This manual covers the Sportsman Touring 500 EFI, a versatile utility All-Terrain Vehicle (ATV) produced for model years 2009 through 2011. Designed for both recreational exploration and demanding work, this ATV is recognized for its comfortable touring capabilities, often featuring a passenger seat and extended wheelbase for enhanced rider and passenger comfort. Engineered with a 499cc liquid-cooled, 4-stroke, SOHC, single-cylinder engine and an On-Demand All-Wheel Drive system, the Sportsman Touring 500 EFI offers robust performance and reliable traction across various terrains. Its robust build and thoughtful design position it as a capable competitor in the utility ATV segment, emphasizing durability and user-friendly operation for a wide range of applications. This comprehensive factory service and repair manual, written in English, provides in-depth technical information essential for the maintenance, troubleshooting, and repair of your Sportsman Touring 500 EFI. It meticulously details every major system, including the engine, fuel system, ignition, transmission, drivetrain, suspension, brakes, and electrical systems. Within its pages, you will find detailed procedures for routine maintenance, component overhauls, diagnostic troubleshooting, fluid changes, and specifications such as torque values. This manual serves as an indispensable resource for owners, mechanics, and technicians, enabling them to effectively service and maintain the vehicle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Touring 500 EFI Year: 2009-2011 Codes Model Code Range: Specific model codes vary by year and configuration; refer to VIN decoding for precise identification. 👋 Introduction Market Position Category: Utility ATV (All-Terrain Vehicle) for recreational and working purposes. Target User: Owners seeking to perform maintenance, repairs, and diagnostics on their Polaris Sportsman Touring 500 EFI. Competitive Analysis Competitors: Competes with models from brands like Can-Am Outlander, Yamaha Grizzly, Honda Foreman, and Arctic Cat in the utility ATV segment. Key Features Feature Highlight: The 'Touring' designation indicates a focus on comfort and extended ride capabilities, often with features like a passenger seat and a longer wheelbase. Value Proposition: Provides comprehensive factory information for DIY mechanics, reducing reliance on dealership service. 📋 Manual Details Coverage Areas Covered Models: Polaris Sportsman Touring 500 EFI for model years 2009, 2010, and 2011. Page Count Estimated Pages: Comprehensive; likely over 500 pages, typical for a full factory service manual. Manual Type Type: Full Factory Service & Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul procedures for the 499cc liquid-cooled, 4-stroke, SOHC, single-cylinder engine. Fuel System: EFI system (Electronic Fuel Injection) troubleshooting, component testing (injectors, throttle body, fuel pump), and calibration. Ignition System: CDI unit, spark plug analysis, coil testing, and timing procedures. Transmission Drive: Automatic PVT (Polaris Variable Transmission) clutch service (primary and secondary), belt inspection and replacement, roller maintenance, and gearbox overhaul. Drivetrain: All-Wheel Drive (AWD) system diagnostics, AWD lock actuator service, front differential maintenance, rear differential service, and driveshaft U-joint inspection. Suspension: Front and rear suspension component inspection, shock absorber adjustment and replacement, A-arm bushings, and steering linkage maintenance. Brakes: Hydraulic brake system service, caliper overhaul, brake pad replacement, rotor inspection, brake fluid flushing and bleeding, and parking brake adjustments. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor service, lighting system troubleshooting, and accessory wiring. Cooling System: Radiator service, fan operation, coolant type and capacity, thermostat testing, and hose inspection. Exhaust System: Muffler and pipe inspection, gasket replacement, and heat shield maintenance. Frame Chassis: Frame inspection for damage, steering column service, and rider controls (handlebars, levers). Bodywork: Plastic panel removal and installation, fender maintenance, and seat service. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain/belt adjustments, and general inspections. Troubleshooting: Step-by-step diagnostic guides for common and uncommon issues across all major systems. Component Overhaul: Detailed rebuild procedures for engines, transmissions, differentials, and other major components. Electrical Diagnostics: Schematics, wiring harness troubleshooting, component testing using multimeters, and fault code interpretation (if applicable). Suspension Alignment: Procedures for checking and adjusting steering geometry and suspension settings. Clutch Adjustment: Specific instructions for maintaining optimal performance of the PVT system. Fluid Changes: Correct types, capacities, and intervals for engine oil, transmission oil, coolant, and brake fluid. Torque Specifications: Essential torque values for critical fasteners throughout the vehicle. Technical Depth Depth: Factory-level, in-depth technical information covering everything from routine maintenance to complete engine and transmission rebuilds. Diagnostic Tools: Information on diagnostic connectors and basic diagnostic procedures. Special Tools: Identification of any specialized tools required for specific repair procedures. 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Print Quality Quality: High-resolution scans suitable for clear viewing and printing. Text is likely searchable. Binding Type Binding: Not applicable (Digital download format) Paper Type Paper: Not applicable (Digital download format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, single-cylinder Displacement: 499cc Cooling System: Liquid-cooled Bore X Stroke: Specifics available in manual, typically around 92mm x...