Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2009 Model Variants: 500 H.O., 500 EFI, X2 500 EFI, Touring 500 EFI Introduction Market Position Market Position: The Polaris Sportsman 500 line in 2009 represented a robust and versatile ATV platform, known for its trail-riding capabilities, utility features, and rider comfort, particularly in the Touring models. This manual targets owners and technicians seeking to maintain, repair, and optimize these specific 2009 models. Competitive Analysis Competitive Analysis: Competed against models from brands like Can-Am Outlander, Arctic Cat 500, and Yamaha Grizzly 550, offering a balance of power, features, and Polaris's established reputation for off-road vehicles. Key Features Key Features: 500cc class engine, Automatic PVT (Polaris Variable Transmission) with Engine Braking, On-Demand AWD, independent front and rear suspension, hydraulic disc brakes, and specific features like the X2's convertible cargo bed and the Touring's enhanced comfort amenities. Manual Details Coverage Coverage Areas: Complete service, repair, diagnostics, maintenance, troubleshooting, electrical systems, engine, transmission, chassis, body, suspension, brakes, and more for all listed 2009 Polaris Sportsman 500 variants. Identification Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download Completeness Manual Completeness: This is a full workshop service and repair manual, intended to cover all aspects of vehicle maintenance and repair performed by dealership technicians. It is not an owner's manual or a condensed guide. Manual Coverage Systems Systems Covered: Engine mechanical (including top-end and bottom-end), fuel injection (EFI) system, ignition system, cooling system, exhaust system, drivetrain (AWD, differentials), transmission (CVT), braking system (hydraulic disc), steering, suspension (independent front and rear), electrical system (wiring diagrams, lighting, accessories, charging system), chassis, body panels, and maintenance procedures. Procedures Procedures Included: Routine maintenance, lubrication, fluid changes, filter replacements, engine diagnostics and repair (including piston, rings, cylinder, crankshaft, camshaft), fuel system troubleshooting and repair (injectors, fuel pump, regulator), ignition system diagnosis, CVT belt inspection and replacement, brake system bleeding and pad replacement, suspension component inspection and replacement, electrical troubleshooting with detailed wiring diagrams, component testing, and general assembly/disassembly procedures. Depth Technical Depth: Comprehensive; covers basic maintenance to full engine rebuilds and in-depth electrical system diagnostics. Provides detailed step-by-step instructions, torque specifications, special tool requirements, and troubleshooting flowcharts. Electrical Electrical Coverage Detail: Extensive coverage including detailed color wiring diagrams for all electrical components (lights, ignition, charging system, starter, accessories, EFI system components). Includes troubleshooting guides for common electrical faults, component testing procedures, and connector pinouts. Engine Rebuild Engine Rebuild Detail: Complete instructions for engine disassembly, inspection, repair, and reassembly. Covers cylinder head removal and reconditioning, piston and connecting rod service, crankshaft inspection and installation, valve timing, and torque specifications for all critical fasteners. Transmission Service Transmission Service Detail: Detailed procedures for CVT clutch inspection, belt replacement, and adjustment. Covers maintenance of the PVT system, including servicing of the primary and secondary clutches. Explains gearcase lubrication and maintenance. Suspension Steering Suspension Steering Detail: Instructions for inspecting and replacing front and rear suspension components, including A-arms, bushings, ball joints, shocks, and sway bars. Covers steering system maintenance, including tie rod ends and steering rack adjustments. Braking System Braking System Detail: Comprehensive guides for brake system maintenance, including front and rear brake caliper removal and installation, brake pad replacement, brake line bleeding procedures, master cylinder service, and inspection of brake discs. Troubleshooting Troubleshooting Guides: Includes step-by-step troubleshooting flowcharts and diagnostic trees for various systems, such as starting problems, engine performance issues, charging system faults, and braking system malfunctions. Manual Specifications File File Format: PDF Searchable Text: Yes, the PDF format allows for keyword searching, making it efficient to find specific information. Printable Pages: Yes, the PDF is designed to be printable for workshop use. Quality Print Quality: High-resolution scans of original dealership service manuals, ensuring clear diagrams, illustrations, and text. Binding Binding Type: N/A (Digital PDF Download) Paper Paper Type: N/A (Digital PDF Download) Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder engine (specific variants may feature minor tuning differences). Performance Displacement: 499 cc Bore X Stroke: 92 mm x 77.4 mm Horsepower Estimate: Approximately 30-32 hp (varies slightly by model variant). Fuel System Fuel System: Electronic Fuel Injection (EFI) with single throttle body and injectors. Fuel Type: Unleaded gasoline, minimum 87 octane. Ignition Ignition System: CDI with electronic advance. Cooling Cooling System: Liquid-cooled. Oil Oil Type Capacity: API SG, SH, SJ rated 4-stroke synthetic motorcycle oil, SAE 10W-40. Capacity: 2.7 US quarts (2.56 liters) with filter change. Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking. Optional Optional Gear Reduction: High and Low range, Reverse, Neutral, Park. Features Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD). Fluid Transmission Fluid Type: Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent SAE 80W-90 hypoid gear lubricant. Dimensions Exterior Length: 83 in. (210.8 cm) / 91.5 in. (232.4 cm) for Touring models. Width: 46 in. (116.8 cm) Height: 47 in....