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2009 Polaris Sportsman 500 Service Manual

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This manual covers the 2009 All-Terrain Vehicle (ATV), including the HO, EFI, X2 EFI, and Touring EFI variants. The Sportsman line has been engineered for robust performance and off-road capability. Known for its versatility and durability, the Sportsman 500 is a popular choice for recreational riding and utility tasks, offering a balance of power and comfort. This comprehensive service and repair manual provides essential information for maintaining and repairing your 2009 Sportsman 500. It details procedures for engine systems, transmission, drivetrain, electrical systems, chassis, body, and brakes. Coverage includes scheduled maintenance, troubleshooting common issues, detailed assembly and disassembly instructions, and diagnostic procedures for EFI models. This resource is designed to assist owners and technicians in keeping the ATV in optimal working condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Model Variant: HO / EFI / X2 EFI / Touring EFI Year: 2009 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Target User: Home mechanics, DIY enthusiasts, ATV owners performing routine maintenance and repairs. Competitive Analysis Value Proposition: Provides cost savings over dealership service, enhances owner's understanding and ability to maintain the ATV, prolonging its lifespan. Key Features Repair Ease: Designed with relative simplicity and ease of repair in mind, making home maintenance accessible. Benefit Of Manual: Essential tool for identifying parts, performing routine maintenance, and troubleshooting repairs. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service and repair information for 2009 Polaris Sportsman 500 HO, 500 EFI, X2 500 EFI, and Touring 500 EFI models. Page Count Page Count: 386 Manual Type Manual Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end components, lubrication, cooling, fuel system (EFI), exhaust. Transmission Systems: Automatic transmission (PVT - Polaris Variable Transmission), gear cases, drive shafts. Drivetrain Systems: Final drive, differential, axles, CV joints, drive belts. Electrical Systems: Ignition, charging system, battery, starter, lighting, diagnostics, wiring diagrams. Chassis Systems: Frame, suspension (front and rear), steering system, wheels, tires. Body Systems: Body panels, racks, seating, storage. Brake Systems: Hydraulic brake system, calipers, master cylinders, brake lines. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, drive belt inspection and replacement, brake system maintenance. Diagnostic Procedures: Troubleshooting common problems, diagnostic codes (for EFI models), electrical system testing. Repair Procedures: Engine component repair, transmission overhaul, suspension and steering component replacement, brake system repair, electrical component repair, drive belt replacement. Assembly Disassembly: Detailed step-by-step instructions for disassembly and reassembly of all major components. Technical Depth Depth Of Coverage: Comprehensive, from basic routine maintenance to in-depth engine and transmission rebuilds, electrical diagnostics, and chassis repairs. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely searchable due to PDF format, facilitating quick information retrieval. Print Quality Print Options: Allows printing of specific sections or the entire manual. Binding Type Binding Options: Digital (PDF download), user printable for desired binding. Paper Type Paper Recommendation: Recommend durable paper for workshop use. ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, SOHC, 2-Valve Displacement: 499cc Bore X Stroke: 92mm x 75mm (estimated, requires manual verification) Cooling System: Liquid-Cooled Performance Horsepower: Approximately 30-35 HP (estimated, varies by model variant and specific tuning). Torque: Not specified in product description, but estimated to be in the range of 30-35 lb-ft. Fuel System Efi Type: Electronic Fuel Injection (for EFI models) Carburetion: Not applicable for EFI models, HO model may use carburetor (requires manual verification). 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Drive System: Shaft Drive with On-Demand AWD / 2WD Features Gear Selection: High, Low, Neutral, Reverse, Park 📐 Dimensions Exterior Length: Varies by model (e.g., Sportsman 500 HO ~81 inches, Touring 500 EFI ~85 inches) - refer to manual for specifics. Width: Varies by model (e.g., Sportsman 500 HO ~46 inches) - refer to manual for specifics. Height: Varies by model (e.g., Sportsman 500 HO ~45 inches) - refer to manual for specifics. Weights Dry Weight: Approximately 650-700 lbs (varies by model) - refer to manual for specifics. Ground Clearance: Approximately 10.5 inches (varies by model) - refer to manual for specifics. 🛡️ Safety Features Ratings Atv Safety Guidelines: Manual will detail safe operating practices, recommended protective gear (helmet, eyewear, gloves, etc.), and riding techniques. Active Features Braking System: Hydraulic disc brakes front and rear for effective stopping power. Engine Braking: PVT system provides engine braking during deceleration. Passive Features Lighting: Headlights, taillight, brake light for visibility. Rollover Protection: Not applicable as ATVs do not typically have integrated ROPS. Manual will emphasize safe riding to avoid rollovers. 💡 Technology Features Infotainment Infotainment Features: Basic, typically limited to analog instrumentation (speedometer, odometer, fuel gauge, warning lights). Driver Assistance Diagnostic Ports: On EFI models, diagnostic port for accessing engine data and fault codes. Connectivity Accessory Power:...
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Type: Atv
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Sku: 41590
Collections: ALL ATV Powersports

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2009 Polaris Sportsman 500 Service Manual2009 Polaris Sportsman 500 Service Manual2009 Polaris Sportsman 500 Service Manual2009 Polaris Sportsman 500 Service Manual
This manual covers the 2009 All-Terrain Vehicle (ATV), including the HO, EFI, X2 EFI, and Touring EFI variants. The Sportsman line has been engineered for robust performance and off-road capability. Known for its versatility and durability, the Sportsman 500 is a popular choice for recreational riding and utility tasks, offering a balance of power and comfort. This comprehensive service and repair manual provides essential information for maintaining and repairing your 2009 Sportsman 500. It details procedures for engine systems, transmission, drivetrain, electrical systems, chassis, body, and brakes. Coverage includes scheduled maintenance, troubleshooting common issues, detailed assembly and disassembly instructions, and diagnostic procedures for EFI models. This resource is designed to assist owners and technicians in keeping the ATV in optimal working condition.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 500
Model Variant:
HO / EFI / X2 EFI / Touring EFI
Year:
2009
Codes
Vehicle Type:
All-Terrain Vehicle (ATV)
👋 Introduction
Market Position
Target User:
Home mechanics, DIY enthusiasts, ATV owners performing routine maintenance and repairs.
Competitive Analysis
Value Proposition:
Provides cost savings over dealership service, enhances owner's understanding and ability to maintain the ATV, prolonging its lifespan.
Key Features
Repair Ease:
Designed with relative simplicity and ease of repair in mind, making home maintenance accessible.
Benefit Of Manual:
Essential tool for identifying parts, performing routine maintenance, and troubleshooting repairs.
📋 Manual Details
Coverage Areas
Coverage Summary:
Comprehensive service and repair information for 2009 Polaris Sportsman 500 HO, 500 EFI, X2 500 EFI, and Touring 500 EFI models.
Page Count
Page Count:
386
Manual Type
Manual Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, top-end components, lubrication, cooling, fuel system (EFI), exhaust.
Transmission Systems:
Automatic transmission (PVT - Polaris Variable Transmission), gear cases, drive shafts.
Drivetrain Systems:
Final drive, differential, axles, CV joints, drive belts.
Electrical Systems:
Ignition, charging system, battery, starter, lighting, diagnostics, wiring diagrams.
Chassis Systems:
Frame, suspension (front and rear), steering system, wheels, tires.
Body Systems:
Body panels, racks, seating, storage.
Brake Systems:
Hydraulic brake system, calipers, master cylinders, brake lines.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, drive belt inspection and replacement, brake system maintenance.
Diagnostic Procedures:
Troubleshooting common problems, diagnostic codes (for EFI models), electrical system testing.
Repair Procedures:
Engine component repair, transmission overhaul, suspension and steering component replacement, brake system repair, electrical component repair, drive belt replacement.
Assembly Disassembly:
Detailed step-by-step instructions for disassembly and reassembly of all major components.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic routine maintenance to in-depth engine and transmission rebuilds, electrical diagnostics, and chassis repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely searchable due to PDF format, facilitating quick information retrieval.
Print Quality
Print Options:
Allows printing of specific sections or the entire manual.
Binding Type
Binding Options:
Digital (PDF download), user printable for desired binding.
Paper Type
Paper Recommendation:
Recommend durable paper for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, SOHC, 2-Valve
Displacement:
499cc
Bore X Stroke:
92mm x 75mm (estimated, requires manual verification)
Cooling System:
Liquid-Cooled
Performance
Horsepower:
Approximately 30-35 HP (estimated, varies by model variant and specific tuning).
Torque:
Not specified in product description, but estimated to be in the range of 30-35 lb-ft.
Fuel System
Efi Type:
Electronic Fuel Injection (for EFI models)
Carburetion:
Not applicable for EFI models, HO model may use carburetor (requires manual verification).
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive System:
Shaft Drive with On-Demand AWD / 2WD
Features
Gear Selection:
High, Low, Neutral, Reverse, Park
📐 Dimensions
Exterior
Length:
Varies by model (e.g., Sportsman 500 HO ~81 inches, Touring 500 EFI ~85 inches) - refer to manual for specifics.
Width:
Varies by model (e.g., Sportsman 500 HO ~46 inches) - refer to manual for specifics.
Height:
Varies by model (e.g., Sportsman 500 HO ~45 inches) - refer to manual for specifics.
Weights
Dry Weight:
Approximately 650-700 lbs (varies by model) - refer to manual for specifics.
Ground Clearance:
Approximately 10.5 inches (varies by model) - refer to manual for specifics.
🛡️ Safety Features
Ratings
Atv Safety Guidelines:
Manual will detail safe operating practices, recommended protective gear (helmet, eyewear, gloves, etc.), and riding techniques.
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Engine Braking:
PVT system provides engine braking during deceleration.
Passive Features
Lighting:
Headlights, taillight, brake light for visibility.
Rollover Protection:
Not applicable as ATVs do not typically have integrated ROPS. Manual will emphasize safe riding to avoid rollovers.
💡 Technology Features
Infotainment
Infotainment Features:
Basic, typically limited to analog instrumentation (speedometer, odometer, fuel gauge, warning lights).
Driver Assistance
Diagnostic Ports:
On EFI models, diagnostic port for accessing engine data and fault codes.
Connectivity
Accessory Power:
Provision for 12V accessory outlets or wiring harnesses for lights, winches, etc.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact intervals).
Air Filter Inspection:
Inspect every 25 hours, clean/replace as needed. Frequent inspection in dusty conditions.
Spark Plug Replacement:
Typically every 100 hours or annually (refer to manual for specific plug type and interval).
Fluid Specifications
Engine Oil Type:
SAE 0W-40 Synthetic or 5W-50 Synthetic (Polaris branded recommended, verify with manual).
Engine Oil Capacity:
Approximately 2.0 quarts (verify with manual).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors (Polaris branded recommended, verify with manual).
Gearcase Oil Type:
SAE 75W-90 Synthetic Gear Oil (verify with manual).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid (verify with manual).
Known Issues
Common Wear Items:
Drive belts, wheel bearings, tie rod ends, ball joints, suspension bushings are common wear items on ATVs of this era and usage.
Efi System Maintenance:
Regular cleaning of fuel injectors and throttle body may be beneficial for EFI models.
📚 Vehicle History
Brand Heritage
Manufacturer Legacy:
Polaris Industries is a long-standing manufacturer of powersports vehicles, known for its innovation in ATVs and snowmobiles.
Model Evolution
Sportsman Lineage:
The Sportsman line is a flagship series for Polaris, known for its versatility, comfort, and off-road capability. The 500cc engine has been a staple for many years, evolving with fuel injection and improved features.
Production
Manufacturing Era:
2009 model year.
🏆 Awards & Recognition
Recognitions
Atv Market Recognition:
The Polaris Sportsman 500 has historically been a highly regarded and popular ATV in its class, recognized for its reliability and capability.
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