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Polaris Sportsman 500 2009 ATV Service Repair Workshop Manual

$16.99
$16.99
The 2009 Sportsman 500 is a robust All-Terrain Vehicle (ATV) designed for utility and recreational use. Engineered with a powerful 499cc liquid-cooled engine and a True On-Demand All-Wheel Drive system,...
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Type: Atv
Vendor:
Polaris
Sku: 91488
Tags: 2009 ATV Misc Polaris Powersports Sportsman 500
Polaris Sportsman 500 2009 ATV Service Repair Workshop Manual
The 2009 Sportsman 500 is a robust All-Terrain Vehicle (ATV) designed for utility and recreational use. Engineered with a powerful 499cc liquid-cooled engine and a True On-Demand All-Wheel Drive system, it offers exceptional capability across diverse terrains. Key features like the Independent Rear Suspension (IRS) enhance ride comfort and traction, while the durable Variable Transmission (PVT) ensures smooth power delivery. With a significant towing capacity and substantial rack storage, this ATV is built to handle demanding tasks and adventurous excursions, reflecting a long-standing reputation for innovation and reliability in the powersports industry. This comprehensive factory service manual provides detailed guidance for the maintenance, repair, and troubleshooting of your 2009 Sportsman 500 ATV. Covering all major systems from the engine and fuel delivery to the transmission, brakes, and electrical components, this manual includes step-by-step procedures, diagnostic charts, torque specifications, and clear illustrations. It is an essential resource for owners and technicians alike, offering the necessary information to ensure the vehicle's optimal performance, longevity, and safe operation, facilitating everything from routine servicing to complex overhauls.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 500
Year:
2009
Vehicle Type:
All-Terrain Vehicle (ATV)
Chassis Code:
A09CE50AO (US/Canada/Mexico)
👋 Introduction
Market Position
Category:
Utility ATV
Segment:
Mid-size utility ATV, known for its versatility and capability
Competitive Analysis
Competitors:
Honda FourTrax Foreman, Yamaha Grizzly 550, Kawasaki Brute Force 650/750, Can-Am Outlander 500/650
Key Features
Powertrain:
Powerful 499cc liquid-cooled, 4-stroke engine
Drivetrain:
True On-Demand All-Wheel Drive (AWD) system
Suspension:
Independent Rear Suspension (IRS) for a smoother ride and better traction
Transmission:
Durable Polaris Variable Transmission (PVT) with engine braking
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Specific Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul, Adjustments
Page Count
Estimated Pages:
200-300 (typical for this model and manual type)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, inspection, assembly, timing, cooling system, lubrication system
Fuel System:
Carburetor (Mikuni BSR42) specifications, adjustment, cleaning, fuel pump, fuel tank, lines
Ignition System:
CDI unit, ignition coil, spark plug, wiring diagrams
Transmission Drivetrain:
PVT (Polaris Variable Transmission - primary and secondary clutches), belt inspection/replacement, gearbox, driveshafts, differentials, AWD system
Brakes:
Hydraulic disc brakes (front and rear), master cylinders, calipers, brake pads, brake lines, bleeding procedure
Suspension:
Front and rear suspension (dual A-arm front, independent rear suspension - IRS), shock absorbers, springs, bushings, alignment
Steering:
Handlebars, steering shaft, tie rods, steering linkage, steering assist (if equipped with EPS)
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), switches, wiring harness, fuses, electrical troubleshooting diagrams
Frame Chassis:
Frame inspection, body panel removal/installation, fenders, racks
Cooling System:
Radiator, fan, coolant, thermostat, hoses
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug maintenance, air filter cleaning/replacement, lubrication points, chain/belt adjustment (if applicable)
Troubleshooting:
Diagnostic charts for common problems (engine starting issues, running problems, electrical faults, clutch issues)
Repair:
Component replacement (e.g., carburetor rebuild, starter motor replacement, brake caliper overhaul)
Rebuild:
Engine disassembly and reassembly, transmission servicing
Adjustments:
Carburetor idle speed and mixture, clutch engagement, valve clearance (if applicable, though this is typically solid lifters on this model)
Torque Specifications:
Crucial torque values for engine, chassis, and suspension fasteners
Technical Depth
Depth:
Comprehensive, covering routine maintenance to complete engine and drivetrain overhauls
Diagnostics:
Detailed troubleshooting guides and diagnostic flowcharts
Wiring Diagrams:
Complete electrical system wiring schematics
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Typically text-searchable PDF for easy information retrieval
Print Quality
Quality:
High-resolution digital scans/originals ensuring clarity of text and illustrations
Illustrations:
Includes clear, step-by-step illustrations and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, Single Cylinder, SOHC
Displacement:
499 cc
Cooling System:
Liquid-Cooled
Bore X Stroke:
92 mm x 77 mm
Compression Ratio:
10.5:1
Performance
Horsepower Est:
~32 HP @ 6500 RPM (Estimated)
Torque Est:
~30 lb-ft @ 5000 RPM (Estimated)
Fuel System
Fuel Delivery:
Carburetor (Mikuni BSR42)
Fuel Type:
Unleaded Gasoline
Fuel Capacity:
4.0 US gal (15.1 L) with 0.8 US gal (3.0 L) reserve
🔧 Transmission
Standard
Type:
Polaris Variable Transmission (PVT) with all-wheel engine braking
Gears:
High, Low, Neutral, Reverse, Park
Features
Clutch Type:
Centrifugal Clutch (Primary), Drive Clutch (Secondary)
Drive System:
Shaft Drive
AWD System:
True On-Demand AWD
📐 Dimensions
Exterior
Length:
81 in (205.7 cm)
Width:
46 in (116.8 cm)
Height:
47 in (119.4 cm)
Wheelbase:
50.25 in (127.6 cm)
Ground Clearance:
11.5 in (29.2 cm)
Cargo
Front Rack Capacity:
100 lbs (45.4 kg)
Rear Rack Capacity:
200 lbs (90.7 kg)
Weights
Dry Weight:
650 lbs (295 kg)
Towing Capacity:
1,500 lbs (680.4 kg)
Gvw:
1,200 lbs (544 kg)
🛡️ Safety Features
Ratings
Safety Features:
Standard safety features typical for ATVs of this era, including handguards, throttle limiter, brake lever guards
Active Features
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Parking Brake:
Hand-actuated parking brake
Passive Features
Lighting:
Dual 35W headlights, 8W taillight/stop light
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic utility focus)
Driver Assistance
Electronic Features:
True On-Demand AWD, Engine Braking
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or annually (whichever comes first)
Air Filter Cleaning:
Every 25 hours or more frequently in dusty conditions
Spark Plug Inspection:
Every 100 hours
Clutch Belt Inspection:
Every 50 hours, replace as needed (typically every 1-2 years or per wear indicators)
Transmission Oil Change:
Every 100 hours or annually
Fluid Specifications
Engine Oil Type:
SAE 20W-50 Synthetic or Polaris PS-4 Full Synthetic 4-stroke engine oil
Engine Oil Capacity:
2.8 US qt (2.6 L) with filter change
Transmission Fluid Type:
Polaris Angle Drive Fluid (Syn) or SAE 80W-90 Hypoid Gear Oil
Transmission Fluid Capacity:
Approximately 18 oz (0.53 L) for rear differential; front differential is shared with AWD system and has its own fill.
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Known Issues
Common Problems:
CV joint boot wear, PVT belt wear/slippage, carburetor gumming (if fuel sits), potential starter solenoid issues, water pump seal leaks
Maintenance Tips:
Regularly inspect CV boots for tears; keep fuel tank full during storage; use a fuel stabilizer; promptly address any coolant leaks.
📚 Vehicle History
Brand Heritage
Manufacturer:
Polaris Industries Inc.
Founding:
Founded in 1954, Polaris is a pioneer in the powersports industry.
Model Evolution
Sportsman Line:
The Sportsman line, introduced in 1993, is Polaris's flagship utility ATV platform, known for its comfort, capability, and innovation.
500 Engine:
The 500cc engine has been a workhorse for Polaris for many years, evolving through various iterations.
Production
Production Years:
The Sportsman 500 model has been in production for many years, with the 2009 model representing a mature and refined iteration of the platform.
🏆 Awards & Recognition
Recognitions
Atv Awards:
While specific awards for the 2009 model aren't readily cited, the Polaris Sportsman line has consistently been recognized for its utility, comfort, and off-road capability throughout its production years.
Ratings
Consumer Ratings:
Generally well-received by consumers for its robust performance and versatility in various terrains.
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