🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 500

Year:

2009

Product Type:

Service Repair Manual

Format:

Digital Download (PDF)

Covered Generations:

Specific to 2009 model year variants

👋 Introduction

Segment:

Mid-size to Large Bore ATV Segment

Competitors:

Polaris Sportsman series competes with models from Arctic Cat (e.g., 500 TRV), Can-Am (e.g., Outlander 500), Honda (e.g., Foreman 500), Kawasaki (e.g., Brute Force 500), Suzuki (e.g., KingQuad 500), Yamaha (e.g., Grizzly 550)

Model Focus:

The 2009 Sportsman 500 range represents a robust and versatile platform for utility and recreational off-roading, known for its independent rear suspension and powerful engine.

Versatility:

The Sportsman 500 platform is renowned for its versatility, capable of handling trail riding, utility tasks, and off-road exploration.

Benefit To Owner:

Essential resource for owners to perform DIY maintenance, understand system operations, and execute repairs accurately, saving time and money on professional service.

📋 Manual Details

Models Covered:

Total Pages:

386

Type:

Comprehensive Service and Repair Manual

Language:

English

File Format:

PDF

Compatibility:

All Versions of Windows, Mac, and Linux

Delivery Method:

Instant Download

Shipping:

No Shipping Cost

Required Software:

Adobe PDF Reader, Winzip

📖 Manual Coverage

Major Systems:

Specific Models Coverage:

Includes dedicated sections for 500 EFI X2 and Touring Quadricycle variants

Wire Diagrams:

Includes detailed wire diagrams for electrical troubleshooting and repairs.

Maintenance Operations:

Detailed procedures for all maintenance tasks

Component Identification:

Component identification and location for all major parts

Unit Repair:

Step-by-step unit repair procedures

Troubleshooting:

Implied through detailed repair procedures and component diagnostics

Engine Overhaul:

Detailed procedures for engine disassembly, inspection, repair, and reassembly.

Fuel System Service:

Procedures for fuel injection system diagnosis, cleaning, and component replacement.

Suspension Geometry:

Information on steering and suspension component inspection, adjustment, and replacement.

Clutch Maintenance:

Service and replacement procedures for the Polaris Variable Transmission (PVT) belt and clutch components.

Final Drive Repair:

Maintenance and repair for the transmission, differential, and driveshafts.

Brake System Service:

Detailed procedures for hydraulic brake system maintenance, bleeding, and component replacement.

Electrical Diagnostics:

Comprehensive diagnostic procedures for all electrical systems, including lighting, ignition, and starting.

Depth Of Information:

Comprehensive, covering maintenance, repair, and service specifications

Diagnostic Procedures:

Includes electrical system diagnostics and wire diagrams for troubleshooting

Technical Specifications:

Service specifications for all covered components and systems

📊 Manual Specifications

PDF Quality:

High-quality PDF, suitable for printing

Searchability:

Likely searchable PDF text, enhancing ease of finding information.

Printability:

All pages are printable

Binding:

Not Applicable (Digital Download)

Paper Quality:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-Stroke Single Cylinder (Liquid-Cooled)

Displacement:

499cc (Exact displacement may vary slightly between H.O. and EFI models, but generally around 499cc)

Bore X Stroke:

Approximately 92mm x 75mm (typical for this engine family)

Horsepower:

Estimated 30-35 HP (Varies by exact model and tuning, H.O. generally slightly higher)

Torque:

Estimated 27-30 lb-ft (Varies by exact model)

Efi Models:

Electronic Fuel Injection (EFI) system for improved throttle response, cold starting, and fuel efficiency.

Carbureted Models:

H.O. (High Output) models may feature a carburetor (e.g., Mikuni BSR42) for certain configurations, though EFI became dominant.

Cooling System:

Liquid-cooled with fan assist

Ignition System:

Electronic Ignition (CDI)

Starting System:

Electric Starter

🔧 Transmission

Transmission Type:

Automatic (Polaris PVT - Polaris Variable Transmission)

Drive Modes:

High, Low, Neutral, Reverse, Park

Clutch System:

Durable belt-driven CVT with centrifugal clutch and driver/driven pulleys.

Final Drive:

Shaft drive with front and rear differentials (often with AWD engagement).

Pvtfail Safe Oil:

Specific Polaris PVT Fluid or equivalent API GL-4 SAE 75W-90 Gear Oil (Check manual for exact specification as variants exist)

📐 Dimensions

Length:

Approx. 83" (210.8 cm) (Varies slightly by model configuration)

Width:

Approx. 48" (121.9 cm)

Height:

Approx. 47" (119.4 cm)

Dry Weight:

Approx. 650-700 lbs (295-318 kg) (Varies by model)

Towing Capacity:

Typically rated at 1,500 lbs (680 kg) or more.

Rack Capacity Front:

Approx. 100 lbs (45 kg)

Rack Capacity Rear:

Approx. 200 lbs (90 kg)

🛡️ Safety Features

Atv Safety Standards:

Designed to meet industry standards for ATVs, though formal crash ratings like automobiles are not applicable.

Braking System:

Hydraulic disc brakes (typically front and rear).

Parking Brake:

Integrated parking brake mechanism.

Lighting:

Dual headlights, tail light, brake light for visibility.

Ergonomics:

Ergonomically designed controls and seating position for rider comfort and control.

💡 Technology Features

Infotainment Features:

Basic instrumentation cluster (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems typical of cars.

Atv Assist Features:

Features like Engine Braking System (EBS) on some models, Active Descent Control (ADC) on select 4x4 variants, and Automatic All-Wheel Drive (AWD) engagement.

Connectivity Features:

No on-board connectivity or smartphone integration. Focus is on mechanical and electrical functionality.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or 6 months, whichever comes first. (Refer to manual for precise interval based on usage).

Air Filter Inspection:

Frequent inspection recommended, especially in dusty conditions. Cleaning/replacement as needed.

Spark Plug Replacement:

Recommended every 12 months or as per manual, typically around 200-300 hours.

Engine Oil Type:

Polaris Premium 4 Synthetic 0W-40 or equivalent API SG, JASO MA certified 4-stroke motorcycle oil.

Engine Oil Capacity:

Approx. 2.3 U.S. quarts (2.2 liters) with filter change. (Confirm in manual).

Coolant Type:

Ethylene Glycol based antifreeze with corrosion inhibitors (e.g., Polaris Brand Antifreeze).

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Differential Fluid Type:

Polaris Demand Drive Fluid or equivalent SAE 75W-90 GL-5 Gear Lubricant for front differential. Rear differential uses specific gearcase oil, often same as transmission fluid or specified separately.

Common Wear Items:

Drive belts (PVT), wheel bearings, tie rod ends, ball joints, brake pads are common wear items subject to replacement based on usage and conditions.

Electrical Connectors:

Occasional issues with corroded electrical connectors due to exposure to elements, emphasizing the importance of the electrical section and wire diagrams in the manual.

📚 Vehicle History

Polarishistory:

Polaris Industries, founded in 1954, has a long history of innovation in snowmobiles and has since expanded significantly into the powersports market, including ATVs, motorcycles, and military vehicles. The Sportsman line has been a cornerstone of their ATV offerings for decades.

Sportsman 500 Lineage:

The Sportsman 500 has evolved significantly since its introduction, consistently receiving updates in engine technology, suspension, ergonomics, and features. The 2009 models represent a mature iteration of this popular platform, with EFI becoming a standard feature on many variants.

2009 Updates:

The 2009 model year saw continued refinement of the EFI system and other components, building upon the reliable foundation of previous Sportsman 500 generations.

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States, with significant production facilities in Minnesota and Iowa.