Positioning:
The Polaris Sportsman 500 is positioned as a versatile and capable all-terrain vehicle, suitable for work, recreation, and trail riding. It is a popular model known for its robust features and Polaris's reputation in the ATV market.
Competitors:
Competes with other 500cc-class ATVs from manufacturers like Can-Am (Outlander 500), Honda (FourTrax Foreman/Rancher), Yamaha (Kodiak/Grizzly), and Kawasaki (Brute Force 500).
Features:
Known for its independent rear suspension (IRS), electronic fuel injection (EFI) on some variants, powerful engine, and Polaris's proprietary Automatic PVT transmission. Often praised for comfort and capability.
Coverage Description:
Complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting.
Estimated Pages:
Extensive (factory service manuals typically range from 500 to over 1000 pages for comprehensive coverage).
Type:
Factory Service Manual / Repair Manual
Engine Systems:
Engine disassembly, assembly, lubrication, cooling, fuel delivery, ignition, exhaust, emissions control.
Drivetrain Systems:
Transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, drive belts, final drive, differential, axles, CV joints.
Suspension Steering:
Front and rear suspension, shock absorbers, springs, control arms, bushings, steering system, tie rods, wheel alignment.
Braking Systems:
Hydraulic brake system, master cylinder, brake calipers, brake pads, brake lines, parking brake.
Electrical Systems:
Battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlights, taillights, brake lights), instrumentation, wiring diagrams, fuses, relays.
Fuel System:
Fuel tank, fuel pump, fuel filter, carburetor (if applicable, or EFI system components).
Chassis Body:
Frame, body panels, plastics, seat, storage compartments, racks.
Maintenance Procedures:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, chain/belt adjustments, general inspections.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), electrical system troubleshooting.
Repair Procedures:
Detailed instructions for disassembly, inspection, repair, and reassembly of all major components and systems.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance tasks.
Depth:
Comprehensive. Covers routine maintenance, in-depth diagnostics, component-level repair, and complete engine/transmission rebuilds.
Engine Type:
4-stroke, SOHC, 2-valve, 1-cylinder
Displacement:
499cc (approximately)
Cooling System:
Liquid-cooled
Horsepower Est:
Approx. 30-35 HP (specific output varies slightly by sub-model and tuning)
Torque Est:
Approx. 28-32 lb-ft (specific output varies slightly)
Fuel Delivery:
EFI (Electronic Fuel Injection) or Carburetor (depending on specific 2009 sub-model, e.g., HO EFI vs. base models)
Fuel Type:
Unleaded gasoline
Ignition System:
Electronic Ignition (CDI or similar)
Engine Oil Type:
SAE 10W-40 Synthetic (or specified alternative from manual)
Engine Oil Capacity:
Approx. 2.0-2.5 quarts (with filter change - refer to manual for exact capacity)
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Drive System:
On-Demand All-Wheel Drive (AWD) / 2WD selectable (specific models)
Drive Belt Maintenance:
Critical component requiring regular inspection for wear, damage, and proper tension.
Length:
Approx. 83 in. (210.8 cm) (Varies slightly by model configuration)
Width:
Approx. 46 in. (116.8 cm)
Height:
Approx. 48 in. (121.9 cm) (Varies slightly by model configuration)
Dry Weight:
Approx. 625 lbs (283.5 kg) (Varies slightly by model configuration)
Ground Clearance:
Approx. 11.25 in. (28.6 cm)
Rack Capacity Front:
Approx. 100 lbs (45.4 kg)
Rack Capacity Rear:
Approx. 200 lbs (90.7 kg)
Towing Capacity:
Approx. 1,500 lbs (680 kg)
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheel Bolt Pattern:
4x110 mm (common for Polaris ATVs)
Safety Certification:
Meets ANSI standards for recreational use (typical for ATVs of this era).
Braking System Type:
Hydraulic disc brakes, front and rear.
Parking Brake:
Hand lever activated, typically locking the rear brake caliper.
Lighting:
Dual front headlights, rear tail/brake light.
Handlebars:
Comfortable grip, integrated controls for throttle, brakes, and AWD engagement.
Infotainment System:
N/A (Focus is on mechanical and electrical systems, not entertainment features).
Driver Assistance Features:
On-Demand AWD system is a key technological feature for traction control.
Connectivity Features:
N/A (No integrated communication or data features typical in modern vehicles).
Efi Features:
If equipped with EFI, features include automatic altitude and temperature compensation for optimal fuel delivery.
Oil Change Interval:
Every 100 hours or annually (whichever comes first, refer to manual for exact spec).
Air Filter Cleaning:
Clean every 25 hours, replace as needed.
Spark Plug Service:
Inspect/replace every 100 hours or annually.
Drive Belt Inspection:
Inspect every 50 hours, replace as needed (critical for performance and longevity).
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent specified gear oil (refer to manual).
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors (e.g., Polaris Premium All-Season Antifreeze or equivalent).
Common Wear Items:
Drive belts (PVT), tie rod ends, wheel bearings, bushings, brake pads, starter motor brushes.
Engine Performance Issues:
Carburetor tuning (if applicable), fuel injector issues (if EFI), PVT system performance (clutch wear/alignment).
Preventative Maintenance:
Regular cleaning, lubrication of pivot points, proper tire inflation, and adherence to service intervals are key for longevity.
Manufacturer History:
Polaris Inc. is a long-standing American manufacturer known for its leadership in the powersports industry, particularly with ATVs and snowmobiles.
Sportsman Lineage:
The Sportsman line has been a cornerstone for Polaris, evolving significantly over the years with improvements in suspension, engine technology, and chassis design. The 500cc engine has been a popular displacement for this versatile platform.
Manufacturing Location:
Primarily manufactured in the United States.
