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Polaris
Polaris Sportsman 500 H.O. 500 EFI X2 500 EFI Touring 500 EFI 2009 Workshop Service Repair Manual
Polaris Sportsman 500 H.O. 500 EFI X2 500 EFI Touring 500 EFI 2009 Workshop Service Repair Manual
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Vehicle data plateRef 42655
- Brand
- Polaris
- Vehicle
- ATV
- Models covered
- Misc, Sportsman 500 EFI, Sportsman 500 EFI Touring, Sportsman 500 EFI X2, Sportsman 500 H.O.
- Years
- 2009
- Format
- PDF, searchable, print-ready
- Delivery
- Instant download after checkout
- Language
- English
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- Download link opens on the order page immediately
- The same link is emailed to you — re-download any time
- Open on phone, tablet or PC; print only the pages you need
- Not sure it covers your model year? Ask us before you buy
| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | Sportsman 500 |
| Year: | 2009 |
| Model Variants: | 500 H.O., 500 EFI, X2 500 EFI, Touring 500 EFI |
| Introduction | |
| Market Position | |
| Market Position: | The Polaris Sportsman 500 line in 2009 represented a robust and versatile ATV platform, known for its trail-riding capabilities, utility features, and rider comfort, particularly in the Touring models. This manual targets owners and technicians seeking to maintain, repair, and optimize these specific 2009 models. |
| Competitive Analysis | |
| Competitive Analysis: | Competed against models from brands like Can-Am Outlander, Arctic Cat 500, and Yamaha Grizzly 550, offering a balance of power, features, and Polaris's established reputation for off-road vehicles. |
| Key Features | |
| Key Features: | 500cc class engine, Automatic PVT (Polaris Variable Transmission) with Engine Braking, On-Demand AWD, independent front and rear suspension, hydraulic disc brakes, and specific features like the X2's convertible cargo bed and the Touring's enhanced comfort amenities. |
| Manual Details | |
| Coverage | |
| Coverage Areas: | Complete service, repair, diagnostics, maintenance, troubleshooting, electrical systems, engine, transmission, chassis, body, suspension, brakes, and more for all listed 2009 Polaris Sportsman 500 variants. |
| Identification | |
| Manual Type: | Workshop Service Repair Manual |
| Language: | English |
| Format: | PDF Download |
| Completeness | |
| Manual Completeness: | This is a full workshop service and repair manual, intended to cover all aspects of vehicle maintenance and repair performed by dealership technicians. It is not an owner's manual or a condensed guide. |
| Manual Coverage | |
| Systems | |
| Systems Covered: | Engine mechanical (including top-end and bottom-end), fuel injection (EFI) system, ignition system, cooling system, exhaust system, drivetrain (AWD, differentials), transmission (CVT), braking system (hydraulic disc), steering, suspension (independent front and rear), electrical system (wiring diagrams, lighting, accessories, charging system), chassis, body panels, and maintenance procedures. |
| Procedures | |
| Procedures Included: | Routine maintenance, lubrication, fluid changes, filter replacements, engine diagnostics and repair (including piston, rings, cylinder, crankshaft, camshaft), fuel system troubleshooting and repair (injectors, fuel pump, regulator), ignition system diagnosis, CVT belt inspection and replacement, brake system bleeding and pad replacement, suspension component inspection and replacement, electrical troubleshooting with detailed wiring diagrams, component testing, and general assembly/disassembly procedures. |
| Depth | |
| Technical Depth: | Comprehensive; covers basic maintenance to full engine rebuilds and in-depth electrical system diagnostics. Provides detailed step-by-step instructions, torque specifications, special tool requirements, and troubleshooting flowcharts. |
| Electrical | |
| Electrical Coverage Detail: | Extensive coverage including detailed color wiring diagrams for all electrical components (lights, ignition, charging system, starter, accessories, EFI system components). Includes troubleshooting guides for common electrical faults, component testing procedures, and connector pinouts. |
| Engine Rebuild | |
| Engine Rebuild Detail: | Complete instructions for engine disassembly, inspection, repair, and reassembly. Covers cylinder head removal and reconditioning, piston and connecting rod service, crankshaft inspection and installation, valve timing, and torque specifications for all critical fasteners. |
| Transmission Service | |
| Transmission Service Detail: | Detailed procedures for CVT clutch inspection, belt replacement, and adjustment. Covers maintenance of the PVT system, including servicing of the primary and secondary clutches. Explains gearcase lubrication and maintenance. |
| Suspension Steering | |
| Suspension Steering Detail: | Instructions for inspecting and replacing front and rear suspension components, including A-arms, bushings, ball joints, shocks, and sway bars. Covers steering system maintenance, including tie rod ends and steering rack adjustments. |
| Braking System | |
| Braking System Detail: | Comprehensive guides for brake system maintenance, including front and rear brake caliper removal and installation, brake pad replacement, brake line bleeding procedures, master cylinder service, and inspection of brake discs. |
| Troubleshooting | |
| Troubleshooting Guides: | Includes step-by-step troubleshooting flowcharts and diagnostic trees for various systems, such as starting problems, engine performance issues, charging system faults, and braking system malfunctions. |
| Manual Specifications | |
| File | |
| File Format: | |
| Searchable Text: | Yes, the PDF format allows for keyword searching, making it efficient to find specific information. |
| Printable Pages: | Yes, the PDF is designed to be printable for workshop use. |
| Quality | |
| Print Quality: | High-resolution scans of original dealership service manuals, ensuring clear diagrams, illustrations, and text. |
| Binding | |
| Binding Type: | N/A (Digital PDF Download) |
| Paper | |
| Paper Type: | N/A (Digital PDF Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Liquid-cooled, 4-stroke, SOHC, 4-valve, single-cylinder engine (specific variants may feature minor tuning differences). |
| Performance | |
| Displacement: | 499 cc |
| Bore X Stroke: | 92 mm x 77.4 mm |
| Horsepower Estimate: | Approximately 30-32 hp (varies slightly by model variant). |
| Fuel System | |
| Fuel System: | Electronic Fuel Injection (EFI) with single throttle body and injectors. |
| Fuel Type: | Unleaded gasoline, minimum 87 octane. |
| Ignition | |
| Ignition System: | CDI with electronic advance. |
| Cooling | |
| Cooling System: | Liquid-cooled. |
| Oil | |
| Oil Type Capacity: | API SG, SH, SJ rated 4-stroke synthetic motorcycle oil, SAE 10W-40. Capacity: 2.7 US quarts (2.56 liters) with filter change. |
| Transmission | |
| Standard | |
| Transmission Type: | Polaris Variable Transmission (PVT) with Engine Braking. |
| Optional | |
| Optional Gear Reduction: | High and Low range, Reverse, Neutral, Park. |
| Features | |
| Drive System: | Shaft Drive, On-Demand All-Wheel Drive (AWD). |
| Fluid | |
| Transmission Fluid Type: | Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent SAE 80W-90 hypoid gear lubricant. |
| Dimensions | |
| Exterior | |
| Length: | 83 in. (210.8 cm) / 91.5 in. (232.4 cm) for Touring models. |
| Width: | 46 in. (116.8 cm) |
| Height: | 47 in. (119.4 cm) |
| Cargo | |
| Rack Capacity Front: | 100 lbs. (45.4 kg) |
| Rack Capacity Rear: | 200 lbs. (90.7 kg) |
| Towing Capacity: | 1500 lbs. (680.4 kg) |
| Weights | |
| Dry Weight: | Approximately 640-660 lbs. (290-300 kg) depending on configuration. |
| Ground Clearance: | 11.25 in. (28.6 cm) |
| Wheelbase | |
| Wheelbase: | 50.1 in. (127.3 cm) / 54.5 in. (138.4 cm) for Touring models. |
| Safety Features | |
| Ratings | |
| Safety Ratings: | ATVs are not subject to standardized crash test ratings like automobiles. Safety relies on operator training, adherence to safety guidelines, and proper maintenance. |
| Active Features | |
| Active Safety Features: | On-Demand AWD, Engine Braking, hydraulic disc brakes on all wheels, low center of gravity for stability. |
| Passive Features | |
| Passive Safety Features: | Integrated handgrips, comfortable seating position, robust frame construction. |
| Technology Features | |
| Infotainment | |
| Infotainment Features: | Typically basic, focused on functionality. May include odometer, trip meter, hour meter, fuel gauge, and indicator lights for 2WD/AWD, oil pressure, etc. No complex infotainment systems expected. |
| Driver Assistance | |
| Driver Assistance Features: | On-Demand AWD is a primary traction assistance feature. Engine braking aids in downhill control. |
| Connectivity | |
| Connectivity Features: | No modern connectivity features like Bluetooth or smartphone integration. Focus is on mechanical and electrical systems for operation. |
| Diagnostics | |
| Diagnostic Capabilities: | EFI models feature a diagnostic port and potentially blink code capabilities for basic error reporting. Advanced diagnostics are covered in detail within the manual. |
| Maintenance | |
| Service Intervals | |
| Initial Service: | First service typically at 10-hour or 1-month interval, including oil change, filter inspection, drive belt check, and general inspection. |
| Regular Maintenance Intervals: | Oil and filter change every 100 hours or 6 months. Air filter cleaning/replacement every 50 hours or 3 months. Inspect spark plug every 100 hours or 6 months. Check brake pads and fluid every 100 hours or 6 months. Inspect drive belts every 50 hours or 3 months. Inspect and lubricate suspension and steering components every 50 hours or 3 months. |
| Fluid Specifications | |
| Engine Oil Spec: | SAE 10W-40 Synthetic Motorcycle Oil (API SG, SH, SJ). |
| Gearcase Oil Spec: | Polaris AGL Premium Synthetic Gearcase Lubricant or SAE 80W-90 Hypoid Gear Lubricant. |
| Coolant Spec: | Ethylene glycol based antifreeze, 50/50 mix with distilled water. Polaris recommends a specific pre-mixed coolant. |
| Known Issues | |
| Common Issues To Monitor: | CVT belt wear, front differential issues (especially with aggressive use), suspension component wear (bushings, ball joints), and potential charging system issues if not properly maintained. EFI system components can require diagnostic checks. |
| Filter Part Numbers | |
| Oil Filter Part Number: | Commonly uses 3089237 or equivalent. |
| Air Filter Part Number: | Commonly uses 3089999 or equivalent. |
| Vehicle History | |
| Brand Heritage | |
| Brand Heritage: | Polaris Industries has a long history in powersports, beginning with snowmobiles and expanding into ATVs, UTVs, and motorcycles. They are recognized for innovation and rugged off-road performance. |
| Model Evolution | |
| Model Evolution Sportsman 500: | The Sportsman 500 platform has been a cornerstone for Polaris since its introduction. Over the years, it has seen continuous improvements in engine technology (like the move to EFI), suspension, ergonomics, and features like the X2's versatility and the Touring model's rider comfort enhancements. |
| Production | |
| Production Location: | Manufactured by Polaris Industries in the United States. |
| Awards & Recognition | |
| Recognitions | |
| Historical Recognitions: | While specific awards for the 2009 models are not readily cataloged, the Polaris Sportsman 500 line has consistently been recognized for its class-leading performance, comfort, and versatility in outdoor publications and rider reviews over many years. |
| Ratings | |
| Industry Ratings: | Consistently rated highly by ATV enthusiasts and media for its reliability, power delivery, and capability in various terrains. Often cited as a benchmark in the 500cc class. |
Delivery & file format
Delivery & file format
This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.
Check the model year and engine before you buy
Check the model year and engine before you buy
Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.
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Polaris Sportsman 500 H.O. 500 EFI X2 500 EFI Touring 500 EFI 2009 Workshop Service Repair Manual
Polaris / Atv · PDF · Instant download
$16.99
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