POLARIS SPORTSMAN TOURING 500 EFI Service Repair PDF Manual 2009-2011 Download
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🏷️ Basic Information Identification Make: Polaris Model: Sportsman Touring 500 EFI Model Variant: Touring Engine Type: EFI (Electronic Fuel Injection) Codes Product Code: SPORTSMAN_TOURING_500_EFI_2009-2011_DOWNLOAD 👋 Introduction Market Position Category: Utility/Recreational ATV Target Audience: Owners seeking to perform their own maintenance and repairs, dealerships, independent repair shops. Competitive Analysis Competitors: Honda Foreman, Yamaha Grizzly, Can-Am Outlander, Arctic Cat Prowler. Key Features Utility: Designed for versatility in work and recreation, with a focus on comfort for longer rides due to its touring designation. Efi Advantage: Electronic Fuel Injection provides improved throttle response, easier cold starts, and better fuel efficiency compared to carbureted models. 📋 Manual Details Coverage Areas Years Covered: 2009, 2010, 2011 Page Count Estimated Pages: Significant (typically 300-600+ pages for a comprehensive service manual) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end, bottom-end, cooling, lubrication, fuel system (EFI components, injectors, pump, regulator), ignition system, exhaust system. Drivetrain: Transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt replacement, gearcase, differential, driveshafts, CV joints, final drive. Chassis And Suspension: Frame, front suspension (A-arms, shocks, ball joints, tie rods), rear suspension (Independent Rear Suspension - IRS, shocks, control arms), steering system (handlebars, steering stem, linkages), wheel bearings, hubs. Electrical System: Battery, charging system (stator, voltage regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), instrumentation, wiring diagrams, sensors, EFI control unit (ECU). Brakes: Hydraulic brake system, front and rear calipers, brake lines, master cylinders, brake pads, rotor inspection and replacement, bleeding procedures. Bodywork And Trim: Front and rear fenders, racks, seat, fairings, plastics, decals, decals placement. Procedures Included Maintenance: Regular service intervals, oil and filter changes, air filter cleaning/replacement, spark plug replacement, valve clearance adjustment, coolant checks and changes, lubrication points, drive belt inspection and replacement. Repair And Rebuild: Complete engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical component diagnosis and repair, brake system servicing. Troubleshooting: Diagnostic procedures for common problems, error code interpretation (if applicable for EFI), electrical system fault finding, engine performance issues, starting problems. Diagnostics: EFI system diagnostics, sensor testing, fuel pressure testing, ignition timing verification, diagnostic connector usage (if applicable). Technical Depth Depth: Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution digital format, suitable for printing with clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement: 499cc Engine Configuration: Single-cylinder, 4-stroke, SOHC Bore X Stroke: Not explicitly stated in product info, requires manual consultation Cooling System: Liquid-cooled Performance Horsepower: Approximately 36 HP (varies slightly by year and tuning) Torque: Not explicitly stated in product info, requires manual consultation Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Fuel Tank Capacity: Approximately 3.0 US gallons (11.3 L) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with engine braking Gear Selection: High, Low, Neutral, Reverse, Park Optional Drive System: On-Demand All-Wheel Drive (AWD) / 2WD Features Clutch System: Automated, belt-driven continuously variable transmission (CVT) with centrifugal clutch. 📐 Dimensions Exterior Length: Approximately 85.5 inches (217.2 cm) Width: Approximately 46 inches (116.8 cm) Height: Approximately 48 inches (121.9 cm) Wheelbase: Approximately 56.5 inches (143.5 cm) Weights Dry Weight: Approximately 695 lbs (315 kg) Ground Clearance: Approximately 11.5 inches (29.2 cm) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Towing Towing Capacity: 1500 lbs (680 kg) Tongue Weight: Not explicitly stated in product info, requires manual consultation 🛡️ Safety Features Ratings Crash Test Ratings: N/A (ATVs are not typically subject to automotive crash testing standards) Active Features Braking System: Hydraulic disc brakes, front and rear. Engine Braking: Standard on PVT transmission for controlled descents. Passive Features Handlebars: Ergonomically designed for rider control and comfort. Lighting: Dual headlights, taillight, and brake light for visibility. 💡 Technology Features Infotainment Instrumentation: Digital LCD display with speedometer, odometer, trip meter, tachometer, fuel gauge, AWD indicator, gear indicator, 12V power outlet. Driver Assistance Engine Braking: Integrated engine braking system (EBS) on PVT for enhanced downhill control. Connectivity Charging Port: Standard 12V accessory outlet for charging devices. 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual; typically every 100 hours or annually, whichever comes first. Air Filter Service: Refer to manual; typically every 50 hours or annually, or more frequently in dusty conditions. Drive Belt Inspection: Refer to manual; typically every 100 hours or annually. Fluid Specifications Engine Oil Type: SAE 0W-40 Synthetic (Polaris recommends their proprietary brand, but high-quality synthetic equivalents can be used. Consult manual for exact specs). Engine Oil Capacity: Refer to manual; typically around 1.5-2 quarts (1.4-1.9 L) with filter change. Coolant Type: Ethylene Glycol based...
Transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt replacement, gearcase, differential, driveshafts, CV joints, final drive.
Chassis And Suspension:
Frame, front suspension (A-arms, shocks, ball joints, tie rods), rear suspension (Independent Rear Suspension - IRS, shocks, control arms), steering system (handlebars, steering stem, linkages), wheel bearings, hubs.
Electrical System:
Battery, charging system (stator, voltage regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), instrumentation, wiring diagrams, sensors, EFI control unit (ECU).
Brakes:
Hydraulic brake system, front and rear calipers, brake lines, master cylinders, brake pads, rotor inspection and replacement, bleeding procedures.
Bodywork And Trim:
Front and rear fenders, racks, seat, fairings, plastics, decals, decals placement.
Procedures Included
Maintenance:
Regular service intervals, oil and filter changes, air filter cleaning/replacement, spark plug replacement, valve clearance adjustment, coolant checks and changes, lubrication points, drive belt inspection and replacement.
Repair And Rebuild:
Complete engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical component diagnosis and repair, brake system servicing.
Troubleshooting:
Diagnostic procedures for common problems, error code interpretation (if applicable for EFI), electrical system fault finding, engine performance issues, starting problems.
Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution digital format, suitable for printing with clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Displacement:
499cc
Engine Configuration:
Single-cylinder, 4-stroke, SOHC
Bore X Stroke:
Not explicitly stated in product info, requires manual consultation
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 36 HP (varies slightly by year and tuning)
Torque:
Not explicitly stated in product info, requires manual consultation
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approximately 3.0 US gallons (11.3 L)
🔧 Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT) with engine braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Drive System:
On-Demand All-Wheel Drive (AWD) / 2WD
Features
Clutch System:
Automated, belt-driven continuously variable transmission (CVT) with centrifugal clutch.
📐 Dimensions
Exterior
Length:
Approximately 85.5 inches (217.2 cm)
Width:
Approximately 46 inches (116.8 cm)
Height:
Approximately 48 inches (121.9 cm)
Wheelbase:
Approximately 56.5 inches (143.5 cm)
Weights
Dry Weight:
Approximately 695 lbs (315 kg)
Ground Clearance:
Approximately 11.5 inches (29.2 cm)
Cargo
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Towing
Towing Capacity:
1500 lbs (680 kg)
Tongue Weight:
Not explicitly stated in product info, requires manual consultation
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (ATVs are not typically subject to automotive crash testing standards)
Active Features
Braking System:
Hydraulic disc brakes, front and rear.
Engine Braking:
Standard on PVT transmission for controlled descents.
Passive Features
Handlebars:
Ergonomically designed for rider control and comfort.
Lighting:
Dual headlights, taillight, and brake light for visibility.
💡 Technology Features
Infotainment
Instrumentation:
Digital LCD display with speedometer, odometer, trip meter, tachometer, fuel gauge, AWD indicator, gear indicator, 12V power outlet.
Driver Assistance
Engine Braking:
Integrated engine braking system (EBS) on PVT for enhanced downhill control.
Connectivity
Charging Port:
Standard 12V accessory outlet for charging devices.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual; typically every 100 hours or annually, whichever comes first.
Air Filter Service:
Refer to manual; typically every 50 hours or annually, or more frequently in dusty conditions.
Drive Belt Inspection:
Refer to manual; typically every 100 hours or annually.
Fluid Specifications
Engine Oil Type:
SAE 0W-40 Synthetic (Polaris recommends their proprietary brand, but high-quality synthetic equivalents can be used. Consult manual for exact specs).
Engine Oil Capacity:
Refer to manual; typically around 1.5-2 quarts (1.4-1.9 L) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze with corrosion inhibitors (Polaris recommends their specific blend, consult manual).
Drive belts (premature wear if overloaded or improperly adjusted), suspension bushings and ball joints, wheel bearings, front differential components.
Efi System Considerations:
Potential for clogged fuel injectors if fuel quality is poor; sensor failures can impact performance.
📚 Vehicle History
Brand Heritage
Manufacturer:
Polaris Inc.
Heritage:
Polaris has a long history in powersports, known for innovation in snowmobiles and ATVs.
Model Evolution
Lineage:
The Sportsman line is a cornerstone of Polaris's ATV offerings, known for its utility and comfort. The Touring models are specifically designed for longer-distance riding and often feature extended seating.
Production
Production Period:
2009-2011 covered by this manual.
🏆 Awards & Recognition
Recognitions
Atv Magazine Reviews:
Polaris Sportsman series generally receives positive reviews for its utility, comfort, and off-road capability. Specific awards for the 500 EFI Touring model would require historical review of ATV publications from the era.
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