The 2009 Sportsman 500 is a robust All-Terrain Vehicle (ATV) renowned for its versatility, catering to recreational riders, farm use, and light trail work. Engineered with a reliable 499cc liquid-cooled engine, independent front and rear suspension for enhanced comfort and handling, and signature On-Demand All-Wheel Drive system, this mid-size utility ATV offers capable performance and user-friendly operation. Its automatic PVT transmission with engine braking further contributes to its ease of use, making it a popular choice in its segment for its blend of power, durability, and practical features. This comprehensive Workshop Service Repair Manual provides essential guidance for the maintenance, repair, and troubleshooting of the 2009 Sportsman 500 ATV. It covers all major systems, including the engine, fuel, ignition, cooling, transmission, drivetrain, suspension, steering, brakes, and electrical systems. Detailed procedures for routine maintenance, engine overhauls, transmission service, and component repairs are included, alongside diagnostic guides, wiring diagrams, torque specifications, and necessary special tool information. This manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) Codes Oem Manual Code Indicator: Likely contains specific Polaris service manual codes for this model and year 👋 Introduction Market Position Segment: Mid-size utility ATV, popular for recreational riding, farm use, and light trail work Reputation: Known for its reliable engine, capable suspension, and user-friendly design Competitive Analysis Key Competitors 2009: Honda Foreman/Rancher, Yamaha Grizzly 450/550, Kawasaki Brute Force 300/400, Suzuki KingQuad 400/500 Key Features Engine Configuration: Liquid-cooled, single-cylinder engine, offering good power and smooth operation Suspension Type: Independent front and rear suspension for improved ride comfort and handling Drivetrain Features: Switchable 2WD/4WD with Polaris's On-Demand AWD system for optimal traction Transmission Type: Automatic PVT (Polaris Variable Transmission) with engine braking 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive repair and service for the 2009 Polaris Sportsman 500 ATV Additional Coverage: Likely includes troubleshooting, diagnostics, maintenance schedules, and component identification Page Count Estimated Page Count: Typically 300-600 pages for a comprehensive service manual of this era Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage of the 499cc liquid-cooled, 4-stroke engine (engine code: P85) Fuel System: Carburetion (likely Mikuni BS34), fuel pump, fuel lines, and tank maintenance Ignition System: CDI ignition, spark plug specifications, timing adjustments Cooling System: Radiator, fan, thermostat, coolant specifications, and bleeding procedures Exhaust System: Muffler, header pipe inspection and replacement Transmission: PVT (Polaris Variable Transmission) clutch system (primary and secondary), belt inspection and replacement, gearcase lubrication Drivetrain: Driveshafts, CV joints, final drive (rear differential), driveshaft U-joints Suspension: Front and rear independent suspension, shock absorbers, A-arms, bushings, wheel alignment Steering: Handlebar assembly, steering stem, tie rods, steering linkage, power steering (if equipped - likely not standard on this model) Brakes: Hydraulic disc brakes (front and rear), brake caliper service, master cylinder, brake lines, fluid specifications (DOT 3/4) Electrical System: Battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), electrical connectors Chassis And Frame: Frame inspection, mounting points, body panels, fenders, racks Wheels And Tires: Tire pressures, wheel lug nut torque, tire replacement Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain adjustments (if applicable - usually shaft drive), lubrication points Engine Overhaul: Top-end rebuild (cylinder head, piston, rings), bottom-end inspection and repair (crankshaft, bearings), valve adjustments Transmission Service: Clutch inspection, belt replacement, gearcase fluid change, potential rebuild procedures for the transmission components Brake System Repair: Bleeding, pad replacement, caliper rebuilding, master cylinder service Electrical Troubleshooting: Wiring diagrams, diagnostic procedures for charging system, starter, lighting faults Suspension Adjustment And Repair: Shock adjustments, bushing replacement, alignment procedures Steering System Repair: Tie rod end replacement, steering stem bearing service Troubleshooting Guides: Diagnostic charts for common starting issues, performance problems, and system failures Wiring Diagrams: Comprehensive electrical schematics for all systems Technical Depth Depth: Extensive, covering both routine maintenance and complete mechanical and electrical overhauls Diagnostics: Includes detailed diagnostic procedures and troubleshooting flowcharts Special Tools: Lists required special tools for specific repair procedures Torque Specifications: Provides precise torque values for critical fasteners Clearances: Specifies critical component clearances (e.g., valve lash, bearing clearances) 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Likely text-searchable for quick information retrieval Print Quality Quality: Very best quality, illustrated with clear step-by-step instructions Illustrations: Clear, detailed diagrams and photographs Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC, 4-valve, single-cylinder Displacement: 499cc (30.4 cu. in.) Bore X Stroke: 92 mm x 75 mm (3.62 in. x 2.95 in.) Compression Ratio: 10.4:1 Carburetor: Mikuni BS34 (likely) Performance Horsepower Estimated: Approx. 36-38 HP (at 6000 RPM) Torque Estimated: Approx. 30-32 lb-ft...