Target Audience:
Both DIY enthusiasts and professional mechanics working on 2009 Polaris Sportsman 500 ATVs.
Vehicle Segment:
Mid-size utility ATV segment, known for its balance of power, capability, and rider comfort.
Value Proposition:
Provides factory-level diagnostic and repair information, offering a cost-effective alternative to dealership service for maintaining and repairing the Sportsman 500.
Manual Benefits:
Instant download, comprehensive coverage, detailed diagrams, step-by-step instructions, cost savings on postage and packaging.
Covered Models:
2009 Polaris Sportsman 500 EFI, 2009 Polaris Sportsman 500 H.O., 2009 Polaris Sportsman X2 500 EFI, 2009 Polaris Sportsman Touring 500 EFI
Estimated Page Count:
Approximately 400-600 pages (typical for this level of detail)
Manual Type:
Factory Service Repair Workshop Manual
Major Systems:
Engine, Fuel Injection (EFI), Drivetrain (Clutch, Final Drive, Transmission), Suspension, Steering, Brakes, Electrical System, Bodywork
Specific Efi Systems:
Detailed information on fuel pump, injectors, throttle body, sensors (e.g., MAP, TPS, IAT), and ECM troubleshooting.
Body Steering Suspension:
Comprehensive coverage including steering linkage, tie rods, ball joints, shocks, A-arms, wheel bearings, and hub assemblies.
Electrical System:
Detailed troubleshooting for starting system, charging system, lighting, ignition, sensors, and EFI control unit.
Wiring Diagram:
Includes detailed, color-coded wiring diagrams essential for electrical diagnostics and repairs.
Repair Procedures:
Complete disassembly and reassembly, troubleshooting, component testing, adjustments, replacement procedures, overhaul instructions
Engine Rebuild:
Full engine disassembly, inspection, and reassembly procedures, including piston, connecting rod, crankshaft, and cylinder head work.
Transmission Overhaul:
Detailed steps for transmission disassembly, component replacement (gears, bearings, seals), and reassembly.
Clutch Maintenance:
Belt inspection, tension adjustment, and replacement procedures for both primary and secondary clutches. Component removal and installation.
Brake System Service:
Bleeding procedures, caliper inspection and rebuild, pad replacement, and rotor servicing.
Depth Of Information:
Comprehensive: From basic maintenance and routine checks to advanced diagnostics, complete engine and transmission rebuilds, and electrical system troubleshooting. Includes detailed specifications and tolerances.
Diagnostic Procedures:
Includes diagnostic trouble codes (DTCs) for EFI system faults and specific troubleshooting flowcharts for common issues.
Torque Specifications:
Includes precise torque values for all critical fasteners and components.
Special Tools:
Highlights any specialized tools required for specific procedures.
File Quality:
High-resolution PDFs with clear, legible text and detailed diagrams. Searchable text capability is implied for efficient navigation.
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Printability:
All pages are printable for convenient use in workshop environments.
Binding Type:
Digital (Instant Download PDF) - implies no physical binding.
Paper Type:
N/A (Digital format)
Software Requirements:
Requires Adobe PDF Reader and WinZip (or similar decompression utility).
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder engine.
Displacement:
499cc (for all 500 models listed)
Bore X Stroke:
Typically 93.0 mm x 71.9 mm
Compression Ratio:
Typically 10.0:1
Fuel Delivery:
Electronic Fuel Injection (EFI) for most models, potentially carbureted for some H.O. variants depending on specific sub-model.
Ignition System:
CDI with electronic advance
Throttle Control:
Handlebar-mounted throttle lever with cable actuation.
Oil Type:
API SG/SH/SJ rated 4-stroke engine oil, SAE 0W-40, 10W-40, or 20W-50 viscosity (refer to manual for specific recommendations based on temperature).
Coolant Type:
Ethylene glycol base antifreeze with corrosion inhibitors (typically 50/50 mix with distilled water).
Transmission Type:
Automatic (Polaris Variable Transmission - PVT) with High/Low range and Reverse.
Drive System:
Shaft drive, On-Demand AWD (All-Wheel Drive) or 2WD selectable.
Clutch System:
Primary and secondary clutches (CVT system).
Final Drive Ratio:
Service manual will provide specific gear ratios for front and rear differentials.
Length:
Approximately 83 inches (210.8 cm) for standard Sportsman 500 models. X2 and Touring models will vary.
Width:
Approximately 46 inches (116.8 cm)
Height:
Approximately 45 inches (114.3 cm)
Dry Weight:
Approximately 680-700 lbs (308-318 kg) depending on model variant.
Towing Capacity:
Typically 1,500 lbs (680 kg).
Wheelbase:
Approximately 50.5 inches (128.3 cm)
Ground Clearance:
Approximately 11.25 inches (28.6 cm)
Front Track Width:
Approximately 36 inches (91.4 cm)
Rear Track Width:
Approximately 37.5 inches (95.3 cm)
Front Rack Capacity:
Typically 100 lbs (45 kg)
Rear Rack Capacity:
Typically 200 lbs (90 kg)
Display Features:
Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, 2WD/AWD mode, and gear indicator (on applicable models).
Instrumentation Layout:
Clear and intuitive display for monitoring key vehicle parameters.
Traction Control:
N/A (Traction control systems were not standard on these models).
Charging System:
12V DC electrical system with charging stator and battery.
Oil Change Interval:
Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact specifications).
Air Filter Cleaning:
Inspect and clean every 50 hours or more frequently in dusty conditions. Replace as needed.
Spark Plug Replacement:
Typically every 1,000 hours or annually, depending on usage and plug condition. Consult manual for specific spark plug type and gap.
Engine Oil Capacity:
Approximately 2.4 US quarts (2.3 L) with filter change. Verify in manual.
Coolant Capacity:
Approximately 2.1 US quarts (2.0 L). Verify in manual.
Gearcase Oil Type:
Polaris HD Gearcase Lubricant or equivalent SAE 80W-90 hypoid gear oil.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, and potential for fuel pump issues (especially with ethanol fuels) are common areas to inspect.
Efi Component Care:
Proper fuel filtration and avoiding water contamination are crucial for EFI system longevity.
Suspension Wear:
Ball joints, tie rod ends, and control arm bushings are common wear items, especially under heavy use. Manual will detail inspection and replacement.
Polarismark:
Polaris Industries is a long-standing American manufacturer known for its innovation in off-road vehicles, snowmobiles, and powersports equipment.
Sportsman Series:
The Sportsman line has been a flagship offering for Polaris, consistently evolving to incorporate advancements in engine technology, suspension, and rider comfort. The 500cc engine has been a popular and reliable choice within the lineup.
