🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 500

Year:

2009

Product Name:

2009 Polaris Sportsman 500 Service Repair Manual Download 09 PDF

Vin Decoder Notes:

VIN typically starts with 1UP for Polaris ATVs. Manual would cover specific model codes within the 2009 lineup.

👋 Introduction

Target Audience:

Do-It-Yourself (DIY) enthusiasts and owners seeking to maintain and repair their 2009 Polaris Sportsman 500 ATV.

Value Proposition:

Offers the most complete service and repair information available for the 2009 Sportsman 500, saving users money on professional labor and ensuring proper maintenance and repairs.

Manual Features:

High-quality diagrams, detailed instructions from front bumper to rear, instant download for immediate access.

📋 Manual Details

Model Variants Covered:

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

Precise page count not specified, but described as 'most complete ever compiled', implying extensive detail likely exceeding 500+ pages for a comprehensive service manual.

Type:

Service Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Mechanical Systems:

Engine, Fuel Injection (EFI), Clutch System, Final Drive, Transmission, Brakes, Body, Steering, Suspension

Electrical Systems:

Electrical System, Wiring Diagrams

Diagnostic Procedures:

Troubleshooting guides for common issues, diagnostic steps for EFI system, electrical faults, mechanical component failures.

Repair Procedures:

Detailed step-by-step repair instructions for all major components and systems, including engine rebuild, transmission overhaul, brake caliper replacement, suspension component service.

Maintenance Procedures:

Routine maintenance tasks such as oil changes, filter replacements, spark plug service, chain adjustment, and general inspections.

Depth Of Information:

Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete overhauls. Suitable for DIY enthusiasts and professional technicians.

📊 Manual Specifications

File Type:

PDF

Printability:

All pages are printable, allowing for physical copies for workshop use. High-quality diagrams are emphasized.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Software Requirements:

Adobe PDF Reader

Operating Systems:

Compatible with All Versions of Windows & Mac

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 4-valve

Engine Displacement:

499cc (for most variants, EFI models specifically)

Bore X Stroke:

Refer to manual for specific dimensions; typically around 92mm x 75.4mm for 500cc class engines.

Compression Ratio:

Refer to manual for specific ratio, typically around 10.0:1 to 11.0:1 for EFI models.

Horsepower:

Approx. 28-32 HP at peak (exact figures vary by specific model variant, consult manual for precise output).

Torque:

Refer to manual for specific torque figures, typically around 28-30 lb-ft.

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

Cooling Method:

Liquid-cooled

Ignition Type:

Electronic Ignition (CDI or similar)

Oil Type:

Refer to manual for exact Polaris specifications (e.g., Polaris Synthetic 4-stroke engine oil or equivalent SAE 5W-50 or 10W-40 JASO MA certified oil).

Oil Capacity:

Refer to manual for exact capacity, typically around 2.0-2.5 quarts (1.9-2.4 liters) with filter change.

🔧 Transmission

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking

Drive System:

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

Gear Selection:

High, Low, Neutral, Reverse, Park

Clutch System:

Primary and secondary clutch system (P90X or similar) with belt drive.

Transmission Fluid Type:

Refer to manual for specific Polaris PVT fluid or equivalent JASO certified fluid.

📐 Dimensions

Length:

Approx. 83.2 inches (211.3 cm) for standard models. Touring models will be longer.

Width:

Approx. 46 inches (116.8 cm)

Height:

Approx. 48 inches (121.9 cm)

Wheelbase:

Approx. 50.5 inches (128.3 cm)

Dry Weight:

Approx. 662 lbs (300 kg) for standard models. X2 and Touring models may vary.

Ground Clearance:

Approx. 10.25 inches (26.0 cm)

Towing Capacity:

1500 lbs (680.4 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Safety Standards:

Designed to meet ANSI standards for recreational ATVs. Manual would detail specific safety precautions and operating guidelines.

Braking System:

Hydraulic disc brakes front and rear.

Parking Brake:

Handlebar-mounted lever or foot pedal controlling rear brake caliper.

Lighting:

Dual headlights, tail light, brake light.

Rollover Protection:

N/A for ATVs; operator awareness and protective gear (helmet, etc.) are critical and emphasized in manuals.

💡 Technology Features

Dashboard Features:

Digital instrument cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter, 2WD/4WD status, and indicator lights.

Suspension Technology:

Independent front and rear suspension (IRS) with adjustable shocks for improved ride comfort and control.

Diagnostic Ports:

Likely features a diagnostic port for connecting service tools to read fault codes and monitor sensor data.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or 6 months, whichever comes first. Refer to manual for specific recommendations based on usage.

Air Filter Cleaning:

Inspect and clean every 25 hours or as needed, replace every 100 hours or as necessary.

Spark Plug Replacement:

Replace typically every 100 hours or annually. Manual will specify plug type and gap.

Clutch Belt Inspection:

Inspect for wear and damage at 50-hour intervals, replace as needed. Belt life is highly dependent on usage.

Valve Clearance Adjustment:

Check and adjust valve clearance typically at 200-hour intervals or annually. Manual provides specific procedures and clearances.

Coolant Type:

Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Polaris Premium 2-Stroke Oil & Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Common Wear Items:

Brake pads, front-end components (tie rods, ball joints), drive belts, wheel bearings, and suspension bushings are common wear items on ATVs of this era and type. Manual will guide diagnosis and replacement.

Efi System Considerations:

EFI systems can be sensitive to fuel quality and require clean air filters. Manual would cover EFI troubleshooting and sensor checks.

📚 Vehicle History

Brand Origins:

Polaris Industries Inc. has a long history in powersports, beginning with snowmobiles and expanding significantly into ATVs and UTVs.

Sportsman Lineage:

The Sportsman line has been a flagship for Polaris, known for its comfort, capability, and rider-friendly features, evolving significantly since its introduction.

Manufacturing Location:

Polaris ATVs are primarily manufactured in the United States.

🏆 Awards & Recognition

Industry Recognition:

The Polaris Sportsman line has consistently been highly rated and recognized in the powersports industry for its innovation, comfort, and utility, though specific awards for the 2009 model are not detailed in product info.