Polaris Sportsman 500 ATV 2009 Service Repair Workshop Manual

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Stichworte: 2009 ATV Misc Polaris Powersports Sportsman 500

Produktvarianten

Beschreibung

The 2009 Sportsman 500 EFI is a versatile All-Terrain Vehicle (ATV) designed for utility and recreational purposes. Renowned for its robust 499cc liquid-cooled engine, Independent Rear Suspension (IRS), and On-Demand All-Wheel Drive (AWD) system, this model offers reliable performance and excellent traction across varied terrain. Its strong towing and carrying capacities, coupled with ergonomic controls, make it a capable companion for off-road enthusiasts, hunters, farmers, and general riders seeking dependability and efficiency in the utility ATV segment. This comprehensive service, repair, and workshop manual provides in-depth information essential for maintaining and repairing the 2009 Sportsman 500 EFI. It covers all major systems, including engine service, fuel system (EFI), cooling, ignition, transmission (PVT), suspension, steering, braking, and electrical systems. With detailed procedures for routine maintenance, diagnostics, component disassembly and assembly, and troubleshooting, this manual serves as an indispensable resource for owners and technicians to ensure the optimal performance and longevity of the ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Variant Covered:

Sportsman 500 EFI

👋 Introduction

Market Position

Segment:

Utility ATV segment, known for versatility and reliability.

Target Audience:

Off-road enthusiasts, hunters, farmers, and recreational riders requiring dependable performance.

Competitive Analysis

Competitors:

Competed with models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Brute Force), and Suzuki (KingQuad) in its class.

Key Features

Powertrain:

Durable 499cc liquid-cooled SOHC engine, known for its strong mid-range torque.

Suspension:

Independent Rear Suspension (IRS) for improved ride comfort and traction over uneven terrain.

Drivetrain:

On-Demand All-Wheel Drive (AWD) system for excellent traction in challenging conditions.

Utility:

Significant towing and carrying capacity, front and rear racks.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive service, repair, and workshop information for the 2009 Polaris Sportsman 500 EFI ATV.

Page Count

Estimated Pages:

High (typical for detailed service manuals, e.g., 300-500+ pages)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Service:

Detailed diagnostics, disassembly, assembly, timing, and troubleshooting for the 499cc engine.

Fuel System:

EFI system components, fuel pump, injectors, throttle body, pressure testing, and troubleshooting.

Cooling System:

Radiator, fan, thermostat, coolant types, flushing, and leak detection.

Ignition System:

Ignition coils, spark plugs, CDI unit, timing checks, and diagnostic procedures.

Transmission Drivetrain:

PVT (Polaris Variable Transmission) operation, belt inspection/replacement, clutch service, gearbox, and final drive servicing.

Suspension Steering:

Front and rear suspension components, shock absorbers, A-arms, bushings, steering system, tie rods, and wheel alignment.

Braking System:

Hydraulic brake system, calipers, master cylinders, brake lines, fluid specifications, bleeding procedures, and pad/rotor replacement.

Electrical System:

Wiring diagrams, battery, charging system, starter, lighting, switches, fuses, relays, and diagnostic tests.

Chassis Frame:

Frame inspection, bodywork removal/installation, and general chassis maintenance.

Wheels Tires:

Tire specifications, inflation pressures, wheel mounting, and bolt patterns.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, chain/belt adjustment, and lubrication points.

Diagnostic Troubleshooting:

Step-by-step troubleshooting guides for common and complex issues.

Engine Overhaul:

Complete engine rebuilding procedures, including piston, ring, cylinder, and valve service.

Transmission Repair:

PVT belt replacement, clutch assembly service, and gearbox maintenance.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams and diagnostic tools.

Brake System Service:

Brake bleeding, caliper rebuilds, and fluid replacement.

Suspension Component Replacement:

Service and replacement of A-arms, ball joints, bushings, and shocks.

Component Disassembly Assembly:

Detailed instructions for taking apart and putting back together all major vehicle components.

Technical Depth

Depth:

Comprehensive from basic maintenance to advanced engine and drivetrain rebuilds.

Diagnostic Level:

Detailed diagnostic procedures for all major systems, including EFI and electrical.

Repair Scope:

Full repair capabilities for all mechanical and electrical components.

Illustrations:

Illustrated with clear, step-by-step instructions and diagrams.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF for quick information retrieval.

Print Quality

Quality:

High-resolution digital format, suitable for printing specific sections or the entire manual.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, SOHC

Displacement:

499cc

Bore X Stroke:

92 mm x 75.7 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 27-30 HP (at crankshaft, varies slightly by source)

Torque:

Approx. 29-30 lb-ft (at crankshaft, varies slightly by source)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 87 octane or higher recommended

Fluid Capacity

Engine Oil Capacity:

1.7 US qt (1.6 L) with filter change

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Full Synthetic (or equivalent SAE 5W-50 API SG, SL, SM)

Coolant Type:

Polaris Premium Antifreeze/Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)

🔧 Transmission

Standard

Transmission Type:

Polaris Variable Transmission (PVT) with Engine Braking

Gear Selection:

High (H), Low (L), Neutral (N), Reverse (R), Park (P)

Features

Drive System:

Shaft drive, On-Demand All-Wheel Drive (AWD)

Pvt Belt Part Number:

3211077 (verify for specific model revisions)

📐 Dimensions

Exterior

Length:

81 in (2057 mm)

Width:

46 in (1168 mm)

Height:

47 in (1194 mm)

Wheelbase:

50.5 in (1283 mm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Weights

Dry Weight:

663 lbs (301 kg)

Towing Capacity:

1500 lbs (680 kg)

Payload Capacity:

260 lbs (118 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to ANSI/SVIA standards for ATVs.

Active Features

Braking System:

Hydraulic disc brakes front and rear, with engine braking from PVT.

Lighting:

Dual 37.5W headlights, 8W taillight/stop light.

Passive Features

Chassis Design:

Strong steel frame providing a stable platform.

Operator Controls:

Ergonomically designed controls for ease of operation.

💡 Technology Features

Infotainment

Instrumentation:

Digital instrumentation with speedometer, odometer, trip meter, tachometer, fuel gauge, and AWD indicator.

Driver Assistance

Efi Management:

Electronic Fuel Injection (EFI) provides optimized fuel delivery for varying altitudes and temperatures, and smooth power delivery.

Connectivity

Diagnostic Ports:

Features diagnostic connectors for servicing EFI and other electronic systems (covered in manual).

🔧 Maintenance

Service Intervals

Initial Service:

First service typically recommended at 10 hours or 1 month (check manual).

Regular Oil Change:

Every 100 hours or 6 months (check manual for specific recommendations).

Pvt Belt Inspection:

Inspect every 12 months or 100 hours; replace as needed based on wear.

Air Filter Cleaning:

Check and clean every 25 hours or as needed based on operating conditions.

Spark Plug Replacement:

Recommended every 12 months or 200 hours (verify exact interval in manual).

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Gearcase Lubricant:

Polaris Synthetic Gearcase Lubricant or equivalent SAE 80W-90 GL-4.

Known Issues

Pvt Belt Wear:

As with most CVTs, belt wear is a common maintenance item and can lead to poor performance if not replaced.

Efi Component Cleaning:

Occasional cleaning of the throttle body and checking fuel injectors for optimal performance.

Suspension Bushings:

Over time and with heavy use, suspension bushings may require replacement to maintain steering precision and ride quality.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, a long-standing American manufacturer of powersports vehicles.

Model Evolution

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, capability, and innovation since its introduction.

2009 Updates:

The 2009 model benefited from refinements in the EFI system for improved throttle response and efficiency.

Production

Manufacturing Location:

Primarily manufactured in the United States by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

The Polaris Sportsman 500 line is generally well-regarded for its robust build and all-around capabilities in the utility ATV segment.