Polaris Sportsman 500 HO 2008 2009 2010 Service Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 2009 SPORTSMAN 500 H.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL NUMBER: A09MH50AX, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2009 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL NUMBER: A09MN50AN, AX, ET (INTERNATIONAL) . . . . . . . . . . . . . . . . . . . . 1.6 2009 SPORTSMAN X2 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL NUMBER: A09TN50AX, AZ / A08TN50EA . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2009 SPORTSMAN TOURING 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 MODEL NUMBER: A09DN50AB, AZ / A09DN50EA . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

1.2 GENERAL INFORMATION MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Vehicle Identification Number (VIN) Transmission I.d. Location Engine And Machine Serial Numbers The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. The machine serial number is stamped on the lower left side of the frame tube (B). A 09 MN 50 AX } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier } Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 4 X A M N 5 0 A * 9 P 0 0 0 0 0 0 The transmission I.D.number is located on top of the transmission snorkel, right side of machine.

1.3 GENERAL INFORMATION 1 Publications Paint Codes Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required. Table 1-1: Publications Year Model Model No. Owner's Manual PN Parts Manual PN 2009 Sportsman 500 H.O. A09MH50A 9921825 9921827 2009 Sportsman 500 EFI A09MN50A 9921828 9921829 2009 Sportsman X2 500 EFI X2 Quadricycle A09TN50A A09TN50E 9921845 9921848 9921846 9921849 2009 Sportsman Touring 500 EFI Touring Quadricycle A09DN50A A09DN50E 9921788 9922172 9921789 9922174 Table 1-2: Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman Frame Black 9440 P-067 Table 1-3: Key Numbers Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Cover PN 5433534

1.4 GENERAL INFORMATION 2009 SPORTSMAN 500 H.O. Model Number: A09MH50AX, AZ Engine Model: EH50PLE Table 1-4: Sportsman 500 General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11 in./27.94 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1210 lbs./549 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg

1.5 GENERAL INFORMATION 1 Table 1-5: Sportsman 500 H.O. ENGINE Platform Fuji Single Cylinder Engine Model Number EH50PLE Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 50-90 psi W/Compression Release Engine Idle Speed 1100 ± 50 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Carburetor Mikuni BST 40mm Main Jet 155 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 2 Turns Out (initial) Pilot Air Jet 160 Float Height 14.7mm ± 1 (.58 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal US / 19.9 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 260 w @ 3000 RPM Voltage Regulator 3-phase Lights : Pod 50 watts Grill 2 x 37 watts Brake 26.9 watts Tail 8.26 watts Worklight 13 watts Indicator 1 watt Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Maintenance-Free / 12 Amp Hr. Circuit Protection 5 / 15 / 20 Amp Fuses 10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD Table 1-6: Sportsman 500 H.O. Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low Rev High Front Drive 23.91:1 16.30:1 10.49:1 3.82:1 Clutch Type PVT Non-EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent - w/ 2" Coil-over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only Table 1-7: Sportsman 500 H.O. Jetting Altitude AMBIENT TEMPERATURE Below 40 ° F Below 5 ° C +40 to +80 ° F +5 to +28 ° C Meters (Feet) 0-1800 (0-6000) 160 155 1800-3700 (6000-12000) 152.5 147.5 Table 1-8: Sportsman 500 H.O. Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven- Helix Meters (Feet) 0-1800 (0-6000) 10 WH (5630710) Blu/Grn (7041157) Black (7041782) 41-37° 2+2 (5132344) 1800-3700 (6000-12000) 10 RH (5630709 Blu/Grn (7041157) Black (7041782) 41-37° 2+2 (5132344)

1.6 GENERAL INFORMATION 2009 SPORTSMAN 500 EFI Model Number: A09MN50AN, AX, ET (International) Engine Model: EH50PLE Table 1-9: Sportsman 500 EFI General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1200 lbs./544 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Unbraked Trailer Towing Capacity (EU)* 1785.7 lbs./810 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg * Data Based On EU Directive 76/432/EEC

1.7 GENERAL INFORMATION 1 Table 1-10: Sportsman 500 EFI ENGINE Platform Fuji Single Cylinder Engine Model Number EH50PLE Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 50-90 psi W/Compression Release Engine Idle Speed 1100 ± 200 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 10 micron in-line 30 micron in tank - (not replaceable) Fuel Injector(s) Visteon EFI Controller Visteon Fuel Capacity / Requirement 4.13 gal US / 15.63 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 13°± 3 BTDC @ 1150 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10 amp / Fuel Pump 10 amp / ECU 15 amp / Ignition Coil 10 amp / Accessory Power 10 amp / Lights 20 Amp Starting Electric Instrument Cluster Analog Speedo w/ LCD Table 1-11: Sportsman 500 EFI Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low Rev High Front Drive 23.91:1 21.74:1 10.57:1 3.82:1 Clutch Type PVT (Standard Models) PVT w/EBS (Deluxe Models) Belt 3211113 EBS 3211077 Non-EBS Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156 Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only Table 1-12: Sportsman 500 EFI Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix* *No Adjustment Meters (Feet) 0-1800 (0-6000) 10 WH (5630710) Blu/Green (7041157) Red (3234451) EBS (3234356) 1800-3700 (6000-12000) 10 RH (5630709) Blu/Green (7041157) Red (3234451) EBS (3234356)

1.8 GENERAL INFORMATION 2009 SPORTSMAN X2 500 EFI Model Number: A09TN50AX, AZ / A08TN50EA (Intl’ Quadricycle) Engine Model: EH50PLE Table 1-13: Sportsman X-2 500 EFI General Specifications Category Dimension / Capacity Length 93 in./236 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 798 lbs./362 kg Gross Vehicle Weight 1500 lbs./680 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Unbraked Trailer Towing Capacity (EU)* 1995.1 lbs./905 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg Rear box capacity and tongue weight not to exceed 400 lbs./181kg * Data Based On EU Directive 76/432/EEC

1.9 GENERAL INFORMATION 1 Table 1-14: Sportsman X2 500 EFI ENGINE Platform Fuji Single Cylinder Engine Model Number EH50PLE Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 60-90 psi W/Compression Release Engine Idle Speed 1150 ± 50 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 30 micron in tank - (not replaceable) Fuel Injector(s) Visteon EFI Controller Visteon Fuel Capacity / Requirement 6 gal US / 22.7 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 10°± 1 BTDC @ 1150 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10 amp / Fuel Pump 10 amp / ECU 15 amp / Ignition Coil 10 amp / Accessory Power 10 amp / Lights 20 Amp Starting Electric Instrument Cluster Analog Speedo w/ LCD Table 1-15: Sportsman X2 500 EFI Drivetrain Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low Rev High Front Drive 23.91:1 21.74:1 10.57:1 3.82:1 Clutch Type PVT w/EBS Belt 3211113 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Rear Travel 8.75 in. / 22.2 cm Ground Clearance 11 in. / 28 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 82 in./208 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel Size / Pattern - Front Steel 12x6 / 4-156 Wheel Size / Pattern - Rear Steel 12x8 / 4-156 Front Tire Size 25x8-12 Rear Tire Size 25x11-12 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc Table 1-16: Sportsman X2 Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix* *No Adjustment Meters (Feet) 0-1800 (0-6000) 10 WH (5630710) Blu/Green (7041157) White/Yel (7041635) EBS (5131674) 1800-3700 (6000-12000) 10 RH (5630709) Blu/Green (7041157) White/Yel (7041635) EBS (5131674)

1.10 GENERAL INFORMATION 2009 SPORTSMAN TOURING 500 EFI Model Number: A09DN50AB, AZ / A09DN50EA (Intl’ Quadricycle) Engine Model: EH50PLE Table 1-17: Sportsman Touring 500 EFI General Specifications Category Dimension / Capacity Length 86 in./218 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 770 lbs./349 kg Gross Vehicle Weight 1500 lbs./680 kg Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./82 kg Towing Capacity 1225 lbs./555.6 kg Unbraked Trailer Towing Capacity (EU)* 1995.1 lbs./905 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg * Data Based On EU Directive 76/432/EEC

Polaris Sportsman 500 HO 2008 2009 2010 Service Manual

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