🏷️ Basic Information

Make:

Polaris

Model:

Sportsman Touring 500 EFI

Model Variant:

Touring

Model Sub Variant:

500 EFI

Years Covered:

2009, 2010

Chassis Code:

Likely A09PN50AA/AB/FG/FB, A10PN50AA/AB/FG/FB (VIN specific)

Engine Code Designation:

ProStar 500 EFI

👋 Introduction

Segment:

Utility ATV (All-Terrain Vehicle)

Target User:

Recreational riders, hunters, farmers, utility users requiring a 2-up riding capability

Competitors:

Honda Foreman/Rancher, Kawasaki Brute Force, Yamaha Grizzly, Arctic Cat Prowler (though Prowler is typically side-by-side, comparing similar displacement utility ATVs)

Distinctive Features:

Long-wheelbase for 2-up riding, Polaris's On-Demand AWD system, Electronic Fuel Injection (EFI) for improved performance and cold starts, robust ProStar engine.

Manual Value Proposition:

Essential for owners to maintain peak performance, troubleshoot issues, and perform repairs, thereby saving on costly dealer service fees.

📋 Manual Details

Primary Coverage:

Repair, Maintenance, Rebuilding, Refurbishing, Restoration

Estimated Page Count:

Hundreds

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Powertrain:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Drivetrain (AWD/2WD operation)

Chassis:

Suspension (Front & Rear), Steering, Brakes (Hydraulic Disc), Frame, Body Panels

Electrical:

Wiring Diagrams, Lighting System, Battery & Charging System, Ignition Switch, ECM, Sensors, Actuators, Instruments & Gauges

Miscellaneous:

Wheels & Tires, Accessories, Storage Cover

Maintenance:

Routine Inspections, Fluid Changes, Filter Replacements, Lubrication Schedule

Troubleshooting:

Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting

Repair:

Component Removal & Installation, Overhaul Procedures, Reassembly Instructions

Rebuild:

Engine Rebuild, Transmission Rebuild, Differential Rebuild

Depth:

Comprehensive (from basic maintenance to complete overhaul and diagnostics)

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable Text (likely, based on typical PDF service manuals)

Image Quality:

High Resolution Images and Diagrams

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-Stroke DOHC Single-Cylinder

Displacement:

499 cc (Cubic Centimeters)

Bore X Stroke:

Approximately 92 mm x 76 mm (Need to confirm specific factory specs, common for this displacement)

Cooling System:

Liquid-Cooled

Horsepower Estimate:

Approx. 36-40 HP (Industry standard for this class and year)

Torque Estimate:

Approx. 28-30 lb-ft (Industry standard for this class and year)

Fuel Delivery:

Electronic Fuel Injection (EFI) - Likely a 40mm throttle body

Fuel Type:

Unleaded Gasoline, Octane Rating: 87 minimum

Fuel Capacity:

Approx. 3.25 gallons (12.3 L) with a 0.8-gallon reserve

Ignition Type:

Electronic Ignition

Oil Type:

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

Oil Capacity:

Approx. 2.0 quarts (1.9 L) with filter change

Oil Filter Part Number:

Polaris 3082371 (Common for this era/engine, confirm in manual)

🔧 Transmission

Transmission Type:

Automatic (PVT - Polaris Variable Transmission)

Drive System:

Shaft Drive

All Wheel Drive:

On-Demand True All-Wheel Drive (AWD)

Gear Selection:

Park, Reverse, Neutral, Low, High

Final Drive Fluid Type:

Polaris Demand Drive Fluid or equivalent (Front Diff)

Final Drive Fluid Capacity:

Approx. 0.25 quarts (0.24 L) for front differential

Transmission Fluid Type:

Polaris Synthetic PS-4 (or suitable CVT fluid meeting specifications)

📐 Dimensions

Length:

Approx. 85.0 inches (215.9 cm)

Width:

Approx. 47.0 inches (119.4 cm)

Height:

Approx. 50.0 inches (127.0 cm)

Wheelbase:

Approx. 56.5 inches (143.5 cm)

Ground Clearance:

Approx. 10.25 inches (26.0 cm)

Dry Weight:

Approx. 647 lbs (293.5 kg)

Gross Vehicle Weight Rating:

Approx. 1175 lbs (533 kg)

Front Rack Capacity:

200 lbs (90.7 kg)

Rear Rack Capacity:

300 lbs (136.1 kg)

Towing Capacity:

1500 lbs (680 kg)

Payload Capacity:

Approx. 350 lbs (158.8 kg)

🛡️ Safety Features

Atv Safety Standards:

Compliance with ANSI B71.1 2003 standards (typical for the era)

Braking System:

Hydraulic Disc Brakes (Front and Rear)

Parking Brake:

Parking Brake on Rear Caliper

Seating:

2-Up Seating with Handholds and Footrests for Passenger

Lighting:

Dual Halogen Headlights, Tail Light, Brake Light

💡 Technology Features

Instrument Cluster:

Digital Gauge Cluster (Speedometer, Odometer, Tripmeter, Tachometer, Fuel Level, High Gear Indicator, AWD Indicator, Oil Temp/Press Warning)

AWD System:

Polaris's signature On-Demand True AWD engages automatically when needed.

Charging System:

12V Accessory Outlet (for charging electronics)

🔧 Maintenance

Initial Break In Service:

Recommended at 10 hours or 100 miles (Refer to owners manual for specific break-in procedure)

Engine Oil Change:

Every 100 hours or 1,000 miles, or annually (whichever comes first)

Air Filter Cleaning:

Every 50 hours or 500 miles (more often in dusty conditions)

Spark Plug Replacement:

Recommended every 1,000 miles or 100 hours

Drive Belt Inspection:

Inspect every 50 hours or 500 miles; Replace as needed (typical replacement interval 2-3 years or specific mileage/hour)

Transmission Fluid Change:

Inspect every 100 hours or 1,000 miles; Change as needed or recommended by manual

Coolant Type:

Polaris Premium 2-Stroke or 4-Stroke Coolant (Ethylene Glycol based, typically 50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid

Common Wear Items:

Drive belt wear, suspension bushings, wheel bearings, starter motor brushes, fuel pump longevity.

Efi Diagnostics:

Potential issues with throttle position sensors (TPS), idle air control (IAC) motors, and fuel injectors require proper diagnostic tools and manual guidance.

📚 Vehicle History

Brand Establishment:

Polaris Industries Inc. founded in 1954, a pioneer in snowmobiles and ATVs.

Sportsman Lineage:

The Sportsman has been Polaris's flagship utility ATV line for decades, evolving through various engine sizes and configurations. The Touring model specifically addresses the need for passenger-carrying capability.

2009 2010 Era Updates:

This period saw continued refinement of the 500 EFI engine, improvements in suspension and braking, and the integration of Polaris's proprietary AWD system.

Manufacturing Location:

USA (Polaris facilities)

🏆 Awards & Recognition

Atv Industry Awards:

Polaris Sportsman line has consistently received praise and awards in the utility ATV segment for its performance, reliability, and features over many years. Specific awards for the 2009-2010 models would be model-year specific but generally indicate strong market reception.