2009 Polaris Scramber 500 ATV Workshop Service Repair Manual

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Tipo: Atv

Proveedor:

SKU: 56800

Etiquetas: 2009 ATV Polaris Powersports Scramber 500 Sportsman Series

Variantes de producto

Descripción

The 2009 Scrambler 500 is a capable All-Terrain Vehicle (ATV) designed for recreational riders and trail riding enthusiasts. This sport ATV, powered by a 499cc single-cylinder, liquid-cooled engine, features a smooth automatic Continuously Variable Transmission (CVT) with reverse and a shaft-driven rear-wheel-drive system. Its independent front suspension and swingarm rear suspension contribute to its agile handling and comfort over varied terrain. The manufacturer engineered the Scrambler 500 for reliability and performance in moderate off-road conditions. This comprehensive Workshop Service Repair Manual provides essential information for the maintenance and repair of your 2009 Scrambler 500. It covers a wide range of systems, including engine overhaul, fuel and cooling systems, transmission, suspension, steering, braking, and electrical components. The manual offers detailed step-by-step repair instructions, preventative maintenance schedules, troubleshooting guides, and critical torque specifications. It is designed to assist owners, mechanics, and technicians in keeping the ATV in optimal working condition, ensuring its longevity and performance.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Scrambler 500

Year:

Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Category:

Sport ATV

Target Audience:

Recreational riders, trail riding, moderate off-road use

Competitive Analysis

Competitors:

Yamaha Warrior 350, Honda Sportrax 400 (historically), Suzuki LT-Z400

Key Features

Engine Configuration:

Single-cylinder, 4-stroke, liquid-cooled

Drive System:

Shaft Drive (typically)

Transmission:

Automatic (CVT) with Reverse

Suspension:

Independent front suspension, Swingarm rear suspension

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

Page Count:

Estimated 300-500 pages (typical for this model and type of manual)

Compatibility:

Windows and Mac OS

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel pump, fuel tank, and lines

Cooling System:

Radiator, fan, thermostat, coolant circulation

Exhaust System:

Muffler, exhaust pipe, heat shields

Transmission And Drivetrain:

Gearbox service, clutch operation, drive shafts, differential (if applicable)

Suspension System:

Front and rear suspension components, shocks, springs, A-arms

Steering System:

Handlebar assembly, steering shaft, tie rods, steering linkage

Braking System:

Hydraulic brake system, calipers, master cylinders, brake lines, pads, rotors

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter motor

Frame And Bodywork:

Chassis inspection, body panel removal and installation, seat, fenders

Wheels And Tires:

Tire pressure, rim specifications, wheel bearing maintenance

Procedures Included

Preventative Maintenance:

Scheduled maintenance, lubrication points, filter replacement

Troubleshooting Guides:

Diagnostic procedures for common problems and symptoms

Repair Instructions:

Step-by-step instructions for component repair and replacement

Disassembly Reassembly:

Detailed procedures for complete machine disassembly and reassembly

Torque Specifications:

Critical torque values for fasteners and bolts

Special Tool Requirements:

Identification of specialized tools needed for specific repairs

Technical Depth

Depth Level:

Comprehensive: Suitable for both DIY enthusiasts and experienced mechanics

Detail Level:

Factory-level detail with hundreds of photos and illustrations

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchable:

Likely, as it is a digital PDF

Printable:

Yes, all pages are printable

Resolution Quality:

High-resolution, factory-standard images and text

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Liquid-Cooled, SOHC

Displacement:

499cc (actual displacement may vary slightly based on exact variant)

Bore X Stroke:

Refer to manual for exact specifications

Compression Ratio:

Refer to manual for exact specifications

Performance

Horsepower:

Approximately 30-35 HP (estimated)

Torque:

Refer to manual for specific torque curves

Fuel System

Fuel Delivery:

Carburetor (e.g., Keihin CV carburetor)

Fuel Type:

Unleaded Gasoline (minimum octane rating to be specified in manual)

Fuel Tank Capacity:

Approximately 3.2 - 4.0 gallons (verify with manual)

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT) with High/Low range and Reverse

Optional

Optional Transmission:

N/A (CVT was standard for this model)

Features

Drive Modes:

2WD (Rear Wheel Drive)

Gear Reduction:

Integrated within the CVT and final drive

Transmission Fluid Type:

Specific CVT fluid (refer to manual for exact specification, e.g., Polaris AGL or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 73 inches

Width:

Approx. 46 inches

Height:

Approx. 43 inches

Weights

Dry Weight:

Approx. 500-550 lbs (verify with manual)

Ground Clearance:

Approx. 8-10 inches (verify with manual)

Cargo

Rack Capacity Front:

Refer to manual (typically 50-75 lbs)

Rack Capacity Rear:

Refer to manual (typically 100-150 lbs)

🛡️ Safety Features

Ratings

Rollover Protection:

ATVs are not designed for rollover protection; rider caution required

Active Features

Braking System Type:

Hydraulic Disc Brakes (front and rear)

Passive Features

Lighting:

Dual headlights, taillight/brake light

Operator Safety:

Emphasis on proper riding gear and awareness of terrain

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic ATV functionality, no integrated infotainment)

Driver Assistance

Driver Assistance Features:

N/A (No electronic driver aids like ABS or traction control)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 50-100 operating hours or annually. Refer to manual for exact interval and oil type.

Air Filter Cleaning:

Regular inspection and cleaning, especially in dusty conditions. Replacement as needed.

Spark Plug Check:

Inspect and gap every 50-100 operating hours. Replacement recommended based on condition.

Valve Lash Adjustment:

Recommended at specific intervals (e.g., 100-200 hours) or if performance issues arise.

Fluid Specifications

Engine Oil Type:

Synthetic or high-quality ATV specific 4-stroke oil (e.g., SAE 10W-40, API SG or higher). Refer to manual for exact grade and quantity.

Engine Oil Capacity:

Refer to manual, typically around 2-3 quarts (with filter change).

Coolant Type:

Ethylene glycol-based antifreeze mixture (50/50 with distilled water). Refer to manual for specific type and capacity.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Refer to manual for exact specification.

Transmission Fluid Type:

Polaris AGL Gearcase Lubricant or equivalent SAE 80W-90 gear oil. Refer to manual for exact specification.

Known Issues

Common Wear Items:

Brake pads, wheel bearings, tie rod ends, drive belts (CVT), ball joints.

Carburetor Tuning:

Can require periodic adjustments due to altitude or fuel changes.

Electrical Connections:

Corrosion or loose connections can lead to intermittent electrical issues. Regular inspection is advised.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, Inc. - established in 1954, known for snowmobiles, ATVs, and UTVs.

Model Evolution

Scrambler Lineage:

The Scrambler line has been a staple in Polaris's ATV lineup, known for its sport-oriented design and capability.

2009 Updates:

While specific major revisions for 2009 are not detailed in the product description, model year updates typically involve minor cosmetic changes, decal packages, or slight refinements in tuning.

Production

Manufacturing Location:

Primarily manufactured by Polaris in the USA.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for the 2009 Scrambler 500 are not readily available, but Polaris ATVs generally receive positive reviews for performance and reliability in their class.

Ratings

Owner Satisfaction:

Generally positive, particularly for its robust engine and handling capabilities.