The 2009 Sportsman 500 is a robust All-Terrain Vehicle (ATV) designed for utility and recreational use. Engineered with a powerful 499cc liquid-cooled engine and a True On-Demand All-Wheel Drive system, it offers exceptional capability across diverse terrains. Key features like the Independent Rear Suspension (IRS) enhance ride comfort and traction, while the durable Variable Transmission (PVT) ensures smooth power delivery. With a significant towing capacity and substantial rack storage, this ATV is built to handle demanding tasks and adventurous excursions, reflecting a long-standing reputation for innovation and reliability in the powersports industry. This comprehensive factory service manual provides detailed guidance for the maintenance, repair, and troubleshooting of your 2009 Sportsman 500 ATV. Covering all major systems from the engine and fuel delivery to the transmission, brakes, and electrical components, this manual includes step-by-step procedures, diagnostic charts, torque specifications, and clear illustrations. It is an essential resource for owners and technicians alike, offering the necessary information to ensure the vehicle's optimal performance, longevity, and safe operation, facilitating everything from routine servicing to complex overhauls. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2009 Vehicle Type: All-Terrain Vehicle (ATV) Chassis Code: A09CE50AO (US/Canada/Mexico) 👋 Introduction Market Position Category: Utility ATV Segment: Mid-size utility ATV, known for its versatility and capability Competitive Analysis Competitors: Honda FourTrax Foreman, Yamaha Grizzly 550, Kawasaki Brute Force 650/750, Can-Am Outlander 500/650 Key Features Powertrain: Powerful 499cc liquid-cooled, 4-stroke engine Drivetrain: True On-Demand All-Wheel Drive (AWD) system Suspension: Independent Rear Suspension (IRS) for a smoother ride and better traction Transmission: Durable Polaris Variable Transmission (PVT) with engine braking 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Specific Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul, Adjustments Page Count Estimated Pages: 200-300 (typical for this model and manual type) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, inspection, assembly, timing, cooling system, lubrication system Fuel System: Carburetor (Mikuni BSR42) specifications, adjustment, cleaning, fuel pump, fuel tank, lines Ignition System: CDI unit, ignition coil, spark plug, wiring diagrams Transmission Drivetrain: PVT (Polaris Variable Transmission - primary and secondary clutches), belt inspection/replacement, gearbox, driveshafts, differentials, AWD system Brakes: Hydraulic disc brakes (front and rear), master cylinders, calipers, brake pads, brake lines, bleeding procedure Suspension: Front and rear suspension (dual A-arm front, independent rear suspension - IRS), shock absorbers, springs, bushings, alignment Steering: Handlebars, steering shaft, tie rods, steering linkage, steering assist (if equipped with EPS) Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), switches, wiring harness, fuses, electrical troubleshooting diagrams Frame Chassis: Frame inspection, body panel removal/installation, fenders, racks Cooling System: Radiator, fan, coolant, thermostat, hoses Procedures Included Maintenance: Oil changes, filter replacements, spark plug maintenance, air filter cleaning/replacement, lubrication points, chain/belt adjustment (if applicable) Troubleshooting: Diagnostic charts for common problems (engine starting issues, running problems, electrical faults, clutch issues) Repair: Component replacement (e.g., carburetor rebuild, starter motor replacement, brake caliper overhaul) Rebuild: Engine disassembly and reassembly, transmission servicing Adjustments: Carburetor idle speed and mixture, clutch engagement, valve clearance (if applicable, though this is typically solid lifters on this model) Torque Specifications: Crucial torque values for engine, chassis, and suspension fasteners Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and drivetrain overhauls Diagnostics: Detailed troubleshooting guides and diagnostic flowcharts Wiring Diagrams: Complete electrical system wiring schematics 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Typically text-searchable PDF for easy information retrieval Print Quality Quality: High-resolution digital scans/originals ensuring clarity of text and illustrations Illustrations: Includes clear, step-by-step illustrations and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Single Cylinder, SOHC Displacement: 499 cc Cooling System: Liquid-Cooled Bore X Stroke: 92 mm x 77 mm Compression Ratio: 10.5:1 Performance Horsepower Est: ~32 HP @ 6500 RPM (Estimated) Torque Est: ~30 lb-ft @ 5000 RPM (Estimated) Fuel System Fuel Delivery: Carburetor (Mikuni BSR42) Fuel Type: Unleaded Gasoline Fuel Capacity: 4.0 US gal (15.1 L) with 0.8 US gal (3.0 L) reserve 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with all-wheel engine braking Gears: High, Low, Neutral, Reverse, Park Features Clutch Type: Centrifugal Clutch (Primary), Drive Clutch (Secondary) Drive System: Shaft Drive AWD System: True On-Demand AWD 📐 Dimensions Exterior Length: 81 in (205.7 cm) Width: 46 in (116.8 cm) Height: 47 in (119.4 cm) Wheelbase: 50.25 in (127.6 cm) Ground Clearance: 11.5 in (29.2 cm) Cargo Front Rack Capacity: 100 lbs (45.4 kg) Rear Rack Capacity: 200 lbs (90.7 kg) Weights Dry Weight: 650 lbs (295 kg) Towing Capacity: 1,500 lbs (680.4 kg) Gvw: 1,200 lbs (544 kg) 🛡️ Safety Features Ratings Safety Features: Standard safety features typical for ATVs of this era, including handguards, throttle limiter, brake lever...