Vehicle Segment:
Utility/Recreational ATV
Key Competitors:
Can-Am Outlander, Yamaha Grizzly, Honda Foreman, Arctic Cat TRV.
Touring Capability:
Designed for longer rides and passenger comfort with a longer wheelbase and dedicated rear seat.
Powertrain Offering:
Features a powerful 500cc class engine, known for its torque and reliability in this segment.
Engine Configuration:
Single-cylinder, liquid-cooled, SOHC, 4-stroke engine.
Suspension Type:
Independent Front Suspension (IFS) and Independent Rear Suspension (IRS) for enhanced ride comfort and handling.
Drivetrain Features:
On-Demand All-Wheel Drive (AWD) system for superior traction.
Primary Coverage:
All mechanical and electrical systems for the 2009 Polaris Sportsman 500 Touring.
Secondary Coverage:
Maintenance schedules, diagnostic procedures, component removal and installation, torque specifications, wiring diagrams, and specifications.
Estimated Page Count:
500+
Manual Type:
Workshop Service Manual
Intended Audience:
Professional Technicians and Advanced DIY Enthusiasts
Engine Systems:
Engine overhaul, fuel system (carburetor/injection, fuel pump, lines), ignition system, cooling system, lubrication system, exhaust system.
Drivetrain Systems:
Transmission (PVT), clutch system (primary and secondary), final drive, AWD system, drive shafts, differentials.
Chassis Systems:
Frame, suspension (front and rear), steering, braking system (hydraulic, calipers, master cylinder, lines), wheels and tires.
Electrical Systems:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, switches, sensors, wiring diagrams.
Bodywork And Accessories:
Body panels, seating, racks, cargo box, lighting covers, accessory installation notes.
Maintenance Procedures:
Routine checks, oil changes, filter replacements, spark plug service, valve adjustments, coolant flushes, belt inspections/replacement.
Repair Procedures:
Engine rebuild, transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component diagnosis and replacement.
Troubleshooting Procedures:
Diagnostic flowcharts for common issues (no start, poor performance, electrical faults), symptom-based troubleshooting.
Diagnostic Procedures:
Step-by-step diagnostic guides for specific systems, including checks for electrical continuity, fuel pressure, and compression.
Depth Of Information:
Comprehensive, covering complete disassembly, overhaul, and reassembly of major components.
Diagnostic Tools Required:
Standard mechanic's tools, specialized Polaris tools (where applicable), multimeter, torque wrench, diagnostic software/scanner (if applicable).
Engine Displacement:
499cc
Engine Type:
4-stroke, Single-Cylinder, SOHC
Bore X Stroke:
92 mm x 75.5 mm
Cooling System:
Liquid-Cooled
Horsepower Estimated:
32 hp @ 6500 rpm (approximate)
Torque Estimated:
30 lb-ft @ 5000 rpm (approximate)
Fuel Delivery:
Carbureted (likely Mikuni BSR40 or similar)
Fuel Type:
Unleaded Gasoline, Octane Rating 87 minimum
Engine Oil Type:
SAE 10W-40, API SG or higher (check manual for exact spec).
Coolant Type:
Ethylene Glycol based antifreeze with corrosion inhibitors (50/50 mix with distilled water).
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Drive Modes:
High, Low, Neutral, Reverse, Park
Clutch System:
Dual clutch, automatic centrifugal clutch and drive clutch.
Gear Reduction:
Integrated into transmission and final drive units.
Transmission Fluid Type:
SAE 10W-40, API SG or higher (often shared with engine oil, but consult manual for specifics).
Atv Safety Standards:
Designed to meet ANSI and industry standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear, foot-operated rear brake, hand-operated front brake.
Engine Braking:
Provided by the PVT system in low gear.
Parking Brake:
Integrated into the transmission/rear brake caliper.
Roll Over Protection:
No roll-over protection structure (ROPS) as standard. Helmets and safety gear are mandatory.
Passenger Seating:
Includes integrated passenger seat with backrest and handholds.
Lighting:
Dual 50W headlights, single 37.5W tail/brake light.
Instrumentation:
Digital gauge cluster displaying speedometer, odometer, trip meter, RPM indicator, fuel gauge, clock, and gear indicator.
AWD System Engagement:
On-Demand AWD system automatically engages the front wheels when rear wheels lose traction.
Engine Management:
Basic electronic ignition and fuel delivery management.
Accessory Ports:
Typically equipped with DC power outlets for charging accessories.
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (refer to manual for specific conditions).
Air Filter Cleaning Inspection:
Every 25 hours or annually. Replace if damaged.
Spark Plug Inspection:
Every 100 hours or annually.
Transmission Fluid Check:
Every 100 hours or annually.
Coolant Flush:
Every 2 years or 200 hours.
Engine Oil Capacity:
Approx. 2.2 L (2.3 US qt) with filter change. Verify in manual.
Coolant Capacity:
Approx. 2.0 L (2.1 US qt). Verify in manual.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
Drive belts (PVT), wheel bearings, tie rod ends, ball joints, brake pads, suspension bushings.
Potential Electrical Concerns:
Stator/regulator-rectifier failures, corrosion in connectors, battery charging issues can be reported in this era of ATVs. The manual will detail diagnostic steps.
Engine Performance Issues:
Carburetor tuning, fuel delivery problems, and valve adjustments are common maintenance points for ensuring optimal engine performance.
Polariss Atv History:
Polaris has a long history in ATV manufacturing, starting with the Polaris ATCs and evolving into the Sportsman line, a market leader in utility and recreational ATVs.
Sportsman Line Evolution:
The Sportsman line has been a cornerstone for Polaris, continuously updated with engine advancements, suspension improvements, and chassis designs. The Touring models were introduced to cater to riders seeking extended comfort and passenger capability.
500 Engine Legacy:
The 500cc engine has been a staple in Polaris ATVs for many years, known for its robust design and reliable performance in a variety of applications.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
