Basic Information Identification Make: Polaris Model: Sportsman X2 500 EFI Year: 2009 Product Type: Factory Service Repair Manual Introduction Market Position Segment: Utility ATV, known for its versatility and dual-seat capability. Competitive Analysis Competitors: Competed against models like the Can-Am Outlander Max, Yamaha Grizzly 550/700, Kawasaki Brute Force 650/750. Key Features X2 Design: Unique convertible passenger seat offering dual-riding capability. Efi Technology: Electronic Fuel Injection for improved throttle response, cold starts, and fuel efficiency. Manual Details Coverage Areas Manual Scope: Comprehensive repair and maintenance for the 2009 Polaris Sportsman X2 500 EFI. Page Count Estimated Page Count: Refer to specific manual for exact count, typically 500-1000 pages for this model year. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of the 499cc ProStar engine. Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, fuel filter replacement. Cooling System: Radiator, fan, hoses, thermostat, coolant type and capacity, flushing procedures. Ignition System: Spark plugs, ignition coil, stator, CDI unit, timing. Exhaust System: Muffler, pipes, heat shields, inspection and replacement. Drivetrain: PVT (Polaris Variable Transmission) - primary and secondary clutches, belt inspection and replacement, gear case, drive shafts, differentials. Suspension: Front and rear suspension components, shocks, springs, bushings, alignment, wheel bearings. Steering: Handlebar, steering shaft, tie rods, ball joints, steering rack, AWD steering components. Braking System: Hydraulic disc brakes (front and rear), brake lines, master cylinders, calipers, pads, bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, sensors, ECU. Body And Frame: Chassis, body panels, seats, racks, winch mounting, cargo box mechanism. Procedures Included Scheduled Maintenance: Detailed checklists for regular service intervals (e.g., oil changes, filter replacements, lubrication). Troubleshooting Diagnostics: Systematic diagnostic charts for common problems and error codes. Repair Procedures: Step-by-step instructions for component removal, disassembly, repair, assembly, and installation. Adjustments: Carburetor/EFI adjustments (if applicable), clutch adjustments, brake adjustments. Torque Specifications: Precise torque values for all critical fasteners and bolts. Technical Depth Depth Level: Expert level, covering complete rebuilds, advanced diagnostics, and component-level repairs. Manual Specifications File Format File Type: PDF Searchable Text: Yes, typically searchable PDF for easy navigation. Print Quality Resolution: High-resolution images and diagrams for clarity. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, Single Cylinder Displacement: 499cc Bore X Stroke: 92mm x 75mm (typical for this engine family) Cooling Method: Liquid-cooled Performance Horsepower: Approx. 30-32 HP (at flywheel, manufacturer specific) Torque: Approx. 27-29 lb-ft (at flywheel, manufacturer specific) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane minimum Lubrication Oil Type: SAE 5W-50 Synthetic (Polaris recommended) Transmission Standard Type: Polaris Variable Transmission (PVT) with Engine Braking Gears: High, Low, Neutral, Reverse, Park Features Drive System: On-Demand All-Wheel Drive (AWD) with 2WD/4WD selection Clutch Type: Dual clutch (Primary and Secondary) Gear Fluid Gearcase Oil Type: SAE 80W-90 Hypoid Gear Lubricant Dimensions Exterior Length: 85.5 inches (217.2 cm) Width: 46 inches (116.8 cm) Height: 47 inches (119.4 cm) Wheelbase: 50.5 inches (128.3 cm) Ground Clearance: 11.25 inches (28.6 cm) Weights Dry Weight: 630 lbs (285.8 kg) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) Cargo Cargo Box Volume: Approx. 7.25 cu ft (with passenger seat folded) Safety Features Ratings Atv Safety Standards: Complies with ANSI and BRP safety standards. Active Features Braking System: Hydraulic disc brakes front and rear, engine braking. AWD System: On-Demand AWD for enhanced traction. Passive Features Roll Over Protection: N/A (ATV design) Seat Belt: N/A (ATV design, rider uses helmet and protective gear) Technology Features Infotainment Instrument Cluster: Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, AWD indicator, gear selection. Driver Assistance Engine Management: ECU (Engine Control Unit) manages EFI, ignition timing, and diagnostics. Connectivity Diagnostic Port: Diagnostic port for connecting specialized diagnostic tools (covered in manual). Maintenance Service Intervals Engine Oil Change: Every 100 hours or 6 months, whichever comes first. Check manual for specific conditions. Air Filter Cleaning: Every 25 hours or 3 months, or more frequently in dusty conditions. Spark Plug Replacement: Refer to manual, typically every 1-2 years or 100-200 hours. Transmission Oil Change: Refer to manual, typically annually or every 100-200 hours. Clutch Inspection: Every 50 hours or annually. Fluid Specifications Engine Oil: Polaris PS-4 5W-50 Synthetic Engine Oil (or equivalent meeting API SG or higher) Gearcase Oil: Polaris Gearcase Lubricant 80W-90 (or equivalent SAE 80W-90 Hypoid Gear Lubricant) Coolant: Polaris Premium All-Season Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors, 50/50 mix with distilled water) Brake Fluid: DOT 3 or DOT 4 Hydraulic Brake Fluid Known Issues Clutch Wear: Standard wear and tear on primary and secondary clutches; belt alignment...