The 2009 Sportsman 500 EFI is a versatile All-Terrain Vehicle (ATV) designed for utility and recreational purposes. Renowned for its robust 499cc liquid-cooled engine, Independent Rear Suspension (IRS), and On-Demand All-Wheel Drive (AWD) system, this model offers reliable performance and excellent traction across varied terrain. Its strong towing and carrying capacities, coupled with ergonomic controls, make it a capable companion for off-road enthusiasts, hunters, farmers, and general riders seeking dependability and efficiency in the utility ATV segment. This comprehensive service, repair, and workshop manual provides in-depth information essential for maintaining and repairing the 2009 Sportsman 500 EFI. It covers all major systems, including engine service, fuel system (EFI), cooling, ignition, transmission (PVT), suspension, steering, braking, and electrical systems. With detailed procedures for routine maintenance, diagnostics, component disassembly and assembly, and troubleshooting, this manual serves as an indispensable resource for owners and technicians to ensure the optimal performance and longevity of the ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2009 Vehicle Type: All-Terrain Vehicle (ATV) Variant Covered: Sportsman 500 EFI 👋 Introduction Market Position Segment: Utility ATV segment, known for versatility and reliability. Target Audience: Off-road enthusiasts, hunters, farmers, and recreational riders requiring dependable performance. Competitive Analysis Competitors: Competed with models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Brute Force), and Suzuki (KingQuad) in its class. Key Features Powertrain: Durable 499cc liquid-cooled SOHC engine, known for its strong mid-range torque. Suspension: Independent Rear Suspension (IRS) for improved ride comfort and traction over uneven terrain. Drivetrain: On-Demand All-Wheel Drive (AWD) system for excellent traction in challenging conditions. Utility: Significant towing and carrying capacity, front and rear racks. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service, repair, and workshop information for the 2009 Polaris Sportsman 500 EFI ATV. Page Count Estimated Pages: High (typical for detailed service manuals, e.g., 300-500+ pages) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Detailed diagnostics, disassembly, assembly, timing, and troubleshooting for the 499cc engine. Fuel System: EFI system components, fuel pump, injectors, throttle body, pressure testing, and troubleshooting. Cooling System: Radiator, fan, thermostat, coolant types, flushing, and leak detection. Ignition System: Ignition coils, spark plugs, CDI unit, timing checks, and diagnostic procedures. Transmission Drivetrain: PVT (Polaris Variable Transmission) operation, belt inspection/replacement, clutch service, gearbox, and final drive servicing. Suspension Steering: Front and rear suspension components, shock absorbers, A-arms, bushings, steering system, tie rods, and wheel alignment. Braking System: Hydraulic brake system, calipers, master cylinders, brake lines, fluid specifications, bleeding procedures, and pad/rotor replacement. Electrical System: Wiring diagrams, battery, charging system, starter, lighting, switches, fuses, relays, and diagnostic tests. Chassis Frame: Frame inspection, bodywork removal/installation, and general chassis maintenance. Wheels Tires: Tire specifications, inflation pressures, wheel mounting, and bolt patterns. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, chain/belt adjustment, and lubrication points. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common and complex issues. Engine Overhaul: Complete engine rebuilding procedures, including piston, ring, cylinder, and valve service. Transmission Repair: PVT belt replacement, clutch assembly service, and gearbox maintenance. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams and diagnostic tools. Brake System Service: Brake bleeding, caliper rebuilds, and fluid replacement. Suspension Component Replacement: Service and replacement of A-arms, ball joints, bushings, and shocks. Component Disassembly Assembly: Detailed instructions for taking apart and putting back together all major vehicle components. Technical Depth Depth: Comprehensive from basic maintenance to advanced engine and drivetrain rebuilds. Diagnostic Level: Detailed diagnostic procedures for all major systems, including EFI and electrical. Repair Scope: Full repair capabilities for all mechanical and electrical components. Illustrations: Illustrated with clear, step-by-step instructions and diagrams. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within the PDF for quick information retrieval. Print Quality Quality: High-resolution digital format, suitable for printing specific sections or the entire manual. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single Cylinder, SOHC Displacement: 499cc Bore X Stroke: 92 mm x 75.7 mm Cooling System: Liquid-cooled Performance Horsepower: Approx. 27-30 HP (at crankshaft, varies slightly by source) Torque: Approx. 29-30 lb-ft (at crankshaft, varies slightly by source) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane or higher recommended Fluid Capacity Engine Oil Capacity: 1.7 US qt (1.6 L) with filter change Fluid Specifications Engine Oil Type: Polaris PS-4 5W-50 Full Synthetic (or equivalent SAE 5W-50 API SG, SL, SM) Coolant Type: Polaris Premium Antifreeze/Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Features Drive System: Shaft drive, On-Demand All-Wheel Drive (AWD) Pvt Belt Part Number: 3211077 (verify for specific model...