The 2009 Sportsman 500 Touring is a versatile All-Terrain Vehicle (ATV) designed for both utility and recreational purposes. Known for its robust engineering and ability to handle diverse terrains, this quadricycle offers an extended wheelbase for enhanced stability and comfort, making it ideal for longer rides and two-up excursions. The Sportsman line is a testament to a commitment to durability, performance, and innovation in the ATV market. This model is equipped with a 499cc liquid-cooled engine, an automatic Variable Transmission (PVT), and an On-Demand All-Wheel Drive system, providing reliable power and traction in challenging conditions. This workshop service manual provides comprehensive mechanical service and repair information for the 2009 Sportsman 500 Touring ATV. It covers all essential systems, including the engine, transmission, drivetrain, suspension, steering, brakes, and electrical systems, offering detailed procedures for maintenance, troubleshooting, and component repair. The manual includes technical specifications, torque values, fluid capacities, and diagnostic information, making it an invaluable resource for professional technicians and experienced owners alike. By following the step-by-step instructions and utilizing the included diagrams and schematics, users can effectively maintain their vehicle, diagnose issues, and perform necessary repairs to ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) Category: Utility/Recreational ATV Designation: Quadricycle 👋 Introduction Market Position Market Segment: Polaris's Sportsman line is a dominant force in the utility and recreational ATV market, known for its durability, performance, and versatility. The Touring model specifically targets riders who value comfort and capability for longer excursions. Competitive Analysis Competitors: Competes with models from Yamaha (Grizzly), Can-Am (Outlander), Arctic Cat (Prowler), Kawasaki (Brute Force), and Honda (Foreman/Rubicon) in the 500cc+ utility/touring ATV segment. Key Features Touring Focus: Extended wheelbase for improved stability and passenger comfort, comfortable seating for two, higher ground clearance, robust suspension system for varied terrain. Manual Purpose Target Audience: Primarily mechanical technicians, but also valuable for experienced ATV owners undertaking their own maintenance and repairs. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive mechanical service and repair Page Count Page Count: Estimated 400-600 pages (typical for this era's workshop manuals) Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, internal components, cooling system, lubrication system, fuel delivery, ignition system Transmission Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission), drive clutches, driven clutches, belt replacement, gearbox, drive shafts, differentials, CV joints, AWD system (if applicable) Suspension Steering: Front and rear suspension (independent front suspension, dual trailing arm rear suspension), shock absorbers, springs, bushings, steering system, tie rods, steering column Brakes: Hydraulic disc brakes (front and rear), brake caliper service, master cylinder, brake lines, bleeding procedures Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, ignition switch, lights, instrumentation, sensors, ECUs Fuel System: Fuel tank, fuel pump, fuel filter, carburetor (likely Keihin or Mikuni for this model), fuel lines Bodywork Frame: Frame inspection, body panels, fenders, racks, seat, handlebars, plastics Cooling System: Radiator, cooling fan, coolant hoses, thermostat, coolant type and capacity Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plugs, valve adjustments), lubrication points, inspection routines Troubleshooting: Diagnostic charts, symptom-based troubleshooting for common issues, electrical system fault finding Repair Rebuild: Step-by-step instructions for component disassembly, repair, and reassembly (e.g., engine rebuild, transmission service, brake caliper overhaul) Technical Specifications: Torque specifications, clearances, measurements, fluid capacities, electrical resistance values Component Identification: Identification of key parts and components with diagrams Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics; covers from basic maintenance to major overhauls and diagnostics 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, optimized for digital viewing and printing, clear diagrams and text Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Searchability Searchable Text: Typically searchable text within the PDF for quick information retrieval Illustrations Illustrations Included: Detailed diagrams, exploded views, schematics, and photographic illustrations ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC (Single Overhead Cam), 4-valve, liquid-cooled Engine Displacement: 499cc Bore X Stroke: 92.0 mm x 75.0 mm Compression Ratio: 9.5:1 Performance Horsepower Est: Approx. 30-35 HP (at flywheel, manufacturer specific) Torque Est: Approx. 30-35 lb-ft (at flywheel, manufacturer specific) Fuel System Fuel Induction: Carburetor (likely Mikuni BSR42 or similar) Fuel Type: Unleaded gasoline, 87 octane (minimum) Cooling System Cooling Method: Liquid-cooled with fan assist Lubrication Oil Type: SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil Oil Capacity W Filter: Approx. 2.2 L (74 fl oz) 🔧 Transmission Standard Transmission Type: Automatic, Polaris Variable Transmission (PVT) Drive Modes: High, Low, Neutral, Reverse, Park Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Features Clutch System: Primary (Drive) Clutch and Secondary (Driven) Clutch Gear Reduction: Integral gearbox with reduction ratios...