The 2009 Sportsman 500 is a versatile All-Terrain Vehicle (ATV) designed for recreational trail riding, demanding utility work, and hunting expeditions. Available in HO, EFI, X2 EFI, and Touring EFI variants, this model exemplifies a commitment to engineering quality and reliability. Its robust construction, liquid-cooled 499cc engine, and On-Demand All-Wheel Drive system provide exceptional capability and traction in challenging off-road conditions. The Sportsman 500 is recognized for its comfortable ergonomics, substantial towing capacity of 1500 lbs, and practical rack storage, making it a popular choice in the mid-size utility ATV segment. This comprehensive Factory Service Repair Manual, written in English, provides in-depth guidance for the maintenance and repair of the 2009 Sportsman 500. It covers all major systems, including the engine's top and lower ends, fuel system, cooling, clutch, transmission, front and rear suspension, brakes, and electrical components. Detailed procedures for routine maintenance, troubleshooting common issues, tune-ups, and complete component overhauls are included, along with essential technical specifications and wiring diagrams. This manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance, longevity, and safe operation of their Sportsman 500 ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Model Variants: HO, EFI, X2 EFI, Touring EFI Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Target Audience: Owners and independent repair shops of 2009 Polaris Sportsman 500 ATVs. Utility: Designed for recreational trail riding, utility work, and hunting. Competitive Analysis Segment: Mid-size utility ATV segment. Key Competitors: Can-Am Outlander, Yamaha Grizzly, Arctic Cat ATV. Key Features Manual Benefit: Empowers users to perform maintenance and repairs, saving on labor costs and ensuring longevity. Diagnostic Advantage: Provides the exact procedures and specifications used by factory-trained technicians. Completeness: Covers all variants of the 2009 Sportsman 500 HO, EFI, X2 EFI, and Touring EFI. 📋 Manual Details Coverage Manual Type: Factory Service Repair Manual Language: English Format File Format: PDF Compatibility: Windows and MAC Requirements: Adobe PDF Reader Availability Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine Top End: Includes cylinder head, valves, camshaft, piston, rings, cylinder, timing. Engine Lower End: Includes crankshaft, connecting rod, bearings, oil pump, engine case. Fuel System: EFI system, fuel pump, injectors, throttle body, fuel filter, fuel tank, pressure regulator. Cooling System: Radiator, fan, coolant, thermostat, hoses, water pump. Clutch Drive Belt System: Primary and secondary clutch inspection, service, belt replacement, alignment. Transmission: Internal components, gear shifting, lubrication, maintenance. Front Drive System: Front differential, CV joints, driveshafts, AWD engagement (if applicable). Electrical System: Ignition system, charging system (stator, regulator/rectifier), battery, starter, lighting, sensors, ECU. Front Suspension Steering: A-arms, shocks, springs, ball joints, tie rods, steering post, wheel bearings. Rear Suspension: Swingarm, shocks, springs, bushings, wheel bearings. Brakes: Hydraulic systems, calipers, master cylinders, brake lines, pads, rotors, bleeding procedures. Body: Body panels, fenders, seat, rack system, plastics, removal and installation. Wiring Diagrams: Detailed electrical schematics for comprehensive troubleshooting. Procedures Included Maintenance Schedule: Recommended service intervals for oil changes, filter replacements, lubrication, and inspections. Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems. Tune Up: Spark plug replacement, air filter cleaning/replacement, carburetor/EFI adjustments (where applicable). Repair Procedures: Step-by-step instructions for disassembly, repair, and reassembly of all major components. Lubrication: Specific lubrication points, recommended lubricants, and capacities. Technical Depth Level Of Detail: Comprehensive, covering from basic maintenance to in-depth engine and transmission rebuilds. Diagnostic Capability: Detailed diagnostic charts and procedures for identifying and resolving malfunctions. Special Tools: Identifies required special tools for specific procedures, often with diagrams. Supplemental Info Supplement Years: 2001-2003 service information included Index: Provides an index for quick reference to specific topics. 📊 Manual Specifications File Attributes File Format: PDF Printability: Yes Searchability: Assumed high due to PDF format and factory origin. Production Manual Source: Factory Original Binding Type: Digital Download (PDF) Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 4-valve, single-cylinder Engine Displacement: 499cc Bore X Stroke: 92mm x 75mm Performance Horsepower: Approximately 33-34 HP (exact figure may vary slightly by variant/tune). Torque: Approximately 29-30 lb-ft (exact figure may vary slightly by variant/tune). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane or higher. Ignition Ignition System: CDI (Capacitor Discharge Ignition) with digital advance Cooling Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Hi/Lo range and reverse Drive System: On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector. Features Engine Braking: Integrated engine braking through the PVT system. Fluid Specifications Transmission Fluid: Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent meeting specific viscosity and additive requirements (refer to manual for exact spec). 📐 Dimensions Exterior Length: Approximately 82.5 inches (209.5 cm) Width: Approximately 46 inches (116.8 cm) Height: Approximately 48 inches (121.9 cm) Weights Dry Weight: Approximately 650-700 lbs (295-318 kg) depending on model variant. Ground Clearance: Approximately 11.25 inches (28.6...