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Polaris Sportsman 500 HO Touring 500 HO All Terrain Vehicle Complete Workshop Service Repair Manual 2010 2011

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Welcome to the comprehensive guide for your All-Terrain Vehicle (ATV), covering models from 2010 and 2011. Engineered for both recreational trail riding and utility tasks, this ATV is recognized for its comfort-focused, extended chassis designed for two-up riding, powered by a capable engine. Its independent front and rear suspension ensures a smooth ride across varied terrain, while the On-Demand True All-Wheel Drive system provides enhanced traction and stability. The ATV offers a robust blend of performance and practicality, making it a reliable choice for off-road adventures and demanding work. This complete workshop service repair manual in English provides detailed instructions and technical specifications essential for the proper maintenance and repair of your ATV. Within these pages, you will find in-depth coverage of all major vehicle systems, including the engine, transmission, drivetrain, chassis, and electrical components. The manual details routine maintenance procedures, diagnostic troubleshooting guides, step-by-step repair instructions, and critical torque specifications. It is an indispensable resource for owners, technicians, and mechanics seeking to ensure the optimal performance, longevity, and safety of their ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 HO Touring Vehicle Type: All-Terrain Vehicle (ATV) Model Years Covered: 2010, 2011 Codes Engine Code General: ProStar 500 Chassis Code General: Touring (specific chassis codes often internal to manufacturers) 👋 Introduction Market Position Vehicle Segment: Recreational/Utility ATV, 2-Up Touring Target Audience: Off-road enthusiasts, riders who value comfort for two, utility work, trail riding. Competitive Analysis Key Competitors: Can-Am Outlander MAX, Arctic Cat Thundercat, Yamaha Grizzly (in its touring configurations). Key Features Touring Focus: Extended chassis for comfortable passenger seating, passenger handholds, and potentially a higher weight capacity for two riders. Engine Power: 500cc class engine known for a good balance of power and usability. Suspension Design: Independent suspension on all four wheels (IRS) for enhanced ride comfort and ground clearance. 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: 500+ Page Count Description: Comprehensive coverage, typically includes hundreds of pages detailing all aspects of the vehicle. 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, cylinder head, piston, crankshaft, valve train, cooling system, lubrication system, fuel system, ignition system, starting system, exhaust system. Transmission Systems: Automatic transmission (PVT - Polaris Variable Transmission) disassembly, assembly, maintenance, troubleshooting, drive clutch, driven clutch, belt replacement. Drivetrain Systems: All-wheel drive (AWD) system, front differential, rear differential, drive shafts, U-joints, CV joints. Chassis Systems: Frame inspection and repair, suspension (front and rear), steering system (handlebars, tie rods, steering shaft), braking system (hydraulic disc brakes, master cylinders, calipers, brake lines, pads). Electrical Systems: Wiring diagrams, battery, charging system (stator, voltage regulator), lighting system (headlights, taillights, brake lights), ignition switch, starter solenoid, relays, fuses, sensors, instrument panel, diagnostic codes. Bodywork And Accessories: Body panel removal and installation, seating, racks, storage compartments, fenders, headlights, taillights. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid flush, coolant flush, lubrication points, belt inspection/replacement. Diagnostic Procedures: Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), electrical testing, fuel system testing, compression testing. Repair Procedures: Step-by-step instructions for engine rebuilds, transmission repairs, suspension component replacement, brake system repairs, electrical component troubleshooting and replacement. Assembly Disassembly: Complete guides for disassembling and reassembling major vehicle components. Torque Specifications: Detailed torque values for all critical fasteners. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system repair. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Likely text-searchable, allowing for quick location of specific information. Printability: Printable pages for workshop use. Print Quality: High resolution, ensuring clear text and diagrams. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, SOHC, Single Cylinder Displacement: 499cc (30.4 cu in) Bore X Stroke: 93.5 mm x 71.5 mm (3.68 in x 2.81 in) Cooling System: Liquid-Cooled Ignition: Electronic Ignition Performance Horsepower Estimated: 36 hp @ 6500 rpm (Approximate, varies slightly by year/tuning) Torque Estimated: 31 lb-ft @ 5000 rpm (Approximate) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline, 87 Octane Minimum Fuel Capacity: 4.1 gal (15.5 L) 🔧 Transmission Standard Transmission Type: Automatic Polaris Variable Transmission (PVT) with Engine Braking Gear Selection: High, Low, Neutral, Reverse, Park Optional Optional Transmission: N/A (Single transmission option for this model) Features Drive System: On-Demand True All-Wheel Drive (AWD) / 2WD Clutch System: Heavy-duty belt, dual-clutch system for engagement and disengagement. 📐 Dimensions Exterior Length: 83.4 in (211.8 cm) Width: 47.6 in (120.9 cm) Height: 48 in (121.9 cm) Wheelbase: 56.5 in (143.5 cm) Ground Clearance: 11.5 in (29.2 cm) Turning Radius: 142 in (3.6 m) Cargo Front Rack Capacity: 100 lbs (45.4 kg)...
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Polaris Sportsman 500 HO Touring 500 HO All Terrain Vehicle Complete Workshop Service Repair Manual 2010 2011Polaris Sportsman 500 HO Touring 500 HO All Terrain Vehicle Complete Workshop Service Repair Manual 2010 2011Polaris Sportsman 500 HO Touring 500 HO All Terrain Vehicle Complete Workshop Service Repair Manual 2010 2011Polaris Sportsman 500 HO Touring 500 HO All Terrain Vehicle Complete Workshop Service Repair Manual 2010 2011
Welcome to the comprehensive guide for your All-Terrain Vehicle (ATV), covering models from 2010 and 2011. Engineered for both recreational trail riding and utility tasks, this ATV is recognized for its comfort-focused, extended chassis designed for two-up riding, powered by a capable engine. Its independent front and rear suspension ensures a smooth ride across varied terrain, while the On-Demand True All-Wheel Drive system provides enhanced traction and stability. The ATV offers a robust blend of performance and practicality, making it a reliable choice for off-road adventures and demanding work. This complete workshop service repair manual in English provides detailed instructions and technical specifications essential for the proper maintenance and repair of your ATV. Within these pages, you will find in-depth coverage of all major vehicle systems, including the engine, transmission, drivetrain, chassis, and electrical components. The manual details routine maintenance procedures, diagnostic troubleshooting guides, step-by-step repair instructions, and critical torque specifications. It is an indispensable resource for owners, technicians, and mechanics seeking to ensure the optimal performance, longevity, and safety of their ATV.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 500 HO Touring
Vehicle Type:
All-Terrain Vehicle (ATV)
Model Years Covered:
2010, 2011
Codes
Engine Code General:
ProStar 500
Chassis Code General:
Touring (specific chassis codes often internal to manufacturers)
👋 Introduction
Market Position
Vehicle Segment:
Recreational/Utility ATV, 2-Up Touring
Target Audience:
Off-road enthusiasts, riders who value comfort for two, utility work, trail riding.
Competitive Analysis
Key Competitors:
Can-Am Outlander MAX, Arctic Cat Thundercat, Yamaha Grizzly (in its touring configurations).
Key Features
Touring Focus:
Extended chassis for comfortable passenger seating, passenger handholds, and potentially a higher weight capacity for two riders.
Engine Power:
500cc class engine known for a good balance of power and usability.
Suspension Design:
Independent suspension on all four wheels (IRS) for enhanced ride comfort and ground clearance.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
500+
Page Count Description:
Comprehensive coverage, typically includes hundreds of pages detailing all aspects of the vehicle.
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, cylinder head, piston, crankshaft, valve train, cooling system, lubrication system, fuel system, ignition system, starting system, exhaust system.
Transmission Systems:
Automatic transmission (PVT - Polaris Variable Transmission) disassembly, assembly, maintenance, troubleshooting, drive clutch, driven clutch, belt replacement.
Drivetrain Systems:
All-wheel drive (AWD) system, front differential, rear differential, drive shafts, U-joints, CV joints.
Chassis Systems:
Frame inspection and repair, suspension (front and rear), steering system (handlebars, tie rods, steering shaft), braking system (hydraulic disc brakes, master cylinders, calipers, brake lines, pads).
Electrical Systems:
Wiring diagrams, battery, charging system (stator, voltage regulator), lighting system (headlights, taillights, brake lights), ignition switch, starter solenoid, relays, fuses, sensors, instrument panel, diagnostic codes.
Bodywork And Accessories:
Body panel removal and installation, seating, racks, storage compartments, fenders, headlights, taillights.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid flush, coolant flush, lubrication points, belt inspection/replacement.
Diagnostic Procedures:
Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), electrical testing, fuel system testing, compression testing.
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission repairs, suspension component replacement, brake system repairs, electrical component troubleshooting and replacement.
Assembly Disassembly:
Complete guides for disassembling and reassembling major vehicle components.
Torque Specifications:
Detailed torque values for all critical fasteners.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system repair.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing for quick location of specific information.
Printability:
Printable pages for workshop use.
Print Quality:
High resolution, ensuring clear text and diagrams.
Binding Type
Binding:
N/A (Digital Download - PDF)
Paper Type
Paper Type:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, SOHC, Single Cylinder
Displacement:
499cc (30.4 cu in)
Bore X Stroke:
93.5 mm x 71.5 mm (3.68 in x 2.81 in)
Cooling System:
Liquid-Cooled
Ignition:
Electronic Ignition
Performance
Horsepower Estimated:
36 hp @ 6500 rpm (Approximate, varies slightly by year/tuning)
Torque Estimated:
31 lb-ft @ 5000 rpm (Approximate)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Fuel Capacity:
4.1 gal (15.5 L)
🔧 Transmission
Standard
Transmission Type:
Automatic Polaris Variable Transmission (PVT) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Optional Transmission:
N/A (Single transmission option for this model)
Features
Drive System:
On-Demand True All-Wheel Drive (AWD) / 2WD
Clutch System:
Heavy-duty belt, dual-clutch system for engagement and disengagement.
📐 Dimensions
Exterior
Length:
83.4 in (211.8 cm)
Width:
47.6 in (120.9 cm)
Height:
48 in (121.9 cm)
Wheelbase:
56.5 in (143.5 cm)
Ground Clearance:
11.5 in (29.2 cm)
Turning Radius:
142 in (3.6 m)
Cargo
Front Rack Capacity:
100 lbs (45.4 kg)
Rear Rack Capacity:
200 lbs (90.7 kg)
Weights
Dry Weight:
650 lbs (294.8 kg)
Gross Vehicle Weight Rating Gvwr:
1050 lbs (476.3 kg)
Towing Capacity:
1500 lbs (680.4 kg)
Payload Capacity:
325 lbs (147.4 kg) (combined rider and cargo)
🛡️ Safety Features
Ratings
Rollover Protection:
N/A (ATVs are not typically rated by NHTSA/IIHS for rollovers like cars; emphasis is on operator responsibility and proper use).
Traction Control:
On-Demand True All-Wheel Drive (AWD) enhances traction and stability.
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Engine Braking:
Standard on PVT transmission, aids in downhill control.
Passive Features
Lighting:
Dual 50W headlights, dual brakelights/taillights.
Ergonomics:
Designed for rider and passenger comfort, including padded seats and handholds.
Operator Training:
Manual emphasizes safe operation, protective gear (helmet, goggles, gloves, boots, long sleeves/pants), and responsible riding practices.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital instrument cluster typically includes speedometer, odometer, trip odometer, tachometer, high-beam indicator, neutral indicator, reverse indicator, oil temperature warning, battery voltage, and AWD indicator.
Driver Assistance
Parking Brake:
Hand-operated parking brake lever, often integrated with the gear selector. Some models might have a foot-actuated parking brake.
Throttle Control:
Thumb throttle for precise acceleration control.
Connectivity
Diagnostic Ports:
Diagnostic connectors for accessing fault codes and live data via Polaris diagnostic tools.
🔧 Maintenance
Service Intervals
Oil Change Interval Engine:
Every 100 hours or 6 months, whichever comes first. Check manual for specific details.
Air Filter Maintenance:
Inspect every 25 hours, clean/replace as needed. More frequent in dusty conditions.
Spark Plug Service:
Inspect and gap every 50 hours, replace as needed. Refer to manual for correct plug type and gap.
Transmission Fluid Change:
Consult manual; typically inspected periodically and changed at longer intervals or based on operating conditions.
Brake Fluid Flush:
Every 2 years or as recommended by the manual.
Coolant Flush:
Every 2 years or as recommended by the manual.
Fluid Specifications
Engine Oil Type:
Polaris Synthetic 10W-40 (or equivalent API SG, JASO MA rated oil)
Engine Oil Capacity:
Approx. 2.1 quarts (2.0 liters) with filter change.
Coolant Type:
Ethylene Glycol based, 50/50 mix with distilled water. Polaris recommends specific coolant or equivalent.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Transmission Fluid Type:
Refer to manual; some Polaris models use specialized PVT fluid or a specific transmission oil blend. Do not use standard ATF.
Known Issues
Common Wear Items:
Drive belt wear (especially with aggressive riding), brake pad and rotor wear, suspension bushings, wheel bearings.
Potential Electrical Issues:
Battery charging system (stator, regulator) can be a point of failure over time; electrical connector corrosion.
Engine Performance Variations:
EFI systems can sometimes require recalibration or sensor cleaning; potential for carbon buildup in older engines.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Polaris Industries Inc. is a long-standing American manufacturer of powersports vehicles, founded in 1954, known for its innovation in ATVs, snowmobiles, and motorcycles.
Model Evolution
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV family, known for its ruggedness, comfort, and versatility. The 500cc engine has been a core offering for many years, with 'HO' denoting 'High Output' for improved performance. The 'Touring' designation signifies models designed for two riders.
Production
Production Period:
The Polaris Sportsman 500 HO Touring model was a prominent offering in the late 2000s and early 2010s, preceding the introduction of the larger displacement ProStar engines in some touring models.
Manufacturing Location:
Primarily manufactured in the United States by Polaris.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Polaris ATVs, including the Sportsman line, have historically received positive reviews and awards from outdoor and powersports publications for their performance, reliability, and features, though specific awards for the 2010-2011 Touring model might be dated.
Ratings
Consumer Ratings:
Generally well-regarded for its capability and comfort for two-up riding. Owner reviews often cite its utility and smooth ride.
Certifications
Safety Certifications:
Meets applicable industry safety standards for ATVs. Operator safety is paramount and emphasized in manual.
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