Polaris Sportsman 500 HO 500 EFI X2 500 EFI Touring 500 EFI 2009 ATV Factory Service Repair Manual Download PDF

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Model Variants: HO, EFI, X2 EFI, Touring EFI Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Target Audience:...

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类型: Atv

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标签: 2009 ATV Polaris Powersports Sportsman 500 EFI Sportsman 500 EFI Touring Sportsman 500 EFI X2 Sportsman 500 HO Sportsman Series

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500

Model Variants:

HO, EFI, X2 EFI, Touring EFI

Year:

Vehicle Type:

ATV (All-Terrain Vehicle)

👋 Introduction

Market Position

Target Audience:

Owners and independent repair shops of 2009 Polaris Sportsman 500 ATVs.

Utility:

Designed for recreational trail riding, utility work, and hunting.

Competitive Analysis

Segment:

Mid-size utility ATV segment.

Key Competitors:

Can-Am Outlander, Yamaha Grizzly, Arctic Cat ATV.

Key Features

Manual Benefit:

Empowers users to perform maintenance and repairs, saving on labor costs and ensuring longevity.

Diagnostic Advantage:

Provides the exact procedures and specifications used by factory-trained technicians.

Completeness:

Covers all variants of the 2009 Sportsman 500 HO, EFI, X2 EFI, and Touring EFI.

📋 Manual Details

Coverage

Manual Type:

Factory Service Repair Manual

Language:

English

Format

File Format:

Compatibility:

Windows and MAC

Requirements:

Adobe PDF Reader

Availability

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Top End:

Includes cylinder head, valves, camshaft, piston, rings, cylinder, timing.

Engine Lower End:

Includes crankshaft, connecting rod, bearings, oil pump, engine case.

Fuel System:

EFI system, fuel pump, injectors, throttle body, fuel filter, fuel tank, pressure regulator.

Cooling System:

Radiator, fan, coolant, thermostat, hoses, water pump.

Clutch Drive Belt System:

Primary and secondary clutch inspection, service, belt replacement, alignment.

Transmission:

Internal components, gear shifting, lubrication, maintenance.

Front Drive System:

Front differential, CV joints, driveshafts, AWD engagement (if applicable).

Electrical System:

Ignition system, charging system (stator, regulator/rectifier), battery, starter, lighting, sensors, ECU.

Front Suspension Steering:

A-arms, shocks, springs, ball joints, tie rods, steering post, wheel bearings.

Rear Suspension:

Swingarm, shocks, springs, bushings, wheel bearings.

Brakes:

Hydraulic systems, calipers, master cylinders, brake lines, pads, rotors, bleeding procedures.

Body:

Body panels, fenders, seat, rack system, plastics, removal and installation.

Wiring Diagrams:

Detailed electrical schematics for comprehensive troubleshooting.

Procedures Included

Maintenance Schedule:

Recommended service intervals for oil changes, filter replacements, lubrication, and inspections.

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems.

Tune Up:

Spark plug replacement, air filter cleaning/replacement, carburetor/EFI adjustments (where applicable).

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major components.

Lubrication:

Specific lubrication points, recommended lubricants, and capacities.

Technical Depth

Level Of Detail:

Comprehensive, covering from basic maintenance to in-depth engine and transmission rebuilds.

Diagnostic Capability:

Detailed diagnostic charts and procedures for identifying and resolving malfunctions.

Special Tools:

Identifies required special tools for specific procedures, often with diagrams.

Supplemental Info

Supplement Years:

2001-2003 service information included

Index:

Provides an index for quick reference to specific topics.

📊 Manual Specifications

File Attributes

File Format:

Printability:

Searchability:

Assumed high due to PDF format and factory origin.

Production

Manual Source:

Factory Original

Binding Type:

Digital Download (PDF)

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, 4-valve, single-cylinder

Engine Displacement:

499cc

Bore X Stroke:

92mm x 75mm

Performance

Horsepower:

Approximately 33-34 HP (exact figure may vary slightly by variant/tune).

Torque:

Approximately 29-30 lb-ft (exact figure may vary slightly by variant/tune).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 87 octane or higher.

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition) with digital advance

Cooling

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Hi/Lo range and reverse

Drive System:

On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector.

Features

Engine Braking:

Integrated engine braking through the PVT system.

Fluid Specifications

Transmission Fluid:

Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent meeting specific viscosity and additive requirements (refer to manual for exact spec).

📐 Dimensions

Exterior

Length:

Approximately 82.5 inches (209.5 cm)

Width:

Approximately 46 inches (116.8 cm)

Height:

Approximately 48 inches (121.9 cm)

Weights

Dry Weight:

Approximately 650-700 lbs (295-318 kg) depending on model variant.

Ground Clearance:

Approximately 11.25 inches (28.6 cm)

Capacities

Towing Capacity:

1500 lbs (680.4 kg)

Rack Capacity Front:

100 lbs (45.4 kg)

Rack Capacity Rear:

200 lbs (90.7 kg)

Wheelbase

Wheelbase:

Approximately 50.5 inches (128.3 cm)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

AWD Engagement:

On-Demand AWD provides enhanced traction in challenging terrain.

Passive Features

Ergonomics:

Designed for rider comfort and control during extended use.

Lighting:

Dual 25W headlights, 3-watt taillight, dual 35W brakelights for visibility.

💡 Technology Features

Infotainment

Display:

Digital instrument cluster displaying speed, RPM, fuel level, gear indicator, odometer, trip meter.

Driver Assistance

Traction Control:

On-Demand AWD system provides automatic traction enhancement.

Connectivity

Charging Port:

Often equipped with a 12V DC outlet for charging accessories.

🔧 Maintenance

Service Intervals

Oil Change:

Recommended every 100 hours or 6 months (refer to manual for specific conditions).

Air Filter:

Inspect every 50 hours, clean/replace as needed based on operating conditions.

Spark Plug:

Replace every 100 hours or annually.

Fluid Specifications

Engine Oil:

Polaris PS-4 Synthetic 5W-50 or PS-4 Extreme Duty 0W-40 (refer to manual for exact specification and capacity).

Coolant:

Ethylene glycol based antifreeze with corrosion inhibitors (50/50 mix with distilled water). Capacity approx. 2.1 quarts.

Known Issues

Common Wear Items:

Tie rod ends, ball joints, wheel bearings, drive belts due to typical off-road use.

Efi Maintenance:

Importance of clean fuel and periodic cleaning of fuel injectors and throttle body for optimal EFI performance.

📚 Vehicle History

Brand Heritage

Polaris Legacy:

Polaris is a long-standing manufacturer of powersports vehicles, known for innovation and ruggedness.

Model Evolution

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, continuously evolving in features and performance.

Production

Manufacturing Location:

Primarily manufactured in the USA by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Industry Standing:

Polaris Sportsman series consistently recognized for utility, capability, and rider comfort in the ATV market.