This manual covers the 2009 Sportsman 500, a versatile mid-size utility All-Terrain Vehicle (ATV) renowned for its robust performance and rider comfort. Engineered with a liquid-cooled, 4-stroke, 499cc single-cylinder engine featuring Electronic Fuel Injection (EFI) on most variants, the Sportsman 500 offers reliable power for a variety of tasks and terrains. Its design prioritizes durability and capability, making it a popular choice for both recreational trail riding and demanding work applications. Key features include a Variable Transmission (PVT) with High/Low range, On-Demand All-Wheel Drive (AWD) or 2WD selectable drive system, and a comfortable suspension setup with ample ground clearance. This comprehensive Factory Service Repair Workshop Manual provides in-depth information for maintaining and repairing the 2009 Sportsman 500 EFI, Sportsman 500 H.O., Sportsman X2 500 EFI, and Sportsman Touring 500 EFI. It details procedures for all major systems, including the engine, fuel injection, drivetrain, suspension, steering, brakes, and electrical system. Owners and technicians will find detailed step-by-step instructions for disassembly, reassembly, troubleshooting, component testing, and adjustments. The manual includes essential technical specifications, torque values, diagnostic trouble codes, and wiring diagrams, empowering users to perform everything from routine maintenance to complex overhauls effectively. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2009 Codes Chassis Code: A09CH50AX / A09CH50AQ / A09CH50AZ / A09CH50AZ / A09CH50AA / A09CH50AB 👋 Introduction Market Position Target Audience: Both DIY enthusiasts and professional mechanics working on 2009 Polaris Sportsman 500 ATVs. Vehicle Segment: Mid-size utility ATV segment, known for its balance of power, capability, and rider comfort. Competitive Analysis Value Proposition: Provides factory-level diagnostic and repair information, offering a cost-effective alternative to dealership service for maintaining and repairing the Sportsman 500. Key Features Manual Benefits: Instant download, comprehensive coverage, detailed diagrams, step-by-step instructions, cost savings on postage and packaging. 📋 Manual Details Coverage Areas Covered Models: 2009 Polaris Sportsman 500 EFI, 2009 Polaris Sportsman 500 H.O., 2009 Polaris Sportsman X2 500 EFI, 2009 Polaris Sportsman Touring 500 EFI Page Count Estimated Page Count: Approximately 400-600 pages (typical for this level of detail) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Major Systems: Engine, Fuel Injection (EFI), Drivetrain (Clutch, Final Drive, Transmission), Suspension, Steering, Brakes, Electrical System, Bodywork Specific Efi Systems: Detailed information on fuel pump, injectors, throttle body, sensors (e.g., MAP, TPS, IAT), and ECM troubleshooting. Body Steering Suspension: Comprehensive coverage including steering linkage, tie rods, ball joints, shocks, A-arms, wheel bearings, and hub assemblies. Electrical System: Detailed troubleshooting for starting system, charging system, lighting, ignition, sensors, and EFI control unit. Wiring Diagram: Includes detailed, color-coded wiring diagrams essential for electrical diagnostics and repairs. Procedures Included Repair Procedures: Complete disassembly and reassembly, troubleshooting, component testing, adjustments, replacement procedures, overhaul instructions Engine Rebuild: Full engine disassembly, inspection, and reassembly procedures, including piston, connecting rod, crankshaft, and cylinder head work. Transmission Overhaul: Detailed steps for transmission disassembly, component replacement (gears, bearings, seals), and reassembly. Clutch Maintenance: Belt inspection, tension adjustment, and replacement procedures for both primary and secondary clutches. Component removal and installation. Brake System Service: Bleeding procedures, caliper inspection and rebuild, pad replacement, and rotor servicing. Technical Depth Depth Of Information: Comprehensive: From basic maintenance and routine checks to advanced diagnostics, complete engine and transmission rebuilds, and electrical system troubleshooting. Includes detailed specifications and tolerances. Diagnostic Procedures: Includes diagnostic trouble codes (DTCs) for EFI system faults and specific troubleshooting flowcharts for common issues. Torque Specifications: Includes precise torque values for all critical fasteners and components. Special Tools: Highlights any specialized tools required for specific procedures. 📊 Manual Specifications File Format File Quality: High-resolution PDFs with clear, legible text and detailed diagrams. Searchable text capability is implied for efficient navigation. Compatibility: Compatible with all versions of Windows and Mac operating systems. Print Quality Printability: All pages are printable for convenient use in workshop environments. Binding Type Binding Type: Digital (Instant Download PDF) - implies no physical binding. Paper Type Paper Type: N/A (Digital format) Requirements Software Requirements: Requires Adobe PDF Reader and WinZip (or similar decompression utility). ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder engine. Performance Displacement: 499cc (for all 500 models listed) Bore X Stroke: Typically 93.0 mm x 71.9 mm Compression Ratio: Typically 10.0:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) for most models, potentially carbureted for some H.O. variants depending on specific sub-model. Ignition System: CDI with electronic advance Throttle Control: Handlebar-mounted throttle lever with cable actuation. Lubrication Oil Type: API SG/SH/SJ rated 4-stroke engine oil, SAE 0W-40, 10W-40, or 20W-50 viscosity (refer to manual for specific recommendations based on temperature). Cooling System Coolant Type: Ethylene glycol base antifreeze with corrosion inhibitors (typically 50/50 mix with distilled water). 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) with High/Low range and Reverse. Features Drive...