This manual covers the All-Terrain Vehicle (ATV), primarily focusing on the 2009 model year, with specific coverage for the 2008 Sportsman Touring 500 EFI. Known for its robust engineering and reliable performance, the Sportsman 500 is designed for a wide range of utility and recreational off-road applications. Its legacy is built on innovation and capability, offering features such as the VersaTrac™ AWD system and advanced Electronic Fuel Injection (EFI) for optimized power delivery and efficiency. The various sub-models, including H.O., EFI, X2 EFI, and Touring EFI, represent a commitment to providing versatile and capable ATVs for diverse user needs. This factory-level repair manual provides comprehensive guidance for the maintenance and repair of your Sportsman 500. It details procedures for all major systems, including the engine, fuel system, drivetrain, transmission, brakes, suspension, steering, and electrical components. Within these pages, you will find step-by-step instructions for scheduled maintenance, troubleshooting common issues, component disassembly and assembly, and essential technical specifications such as torque values and fluid capacities. This resource is invaluable for professional technicians and experienced DIY mechanics seeking to ensure the optimal performance and longevity of their ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Sub Model: H.O., EFI, X2 EFI, Touring EFI Year: 2009 (primarily), 2008 (Touring model) Codes Vehicle Type: All-Terrain Vehicle (ATV) Product Type: Repair Manual (PDF) 👋 Introduction Market Position Target Audience: Professional technicians and experienced DIY mechanics. Value Proposition: Provides factory-level repair knowledge for maintaining and repairing specific 2009 Polaris Sportsman 500 models. Competitive Analysis Differentiation: Model and year-specific, offering detailed technical data not found in generic guides. Key Features Instant Access: Instant download capability post-payment for immediate use. Comprehensive Coverage: Covers all aspects from routine maintenance to major repairs and troubleshooting. Visual Aids: Includes necessary illustrations, diagrams, and specifications. 📋 Manual Details Coverage Areas Primary Coverage: 2009 Polaris Sportsman 500 (H.O., EFI, X2 EFI) Secondary Coverage: 2008 Polaris Sportsman Touring 500 EFI Page Count Estimated Pages: Varies by specific model and manual edition, but comprehensive. Manual Type Type: Factory-level Repair Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnosis, repair, timing, cooling system, lubrication, starting system, charging system. Fuel System: Fuel injection (EFI) systems, fuel pump, injectors, throttle body, fuel filter, fuel tank. Drivetrain: All-wheel drive (AWD) system, viscous coupling, gearcase, final drive, drive shafts, universal joints. Transmission: Automatic transmission (PVT - Polaris Variable Transmission), clutch service (primary and secondary), belt replacement, gearcase. Brakes: Hydraulic brake systems, master cylinders, calipers, brake lines, fluid replacement, bleeding procedures. Suspension: Front and rear suspension, shock absorbers, springs, control arms, bushings, wheel bearings. Steering: Steering system, tie rods, ball joints, steering column, steering rack, Power Steering (if equipped). Electrical: Battery, starter, alternator, ignition system, lighting, sensors, wiring diagrams, diagnostic codes. Bodywork: Fenders, racks, plastics, seat, lighting components, trim. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, fluid checks. Troubleshooting: Advanced diagnostic guide, common problems and solutions, error code interpretation. Repair: Step-by-step repair procedures for all covered systems, from minor adjustments to complete overhauls. Disassembly Assembly: Detailed instructions for component removal, disassembly, cleaning, reassembly, and installation. Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters. Technical Depth Depth: Comprehensive: covers basic maintenance to advanced engine and transmission rebuilds, including EFI diagnostics. 📊 Manual Specifications File Format PDF Quality: High-resolution, suitable for printing and screen viewing. Searchable Text: Yes, typically includes searchable text for easy navigation. Print Quality Printability: Designed to be printable for users who prefer hard copies. Binding Type Digital Binding: N/A (Digital download) Paper Type Digital Paper Type: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, SOHC, 2-valve Displacement: 499cc Bore X Stroke: 92.0 mm x 77.0 mm Cooling System: Liquid-cooled Ignition: Electronic Ignition (CDI) Compression Ratio: Approx. 10.0:1 Performance Horsepower Estimate: ~32 HP (varies slightly by model) Torque Estimate: ~30 ft-lbs (varies slightly by model) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) (specifics vary by model variant) Fuel Type: Unleaded Gasoline, 87 Octane or higher recommended 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with Engine Braking Drive Modes: High, Low, Neutral, Reverse, Park Drive System: Shaft Drive Engagement: Automatic CVT (Continuously Variable Transmission) Features Clutch Service: Includes procedures for primary and secondary clutch removal, inspection, and maintenance. Fluid Type: Polaris AGL Gearcase Lubricant or equivalent SAE 80W-90 Hypoid Gear Oil (check specific model for confirmation). 📐 Dimensions Exterior Wheelbase: Approx. 50.5 inches (128.3 cm) for standard Sportsman 500 models. Ground Clearance: Approx. 11.25 inches (28.6 cm). Weights Dry Weight: Approx. 660 lbs (299 kg) for standard Sportsman 500 models. Towing Capacity: 1500 lbs (680 kg) Cargo Capacity: Front Rack: 100 lbs (45.4 kg), Rear Rack: 200 lbs (90.7 kg) 🛡️ Safety Features Ratings Rollover Protection: Standard ATV design, requires user caution and adherence to safety guidelines....