This manual covers the Sportsman 500 ATV models, including the 500 EFI X2, 500 EFI, and 500 Touring EFI, for the 2008 and 2009 model years. The Sportsman line is renowned for its comfort, capability, and innovation in the utility ATV segment. These vehicles are engineered for a blend of demanding work and recreational trail riding, offering robust performance and versatility. Key features include the Automatic All-Wheel Drive system, independent front and rear suspension for enhanced stability, and a powerful 4-stroke, liquid-cooled engine with Electronic Fuel Injection for optimized performance and efficiency. With a towing capacity of 1500 lbs and substantial rack capacity, these ATVs are designed to handle a variety of tasks. This comprehensive Factory Service Repair Workshop Manual provides essential information for the complete repair and servicing of your Sportsman 500. It details procedures for routine maintenance, such as oil changes and filter replacements, as well as major repairs, including engine and transmission overhauls. The manual covers all major systems, including the engine, drivetrain, suspension, brakes, electrical components, fuel system, and cooling system. It also offers detailed troubleshooting guides, diagnostic procedures for the EFI system, and specific torque values and specifications for all components. This resource is designed to assist both DIY enthusiasts and professional technicians in maintaining the optimal performance and longevity of their vehicles. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Model Variants: 500 EFI X2, 500 EFI, 500 Touring EFI Year: 2008, 2009 👋 Introduction Market Position Positioning: Essential resource for owners and technicians of the Polaris Sportsman 500 ATV line Target Audience: DIY enthusiasts, professional ATV mechanics, and service departments Competitive Analysis Value Proposition: Provides factory-level accuracy and detail, enabling cost-effective repairs and maintenance Key Features Comprehensiveness: Covers all aspects of vehicle repair and maintenance for specified models and years Accessibility: Instant PDF download for immediate use on multiple devices 📋 Manual Details Coverage Areas Engine: Complete engine overhaul, tuning, and diagnostics Drivetrain: Transmission, differential, driveshafts, AWD system Suspension: Front and rear suspension, shocks, A-arms, bushings Brakes: Hydraulic brake systems, master cylinders, calipers, lines Electrical: Wiring diagrams, ignition, lighting, starter, charging system, EFI components Chassis: Frame, body panels, seating, racks, cargo systems Fuel System: EFI system, fuel pump, injectors, fuel tank, lines Cooling System: Radiator, fan, coolant lines, water pump Wheels Tires: Wheel specifications, tire pressure recommendations Troubleshooting: Diagnostic procedures, common faults, and solutions Page Count Estimated Pages: Detailed and comprehensive, likely several hundred pages (exact count not provided, but typical for factory manuals) Manual Type Type: Factory Service Repair Workshop Manual Scope: Complete repair and servicing Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Management: EFI system diagnostics, sensor testing, ECU information Powertrain Assembly: Engine rebuild procedures, transmission disassembly/reassembly Steering Suspension: Alignment procedures, component replacement, shock tuning Braking System: Brake bleeding, pad/rotor replacement, hydraulic circuit troubleshooting Electrical Diagnostics: Detailed wiring diagrams, component testing, fault finding strategies Body And Trim: Panel removal, accessory installation, seating adjustments Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement Major Repairs: Engine internal component replacement, transmission rebuilds, suspension overhaul Troubleshooting Guides: Step-by-step diagnostic flowcharts for common and complex issues Component Disassembly Reassembly: Detailed instructions with torque specifications for all major components Diagnostic Tools: Information on special tools and diagnostic equipment if applicable Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds Diagnostics: Advanced EFI system diagnostics, sensor data interpretation Specifications: Detailed torque values, clearances, and measurements for all components 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick information retrieval Print Quality Quality: High-resolution, clear images and diagrams suitable for printing Binding Type Type: Not applicable (Digital Download) Paper Type Type: Not applicable (Digital Download) Licensing Usage: No expiry dates, unlimited access upon download ⚙️ Engine Specifications Primary Engine Type: 4-stroke, liquid-cooled, SOHC, 2-valve, 1-cylinder (Polaris ProStar engine family) Displacement: 499cc (Exact displacement may vary slightly between specific sub-models, but 499cc is standard for the 500 series) Bore X Stroke: 92 mm x 75 mm (Typical for this engine platform) Compression Ratio: 9.5:1 (Typical for this engine) Performance Horsepower: Approximately 30-32 HP (Advertised figures vary slightly by year/model) Torque: Approximately 28-30 lb-ft (Advertised figures vary slightly by year/model) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane recommended Fuel Capacity: 4.0 gallons (15.1 L) Cooling System Type: Liquid-cooled 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) with High/Low range and Reverse Drive System: Shaft Drive Front Differential: Polaris Automatic All-Wheel Drive (AWD) Optional Type: Not applicable for this model range (PVT is standard) Features Engine Braking: Integrated engine braking via PVT system Transmission Fluid Specification: Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 75W-90 gear oil) Capacity: Refer to specific model sections in manual for exact capacity (typically around 1.0 liter...