🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 500

Year:

2009

Product Type:

Service Repair Workshop Manual

👋 Introduction

Atv Segment:

The 2009 Polaris Sportsman 500 lineup represents a robust and versatile option in the mid-size utility ATV market, known for its capability and comfort.

Competitors Of The Era:

Competed with models like the Can-Am Outlander 500, Yamaha Grizzly 550, and Honda Foreman 500, offering a strong blend of power, handling, and features.

Vehicle Selling Points:

The Sportsman 500 models are recognized for their independent suspension, powerful 499cc engine, Polaris's On-Demand All-Wheel Drive system, and comfortable rider ergonomics, making them suitable for a wide range of off-road tasks and recreational riding.

Manual Benefit:

This manual empowers owners and technicians to perform maintenance, diagnostics, and repairs confidently, saving time and money while ensuring the longevity and optimal performance of the ATV.

📋 Manual Details

Covered Models:

2009 Polaris Sportsman 500 EFI, 2009 Polaris Sportsman 500 EFI Tractor, 2009 Polaris Sportsman 500 HO, 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

Estimated Page Count:

Estimated 500+ pages (typical for this type of comprehensive manual)

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

File Format:

PDF

Compatibility:

All Versions of Windows & Mac

Software Requirement:

Adobe PDF Reader

📖 Manual Coverage

Major Systems:

General Information, Maintenance, Engine, Fuel Injection, Body, Steering, Suspension, Clutch System, Final Drive, Transmission, Brakes, Electrical Systems, Wiring Diagrams

Repair And Maintenance Procedures:

Routine maintenance, troubleshooting, diagnostics, component repair, assembly, disassembly, adjustments, specifications, torque values, wiring schematics, fluid types and capacities.

Depth Of Coverage:

Comprehensive. Covers everything from basic pre-ride checks and fluid changes to detailed engine rebuilds, electrical system diagnostics, and suspension tuning.

📊 Manual Specifications

File Characteristics:

Digital PDF format, allowing for easy searching and navigation. All pages are printable for on-the-go reference.

Print Quality:

High-quality diagrams and instructions, ensuring clarity for repair procedures.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, SOHC, single-cylinder

Engine Displacement:

499cc

Bore X Stroke:

92mm x 75mm (approximate, to be confirmed in manual)

Horsepower:

Approx. 31-32 HP (varies slightly by specific model/tuning, detailed specs in manual)

Fuel Delivery:

Electronic Fuel Injection (EFI) for 500 EFI models, Carbureted for HO models.

Fuel Type:

Unleaded gasoline, minimum 87 octane

Cooling Method:

Liquid-cooled

Ignition Type:

Electronic Ignition (CDI)

🔧 Transmission

Transmission Type:

Automatic PVT (Polaris Variable Transmission)

Drive Modes:

High, Low, Neutral, Reverse, Park

Drive System:

On-Demand All-Wheel Drive (AWD) / 2WD selectable

Final Drive:

Sealed O-ring chain

📐 Dimensions

Length:

Approx. 81 inches (205.7 cm) for standard models, longer for Touring

Width:

Approx. 46 inches (116.8 cm)

Height:

Approx. 45 inches (114.3 cm)

Dry Weight:

Approx. 650-700 lbs (295-318 kg), varies by model configuration

Ground Clearance:

Approx. 11.25 inches (28.6 cm)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Braking System:

Hydraulic disc brakes on all wheels. Front: Dual hydraulic discs with dual-piston calipers. Rear: Single hydraulic disc with dual-piston caliper.

Lighting:

Dual 35W headlights, dual brakelights/taillights

Handlebars:

Rolled and lockable design for stability and safety.

💡 Technology Features

Instrument Panel:

Digital odometer, speedometer, tachometer, fuel gauge, engine hour meter, clock, AWD/2WD indicator, gear indicator.

Braking Enhancements:

Engine braking provided by the PVT system, assisting on descents.

Diagnostic Ports:

Diagnostic port for reading fault codes (EFI models), essential for troubleshooting.

🔧 Maintenance

Oil Change Interval:

Every 100 hours or 12 months (refer to manual for precise intervals and conditions).

Spark Plug Replacement:

Recommended at 100-hour intervals or as needed based on inspection.

Air Filter Cleaning Replacement:

Check and clean at 50-hour intervals, replace as needed.

Engine Oil Type:

Polaris PS-4 10W-40 Synthetic Engine Oil (or equivalent API SG rated)

Engine Oil Capacity:

Approx. 2.2 quarts (2.1 liters) (refer to manual for exact capacity with filter change)

Transmission Drive Fluid:

Polaris AGL Premium Synthetic Gearcase Lubricant (or equivalent API GL-5)

Transmission Drive Fluid Capacity:

Approx. 10 oz (0.3 liters) (refer to manual)

Coolant Type:

Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., 50/50 mix with distilled water)

Common Wear Items:

Drive belts (PVT), suspension bushings, wheel bearings, and brake pads are common wear items that require regular inspection and replacement. Clutch maintenance (cleaning, belt inspection) is crucial for optimal performance.

Efi System Considerations:

EFI systems can be sensitive to fuel quality and cleanliness. Regular maintenance of the fuel filter and injectors is recommended. Troubleshooting EFI codes is a common task covered in this manual.

Lubrication Points:

Crucial lubrication points include suspension pivots, steering components, and drive shafts, all detailed in the manual's maintenance section.

📚 Vehicle History

Polaris Atv Legacy:

Polaris has a long-standing history in the powersports industry, particularly known for its innovation and development of ATVs, often credited with popularizing the three-wheel ATV before transitioning to the four-wheel market.

Sportsman Lineup History:

The Sportsman line has been a flagship for Polaris since its introduction, continuously evolving with advancements in engine technology, suspension, and rider comfort. The 500cc engine has been a mainstay, offering a balance of power and usability.

Manufacturing Location:

Polaris ATVs are primarily manufactured in the United States.

🏆 Awards & Recognition

Industry Reputation:

Polaris Sportsman series consistently receives positive reviews for its ruggedness, comfort, and capability in the utility ATV segment.

Owner Satisfaction:

The 2009 Sportsman 500 is generally regarded as a reliable and capable machine by its owners, with satisfaction often tied to proper maintenance.