🏷️ Basic Information Identification Make: Polaris Model: Sportsman Touring 500 EFI Model Variant: Touring Engine Type: Fuel Injected Generation Model Years Covered: 2009, 2010 Codes Chassis Code: Likely A09CH50AJ/AX/FG (2009), A10CH50AJ/AX/FG (2010) - specific codes may vary by sub-model and region, requiring manual verification 👋 Introduction Market Position Segment: 2-up ATV, utility and recreational segment, known for its comfort and touring capabilities. Competitive Analysis Competitors: Competed with models like Can-Am Outlander Max, Yamaha Grizzly 550/700, Suzuki King Quad 500/750, and Kawasaki Brute Force 650/750. Key Features Touring Focus: Designed for longer rides with a comfortable, stepped passenger seat and extended wheelbase for improved stability and passenger comfort. Efi Technology: Electronic Fuel Injection provides improved throttle response, easier cold starts, and consistent performance across varying altitudes and temperatures. A Arm Suspension: Independent front and rear A-arm suspension for superior ride quality and ground clearance. 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive service and repair for all 2009-2010 Polaris Sportsman Touring 500 EFI models. Page Count Estimated Page Count: Estimated 500-700+ pages (typical for a comprehensive workshop manual of this era). Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Management: EFI system, fuel injection, ignition system, sensors, ECU diagnostics, emissions control. Engine Mechanical: Top-end overhaul (cylinder head, valves, camshaft), bottom-end overhaul (crankshaft, connecting rods, pistons), timing, lubrication system. Powertrain: Transmission (PVT - Polaris Variable Transmission), clutch service, drive belts, final drive, differentials, driveshafts, AWD system. Chassis Suspension: Front and rear suspension systems, shock absorbers, A-arms, bushings, steering components, wheel bearings. Brakes: Hydraulic brake system, master cylinders, calipers, brake lines, pads, rotors, bleeding procedures. Electrical: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation, switches, fuses, relays. Bodywork Frame: Frame inspection, plastic body panels, fenders, racks, seating, handlebars. Procedures Included Maintenance: Regular service checks, oil changes, filter replacements, spark plug service, lubrication points, valve clearance adjustment. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable via diagnostic tools), symptom-based troubleshooting. Repair Overhaul: Step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and installation for all major systems. Technical Specifications: Torque specifications, clearances, fluid capacities, electrical specifications, engine timings. Technical Depth Depth: In-depth technical information suitable for professional technicians and advanced DIY mechanics, covering from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Searchability: Likely text-searchable PDF for quick information retrieval. Image Resolution: High-resolution diagrams and images for clarity. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement: 499 cc Engine Type: 4-stroke, SOHC, 4-valve, Single Cylinder Bore X Stroke: 92 mm x 73.6 mm (typical for this engine family, manual confirmation recommended) Cooling System: Liquid-cooled Performance Horsepower: Approximately 34-38 HP (estimated, subject to model year and tune, requires manual verification) Torque: Approximately 30-32 lb-ft (estimated, subject to model year and tune, requires manual verification) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with throttle body Fuel Type: Unleaded gasoline, minimum 87 octane 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking (EB) Drive Modes: High, Low, Neutral, Reverse, Park Optional Optional Transmission: N/A (PVT is standard) Features Clutch System: Dual clutch system (primary and secondary) for seamless engagement and variable ratio changes. Final Drive: Shaft drive, AWD (Automatic On-Demand) 📐 Dimensions Exterior Length: Approx. 85 inches (2159 mm) Width: Approx. 46 inches (1168 mm) Height: Approx. 48 inches (1219 mm) Wheelbase: Approx. 56 inches (1422 mm) Ground Clearance: Approx. 11.25 inches (286 mm) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Weights Dry Weight: Approx. 660 lbs (299 kg) Towing Capacity: 1500 lbs (680 kg) Gcvw: 2160 lbs (980 kg) 🛡️ Safety Features Ratings Crash Test Ratings: N/A for ATVs (ATVs are not subjected to the same crash testing as passenger vehicles) Active Features Braking System: Hydraulic disc brakes (front and rear), engine braking via PVT. Drive System: On-Demand AWD system for enhanced traction. Passive Features Ergonomics: Comfortable seating for rider and passenger, ergonomic handlebar placement. Lighting: Dual headlights, taillight, brake light for visibility. 💡 Technology Features Infotainment Instrumentation: Digital instrument cluster displaying speedometer, odometer, trip meter, fuel level, engine hour meter, AWD indicator, gear selection. Driver Assistance Engine Braking: Integrated engine braking (EB) system provides downhill control. Connectivity Charging System: 12V DC outlet for charging accessories (may vary by specific sub-model). 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or 12 months, whichever comes first. Air Filter Cleaning: Every 50 hours or as needed based on operating conditions (more frequently in dusty environments). Spark Plug Inspection: Every 100 hours or 12 months. Transmission Fluid Change: Every 200 hours or 24 months (refer to manual for...