.

Repair:

Step-by-step repair instructions for all major components and systems, including complete engine rebuilds, transmission overhauls, suspension repairs, and electrical diagnostics.

Rebuild Refurbish Restore:

Detailed guidance on rebuilding, refurbishing, and restoring all aspects of the vehicle, from mechanical components to cosmetic elements.

Depth Level:

Comprehensive, covering basic maintenance to complex diagnostics and complete unit overhauls. Suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Capabilities:

Includes diagnostic procedures for the Electronic Fuel Injection (EFI) system, likely with specific diagnostic codes and testing methods.

Wiring Diagrams:

Detailed electrical wiring schematics are a hallmark of workshop manuals, essential for troubleshooting electrical faults.

📊 Manual Specifications

Format Details:

PDF (Portable Document Format). Likely searchable text, allowing for quick information retrieval. High-resolution scans for clear diagrams and text.

Print Readability:

Designed for clear printing, with legible diagrams, schematics, and text for easy reference in a workshop environment.

Binding Method:

N/A (Digital download, no physical binding).

Paper Quality:

N/A (Digital download, no physical paper type).

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, SOHC (Single Overhead Camshaft), single-cylinder.

Engine Displacement:

499cc (Actual displacement may vary slightly by specific sub-model or year, but 500cc is the nominal classification).

Bore X Stroke:

Not explicitly provided in product info, but typical for this engine family.

Compression Ratio:

Not explicitly provided in product info, but typical for this engine family.

Horsepower:

Approx. 30-35 HP (Estimated based on typical 500cc single-cylinder ATV engines of the era).

Torque:

Not explicitly provided in product info, but contributes to the vehicle's pulling power.

Fuel Delivery:

Electronic Fuel Injection (EFI) with throttle body.

Fuel Type:

Unleaded gasoline, minimum octane rating typically 87.

Ignition System:

Electronic ignition.

Cooling Method:

Liquid-cooled.

Oil Type:

Likely a SAE 5W-50 or 10W-50 synthetic or semi-synthetic ATV-specific oil. Specific part numbers and viscosities will be detailed in the manual.

Oil Capacity:

Typically around 1.7-2.0 quarts (1.6-1.9 liters), including filter. Specific capacity will be in the manual.

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission).

Drive System:

On-Demand All-Wheel Drive (AWD) with 2WD/AWD selectable modes.

Gear Selection:

High, Low, Neutral, Reverse, Park.

Clutch Type:

Primary and secondary clutches (CVT system).

Final Drive:

Shaft drive with front and rear differentials.

Cvt Belt Inspection Replacement:

The manual will detail inspection intervals and replacement procedures for the CVT belt, a critical maintenance item.

Gearcase Oil Type:

Likely a dedicated ATV gearcase lubricant or a suitable SAE 80W-90 gear oil. Specific part numbers and intervals will be in the manual.

📐 Dimensions

Length:

Approx. 83 inches (210.8 cm).

Width:

Approx. 48 inches (121.9 cm).

Height:

Approx. 50 inches (127 cm) to handlebars.

Wheelbase:

Approx. 56 inches (142.2 cm).

Ground Clearance:

Approx. 10.4 inches (26.4 cm).

Dry Weight:

Approx. 670 lbs (304 kg).

Towing Capacity:

Typically 1,500 lbs (680 kg).

Rack Capacity Front:

Approx. 90 lbs (41 kg).

Rack Capacity Rear:

Approx. 180 lbs (82 kg).

Front Tire Size:

Typically 25 x 8-12.

Rear Tire Size:

Typically 25 x 10-12.

Wheel Bolt Pattern:

Not explicitly specified, but typically 4x110mm or similar for Polaris ATVs of this era.

🛡️ Safety Features

Atv Safety Standards:

Adherence to ANSI standards for recreational off-highway vehicles is standard for Polaris products.

Braking System:

Hydraulic disc brakes on all wheels, often with a locking rear differential for improved traction.

Engine Braking:

CVT system provides engine braking on descents.

Lighting:

Dual headlights, taillight, brake light.

Ergonomics:

Designed for rider comfort and control, with integrated passenger grab handles and footrests.

Operator Training:

The manual will emphasize the importance of reading the owner's manual and proper ATV operation training.

💡 Technology Features

Instrumentation:

Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, 4WD indicator, and warning lights.

Efi Technology:

Electronic Fuel Injection provides optimized fuel delivery for consistent performance, better cold starts, and improved throttle response compared to carbureted models.

Awt System:

The 'On-Demand' AWD system automatically engages front-wheel drive when rear wheel slippage is detected, enhancing traction without constant driver intervention.

Diagnostics Port:

Likely includes a diagnostic port for connecting to diagnostic tools, crucial for EFI system troubleshooting covered in the manual.

🔧 Maintenance

Initial Service:

Break-in service typically around 10-20 hours or 100-200 miles, involving an oil and filter change.

Regular Maintenance:

The manual will provide a detailed schedule covering: engine oil and filter changes (e.g., every 100 hours or annually), air filter cleaning/replacement, spark plug service, checking and topping off coolant, checking tire pressure, lubricating chassis points, inspecting brake pads and fluid, and CVT belt inspection.

Engine Oil Specification:

Refer to engine_specs for general type. The manual will specify exact API service classification and viscosity grade (e.g., SAE 5W-50 API SG).

Coolant Type:

Ethylene glycol-based antifreeze coolant for liquid-cooled engines. Specific mixture ratio and type (e.g., HOAT) will be detailed.

Brake Fluid Type:

DOT 4 hydraulic brake fluid is typically specified for vehicles of this era.

Gearcase Oil Specification:

Refer to transmission section for general type. Manual will specify exact viscosity and GL rating.

Common Wear Items:

CVT belt wear, wheel bearings, suspension bushings, tie rod ends, and brake pads are common wear items on ATVs of this vintage.

Efi System Considerations:

While EFI is generally reliable, issues can arise from fuel pump, injectors, throttle position sensor (TPS), or the ECU. The manual will provide diagnostic steps.

Oil Filter Part Number:

Specific Polaris part numbers (e.g., 3082353 or equivalent) will be listed in the manual.

Air Filter Part Number:

Specific Polaris part numbers will be listed in the manual for replacement.

📚 Vehicle History

Polaris Atv History:

Polaris has been a pioneer and leader in the ATV market since the introduction of the original 'ATV' (All-Terrain Vehicle) in the early 1980s.

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV series, known for its comfort, capability, and often independent rear suspension. The 'Touring' designation signifies a focus on passenger comfort and extended-range use.

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States.

Model Significance:

The 500cc class has historically been a popular choice for its balance of power, efficiency, and affordability in the utility ATV segment.

🏆 Awards & Recognition

Atv Awards General:

While specific awards for the 2009-2010 Sportsman Touring 500 EFI are not detailed in the product info, Polaris Sportsman models have historically received numerous accolades for their performance, reliability, and innovation in the ATV industry.

Consumer Reviews:

Owners generally praise the Sportsman line for its comfortable ride, robust hauling capabilities, and reliable 4x4 system. Specific reviews for the Touring variant would highlight its two-up comfort.

Industry Certifications:

Manufactured to meet relevant safety and emissions standards applicable at the time of production.