2009 Polaris Sportsman 500 ATV Workshop Service Repair Manual Download PDF

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) Codes Engine Code General: 500cc 👋 Introduction Market Position Positioning: The 2009 Polaris Sportsman...

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Tipo: Atv

Proveedor:

SKU: 38661

Etiquetas: 2009 ATV Polaris Powersports Sportsman 500 Sportsman Series

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500

Year:

Vehicle Type:

ATV (All-Terrain Vehicle)

Codes

Engine Code General:

500cc

👋 Introduction

Market Position

Positioning:

The 2009 Polaris Sportsman 500 series represented Polaris's robust offering in the mid-size utility ATV segment, known for its versatility and off-road capability.

Competitive Analysis

Competitors:

Competed with models from brands such as Can-Am (Outlander 400), Yamaha (Grizzly 450), Honda (FourTrax Foreman 4x4), and Kawasaki (Brute Force 300/400).

Key Features

Features Of Vehicle:

• 500cc engine for ample power

• Independent Rear Suspension (IRS) for superior ride comfort and handling

• On-Demand True All-Wheel Drive (AWD) for excellent traction

• Locking front differential

• Versatile platform catering to utility, trail riding, and farm work

• EFI (Electronic Fuel Injection) for improved throttle response, cold starts, and fuel efficiency

📋 Manual Details

Coverage Areas

Models Covered:

• 2009 Polaris Sportsman 500 H.O

• 2009 Polaris Sportsman 500 EFI

• 2009 Polaris Sportsman 500 EFI Tractor

• 2009 Polaris Sportsman Touring 500 EFI

• 2009 Polaris Sportsman Touring 500 EFI Quadricycle

• 2009 Polaris Sportsman X2 500 EFI

• 2009 Polaris Sportsman X2 500 EFI Quadricycle

Page Count

Page Count Estimated:

Detailed page count not specified, but implies comprehensive coverage.

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Systems:

• General Information

• Maintenance

• Engine

• Fuel Injection System

• Body

• Steering

• Suspension

• Clutch System

• Final Drive

• Transmission

• Brakes

• Electrical System

• Wiring Diagrams

• Specific models (X2/Touring Quadricycle variations)

Procedures Included

Procedures:

• Servicing procedures

• Repair procedures

• Troubleshooting guidance

• Component inspection and testing

• Disassembly and assembly instructions

• Adjustment procedures

Technical Depth

Depth:

Comprehensive, suitable for DIY enthusiasts and professional mechanics alike.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High quality, printable pages with clear diagrams.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download, printable)

Compatibility

Compatibility:

All Versions of Windows & Mac

Requirements

Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Liquid-Cooled, Single Cylinder

Displacement:

499cc

Bore X Stroke:

92mm x 75.5mm (estimated)

Valvetrain:

SOHC, 4 valves per cylinder

Performance

Horsepower Estimated:

Approximately 30-35 HP (Varies slightly by specific model/tuning)

Torque Estimated:

Approximately 29-32 lb-ft (Varies slightly by specific model/tuning)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Fuel Capacity:

3.25 gal (12.3 L) (typical)

Lubrication

Oil Type:

SAE 5W-50 Synthetic (recommended by Polaris for this era, verify in manual for exact spec)

Oil Capacity:

Approx. 2.0 qts (1.9 L) (with filter change, verify in manual)

Cooling System

Cooling Method:

Liquid-Cooled

Coolant Type:

Ethylene Glycol based antifreeze (e.g., Polaris PS-4 Extreme, or equivalent)

🔧 Transmission

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission)

Drive System:

Shaft Drive

Drive Modes:

2WD / AWD (On-Demand True All-Wheel Drive with automatic engagement)

Gear Selection:

High, Low, Neutral, Reverse, Park

Features

Clutch System:

Primary and Secondary Clutch System (often referred to as Arctic Cat's P85/P90 or similar Polaris designs for this era)

Final Drive Fluid:

Polaris AGL Plus Synthetic Gearcase Lubricant (or equivalent API GL-5, SAE 80W-90 gear oil)

📐 Dimensions

Exterior

Length Approx:

83 in. (210.8 cm) - Varies slightly by model

Width Approx:

46 in. (116.8 cm) - Varies slightly by model

Height Approx:

47 in. (119.4 cm) - Varies slightly by model

Weights

Dry Weight Approx:

660 lbs (299 kg) - Varies slightly by model

Ground Clearance Approx:

11.25 in. (28.6 cm)

Cargo

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

Towing

Towing Capacity:

1500 lbs (680 kg)

Wheels Tires

Front Tire Size:

25x8-12 (or 26x8-12 for some models)

Rear Tire Size:

25x10-12 (or 26x10-12 for some models)

Wheelbase Approx:

50.5 in. (128.3 cm) - Varies slightly by model

🛡️ Safety Features

Ratings

Safety Ratings:

ATVs are not typically subjected to the same formal crash testing ratings as passenger vehicles. Safety depends heavily on rider skill, adherence to trail etiquette, and proper protective gear.

Active Features

Active Safety Features:

• On-Demand True AWD for enhanced traction

• Locking front differential for extreme conditions

• Engine braking (via PVT system)

Passive Features

Passive Safety Features:

• Rollover Protection (ROPS - Roll Over Protective Structure) not standard on most ATVs of this era, but aftermarket options may exist.

• Integrated fenders and bodywork offer some protection.

💡 Technology Features

Infotainment

Infotainment Features:

Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, engine hour meter, AWD indicator. No advanced infotainment systems typical of modern vehicles.

Driver Assistance

Driver Assistance Features:

Primarily mechanical systems for traction control (AWD, locking diff). No electronic driver assistance features like ABS or traction control in the automotive sense.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 100 hours or 6 months, whichever comes first (verify in manual).

Air Filter Cleaning:

Inspect every 50 hours or 3 months, clean or replace as needed.

Spark Plug Replacement:

Typically every 100 hours or annually.

Clutch Inspection:

Inspect sheaves and belt for wear every 100 hours or annually.

Transmission Fluid Change:

Typically every 200 hours or 12 months (verify in manual).

Fluid Specifications

Engine Oil Spec:

SAE 5W-50 Synthetic (recommended, refer to manual for specific Polaris part number or SAE grade)

Coolant Spec:

Ethylene Glycol based antifreeze (e.g., Polaris PS-4 Extreme or equivalent)

Brake Fluid Spec:

DOT 3 or DOT 4 Hydraulic Brake Fluid (verify in manual)

Known Issues

Common Problems:

• Drive belt wear/failure (common on all CVT systems if abused or worn)

• Water pump seal leaks (potential issue with age/usage)

• Starter solenoid issues

• Fuel pump relay failures (on EFI models)

• Rear differential bushings/bearings wear (especially with heavy use or improper maintenance)

📚 Vehicle History

Brand Heritage

Polariss Heritage:

Polaris Industries, founded in 1954, is a U.S.-based manufacturer renowned for its snowmobiles, ATVs, UTVs, and motorcycles. They have a long history of innovation in the powersports industry.

Model Evolution

Sportsman Evolution:

The Sportsman line has been a cornerstone of Polaris's ATV business, evolving significantly over the years. The 500cc engine has been a popular choice, offering a balance of power and usability across various models and years.

Production

Production Location:

Polaris ATVs are primarily manufactured in the United States (e.g., Roseau, Minnesota; Spirit Lake, Iowa).

🏆 Awards & Recognition

Recognitions

Awards And Recognition:

Polaris Sportsman models consistently received positive reviews and awards from powersports publications for their performance, comfort, and utility in their respective model years. Specific awards for the 2009 500 model may vary but it was generally well-regarded in its class.