Polaris Sportsman 500 EFI / X2 / TOURING / 500 H.O. Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Sportsman 500 EFI / X2 / TOURING / 500 H.O. has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

2009 SPORTSMAN 500 H.O.
Model Number: A09MH50AX, AZ
Engine Model: EH50PLE

2009 SPORTSMAN 500 EFI
Model Number: A09MN50AN, AX, ET (International)
Engine Model: EH50PLE

2009 SPORTSMAN X2 500 EFI
Model Number: A09TN50AX, AZ / A08TN50EA
(Intl’ Quadricycle)
Engine Model: EH50PLE

2009 SPORTSMAN TOURING 500 EFI
Model Number: A09DN50AB, AZ / A09DN50EA
(Intl’ Quadricycle)
Engine Model: EH50PLE


TABLE OF CONTENTS :

CH_01-GENERAL INFORMATION
CH_02-MAINTENANCE
CH_03-ENGINE
CH_04-FUEL INJECTION
CH_05-BODY / STEERING / SUSPENSION
CH_06-CLUTCH SYSTEM
CH_07-FINAL DRIVE
CH_08r01-TRANSMISSION
CH_09-BRAKES
CH 10-ELECTRICAL
CH_11-500 EFI X2 / TOURING QUADRICYCLE
WIRE DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921790
Total Pages : 386


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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9921790_CH_01-GENERAL INFORMATION
    MODEL NUMBER INFORMATION 1.2 
        MODEL NUMBER INFORMATION
            Model Number
            Engine Designation Numbers
            Vehicle Identification Number (VIN)
            Transmission I.d. Location
            Engine And Machine Serial Numbers
            Publications
            Paint Codes
            Replacement Keys
        2009 SPORTSMAN 500 H.O.
            Model Number: A09MH50AX, AZ 
        2009 SPORTSMAN 500 EFI
            Model Number: A09MN50AN, AX, ET (International)
        2009 SPORTSMAN X2 500 EFI
            Model Number: A09TN50AX, AZ / A08TN50EA 
        2009 SPORTSMAN TOURING 500 EFI
            Model Number: A09DN50AB, AZ / A09DN50EA
        MISC. NUMBERS/CHARTS
            Standard Torque Specifications
            SAE Tap Drill Sizes
            Metric Tap Drill Sizes
            Decimal Equivalents
            Conversion Table
            Glossary Of Terms
            
9921790_CH_02-MAINTENANCE
    TABLE OF CONTENTS
        MAINTENANCE
            Periodic Maintenance Chart
            Maintenance Chart Key
            Periodic Maintenance Chart
        LUBRICATION / FLUIDS
            SPORTSMAN Component Locations
            SPORTSMAN X2-Touring Component locations
            Polaris Lubricants, Maintenance and Service Products
            Polaris Lubricant Symbol Identification
            Pre-ride / Daily Inspection
            Lubrication Components
            Front Gearcase Lubrication
            Transmission Lubrication
            ADC Differential Hydraulic Circuit Fluid Change
        VEHICLE INSPECTION
            Shift Link Rod Inspection
            Throttle Inspection
            Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
            Fuel System
            Fuel Lines
            Vent Lines
            Fuel Filter
            Choke (Enricher) Adjustment - (500 Carb)
            Compression Test
            Engine Mounts
            Spark Plug
            Active Descent Control (ADC) Reservoir Level
            Battery Maintenance
            Liquid Cooling System Overview
            Coolant Strength / Type
            Cooling System Hoses
            Radiator/Grill Screen
            Cooling System Pressure Test
            Coolant Level Inspection
            Radiator Coolant Level Inspection
            Air Filter/Pre-Filter Service
            Air Box Sediment Tube
            Breather Filter Inspection
            Breather Hose
            Recoil Housing
            Engine Oil Level
            Oil and Filter Change 
            Oil Pump Priming Procedure
            Valve Clearance
            Intake Valve Clearance Adjustment
            Exhaust Valve Clearance Adjustment
            Steering
            Tie Rod End/Steering Inspection 
            Camber and Caster
            Wheel Alignment
            Toe Alignment Adjustment
            Exhaust Pipe
            Brake System Inspection
            Brake Pad Inspection
            Hose/Fitting Inspection
            Auxiliary Brake Testing
            Auxiliary Brake Adjustment (Hydraulic) 
            Suspension Spring Preload Adjustment
            Front Suspension
            CV Shaft Boot Inspection
            Controls
            Wheels
            Wheel, Hub, And Spindle Torque Table
            Wheel Removal Front or Rear
            Wheel Installation
            Tire Pressure
            Tire Inspection
            Frame, Nuts, Bolts, Fasteners
            Storage Compartments
            Winch Operation (If Equipped)
            ATV Cleaning & Storage
        SPORTSMAN 500 CARBURETED MAINTENANCE
            Choke (Enricher) Adjustment
            Pilot Screw
            Pilot Screw Adjustment
            Idle Speed Adjustment
            Fuel Filter
            Carburetor Draining
            Maintenance Schedule
            Maintenance Schedule
            
9921790_CH_03-ENGINE
    TABLE OF CONTENTS
        SPECIFICATIONS
            Torque Specifications
            Special Tools
            Engine Fastener Torque Patterns
            Engine Service Data
            Engine Service Data
        GENERAL ENGINE SERVICE
            Piston Identification
            Cooling System Specifications
            Cooling System
            Accessible Components
            Engine Removal (TYPICAL)
            Engine Installation Notes
            Cylinder Hone Selection/ Honing Procedure
            Honing To Oversize
            Cleaning the Cylinder After Honing
            Crankshaft Straightening
            Engine Lubrication- EH 50PL
            Oil Pressure Test - EH 50PL
            Oil Pump Priming Procedure
            Oil Flow - EH50PL
            EH50PL Oil Flow Diagram
            EH50PL Engine Exploded Views
        ENGINE DISASSEMBLY
            Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal
            Cam Chain Tensioner Inspection
            Rocker Arm/Shaft Inspection
            Camshaft Removal
            Automatic Compression Release Removal/ Inspection
            Automatic Compression Release Installation
            Camshaft Inspection
            Cylinder Head Removal
            Cylinder Head Exploded View, EH50PL
            Cylinder Head Inspection
            Cylinder Head Warp
            Cylinder Head Disassembly
            Valve Inspection
            Combustion Chamber
            Valve Seat Reconditioning
            Cylinder Head Assembly
            Valve Sealing Test
            Valve Clearance Adjustment
            Cylinder/Piston Removal and Inspection
            Piston Removal
            Cylinder Inspection
            Piston-to-Cylinder Clearance
            Piston/Rod Inspection
            Piston Ring Installed Gap
            Crankcase Disassembly
            Starter Drive Removal/Inspection
            Flywheel/Stator Removal/Inspection
            Cam Chain/Tensioner Blade
            One Way Valve Removal
            Crankcase Separation
            Oil Pump Removal/Inspection
            Oil Pump Assembly
            Counter Balancer Shaft Removal/Inspection
            Crankshaft Removal/Inspection 
            Crankcase Bearing Inspection 
            Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)
            Crankcase Inspection
            Bearing Installation
            End Play Inspection/Adjustment
            Crankshaft End Play Adjustment
            Counter Balancer Shaft End Play Adjustment.
            Oil Pump Shaft End Play Adjustment
        ENGINE REASSEMBLY
            Pump Shaft Oil Seal Installation
            Crankshaft/Counter Balance/Oil Pump Installation
            Crankcase Assembly
            Water Pump Mechanical Seal Installation
            Water Pump Mechanical Seal Removal - Engine Installed
            One Way Valve Installation
            Cam Chain Drive Sprocket Installation
            Tensioner Blade Installation
            Piston Ring Installation
            Piston Installation
            Cylinder Installation
            Cylinder Head Installation
            Cam Chain/Camshaft Installation
            Camshaft Timing
            CAMSHAFT TIMING
            Cam Chain Tensioner Installation
            Stator, Flywheel and Starter Drive Installation
            Rocker Shaft/Rocker Arm Assembly Installation
            Thermostat Installation
            Oil Pipes
        RECOIL (Accessory)
            Recoil Disassembly/Inspection
            Recoil Assembly
        TROUBLESHOOTING
            Spark Plug Fouling
            Engine
            Cooling System 
            
9921790_CH_04-FUEL INJECTION
    TABLE OF CONTENTS
        SPECIAL TOOLS
            Part Numbers / Descriptions
        EFI SERVICE NOTES
            General Service Information
        EFI SYSTEM EXPLODED VIEW
        EFI SYSTEM 
            Component Locations/Identification
        FUEL TANK
            Exploded View
        ELECTRONIC FUEL INJECTION
            General Information
            EFI Operation Overview
            Initial Priming / Starting Procedure
        FUEL LINES
            Quick Connect Removal/Installation
        ELECTRONIC CONTROL UNIT (ECU)
            Operation Overview
            ECU Replacement
            ECU Service
        FUEL PUMP ASSEMBLY
            Operation / Testing
            FUEL PUMP TEST
            Fuel Pump / Tank Assembly Replacement
        FUEL PRESSURE REGULATOR
            General Information
        FUEL FILTER
            General Information
        FUEL INJECTOR
            General Information
        CRANKSHAFT POSITION SENSOR (CPS)
            General Information
        MANIFOLD AIR PRESSURE SENSOR (MAP)
            Operation Overview
            Map Sensor Test
            Map Sensor Replacement
        INTAKE AIR TEMPERATURE SENSOR (IAT)
            Operation Overview
            Intake Air Temperature Sensor Test
            Intake Air Temperature Sensor Replacement
        I DLE AIR CONTROL (IAC)
            General Information
        THROTTLE POSITION SENSOR (TPS)
            Operation Overview
            Throttle Position Sensor Test
            Throttle Position Sensor Replacement
            Throttle Position Sensor Initialization
        ENGINE TEMPERATURE SENSOR
            General Information
            Engine Temperature Sensor Test
            Engine Temperature Sensor Replacement
        FUEL SYSTEM TROUBLESHOOTING
            FUEL STARVATION / LEAN MIXTURE
        EFI DIAGNOSTICS USING ‘BLINK CODES’
            Blink Codes - Operation
        TROUBLESHOOTING DIAGRAMS
            EFI CIRCUIT - Power On
            EFI CIRCUIT - Crank Position Sensor
            EFI CIRCUIT - Fuel Pump
            EFI CIRCUIT - Ignition Coil
            EFI CIRCUIT - Idle Air Control
            EFI CIRCUIT - Throttle Position Sensor
            EFI CIRCUIT - Manifold Absolute Pressure Sensor
            EFI CIRCUIT - Engine Coolant Temperature
            EFI CIRCUIT - Air Temperature Sensor
            EFI CIRCUIT - Malfunction Indicator Light
            
9921790_CH_05-BODY / STEERING / SUSPENSION
    TABLE OF CONTENTS
        GENERAL INFORMATION
            Torque Specifications
            Special Tools 
            Decal Replacement
            Plastic Insert Removal / Installation
        BODY
            Side Panel Removal
            Front Cover Removal / Installation
            Foot Well Removal / Installation
            X2-Touring Foot Well Removal / Installation
            Front Storage Removal
            Front Storage Installation
            Sportsman Rear Rack Removal / Installation
            Front Cab/Fender Removal/Installation
            Sportsman Rear Cab / Fender Removal / Installation
            X2-Touring Rear Quarter Panel Removal / Installation
            Sportsman Rear Storage Removal / Installation
            Radiator Screen Removal
            Sportsman Body Assembly Exploded View
            X2-Touring Body Assembly Exploded View
            Touring Body/Rack Assembly Exploded View
            Body / Rack Exploded Views
            Touring Body/Seat Assembly Exploded View
            Headlight Pod Exploded View
        STEERING
            Handlebar Block Installation Procedure
            Steering / A-arm Exploded View
            A-Arm Replacement
            Ball Joint Replacement
            Steering Post Removal
            Steering Post Assembly
        SUSPENSION
            Front Strut Cartridge Replacement
            Strut Assembly
            Sportsman Rear Suspension Assembly
            X2-Touring Rear Suspension Exploded View
            X2-Touring Torsion Bar Exploded View
        X2 CARGO BOX
            Exploded View
            Removal / Installation
        X2 SEAT assembly
            Exploded Views
            X2 Seat Operation - Configuring Cargo Box For Passenger Riding
            X2 Driver Seat Backrest Removal / Installation
            X2 Passenger Seat Backrest Removal / Installation
            
9921790_CH_06-CLUTCH SYSTEM
    TABLE OF CONTENTS
        SPECIAL TOOLS AND SPECIFICATIONS
            Special Tools
            Service Note
            Component Fastener Torques
        PVT EXPLODED VIEWS
            PVT Sealing And Ducting Components
            Drive Clutch Exploded Views
            Driven Clutch Exploded Views
            Engine Braking System (EBS) Exploded View
        PVT SYSTEM
            PVT Operation Overview
            Drive Clutch Operation
            Driven Clutch Operation
            EBS Clutch Operation
            PVT Maintenance / Inspection
            Drive Clutch Spring
            Optional Shift Weights
            PVT Drying
            PVT Disassembly 
            PVT Installation
            Drive Belt Removal / Inspection
            DRIVE BELT INSTALLATION
            Clutch Alignment
            Clutch Offset
        EBS DRIVE CLUTCH SERVICE
            Drive Clutch Disassembly
            Spider Removal
            Button To Tower Clearance Inspection
            Shift Weight Inspection
            Drive Clutch Inspection
            Moveable Sheave Bushing Inspection
            Drive Clutch Bushing Service
            One-Way Clutch Inspection (Drive Clutch)
            Drive Clutch Reassembly
        EBS DRIVEN CLUTCH SERVICE
            Driven Clutch Disassembly 
            DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION
            EBS DRIVEN CLUTCH REASSEMBLY
        STANDARD DRIVE CLUTCH - 500 Carburetor
            Drive Clutch Disassembly
            Spider Removal
            Button To Tower Clearance Inspection
            Shift Weight Inspection
            Sheave / Bushing Inspection
            Drive Clutch Bushing Service
            Drive Clutch Reassembly
        STANDARD DRIVEN CLUTCH - 500 Carburetor
            Exploded View
            Clutch Disassembly / Inspection
            Bushing Service
            Moveable Sheave - Bushing Installation
            Clutch Assembly
        PVT TROUBLESHOOTING
            Overheating
            Problem, Cause and Remedy Chart
            
9921790_CH_07-FINAL DRIVE
    TABLE OF CONTENTS
        SPECIFICATIONS
            Torque Table
            Special Tools
            Gearcase Fluid / Capacity
        FRONT HUB
            Disassembly
            Assembly
        FRONT DRIVE SHAFT (CV) SERVICE
            Removal
            Installation
            Inspection
            CV Joint/Boot Replacement
        PROP SHAFT - FRONT
            Removal and Installation
        U-JOINT
            Disassembly
            Assembly
        DRIVE AXLE EXPLODED VIEWS
            Drive Shafts and Propshaft
        FRONT GEARCASE - CENTRALIZED HILLIARD
            Exploded View
            Operation
            Gearcase Removal
            Disassembly / Inspection
            Reassembly / Inspection
            Setting Ring Gear Backlash
            Front Gearcase Diagnosis
            Gearcase Installation
        FRONT GEARCASE - Active Descent Control
            ADC Gearcase Exploded View
            Operation
            ADC Coil Testing
            ADC Differential Hydraulic Circuit Bleeding
            Disassembly / Inspection
            ADC Gearcase Piston Replacement Procedure
            Assembly
        REAR HUB
            Removal
            Disassembly
            Assembly
            Installation
        REAR DRIVE (CV) SHAFT SERVICE
            Removal
            Service
            CV Boot Replacement
            INSTALLATION
            Drive Shaft and CV Joint Handling Tips
            
9921790_CH_08r01-TRANSMISSION
    TABLE OF CONTENTS
        TRANSMISSION - GENERAL
            Mounting Exploded View
            Torque Specifications
            Special Tools
            Lubrication
            Gear Selector Removal
            Transmission Removal
            Transmission Installation
            Troubleshooting Checklist
        TRANSMISSION SERVICE
            X2 - Touring Exploded View
            500 Carbureted Exploded View
            Transmission Disassembly
            Transmission Assembly
            Transmission Output Shaft Backlash Procedure and Gearcase Reassembly - Standard Sportsman
            Transmission Output Shaft Disassembly - Sportsman X2/Touring
            Transmission Output Shaft Backlash Procedure and Gearcase Reassembly - Sportsman X2/Touring
            
9921790_CH_09-BRAKES
    TABLE OF CONTENTS
        SPECIFICATIONS
            Torque Table
            Component Service Limits
        BRAKE SYSTEM EXPLODED VIEWS
            X2, Touring System Component Exploded View
            Sportsman System Component Exploded View
        BRAKE CALIPER EXPLODED VIEWS
            Sportsman and X2, Touring Front Caliper Assembly
            X2, Touring Rear Caliper Assembly
            Sportsman Rear Caliper Assembly
        HYDRAULIC BRAKE SYSTEM
            Operation Overview
            Brake Noise Troubleshooting
            Brake Bleeding / Fluid Change
        FRONT MASTER CYLINDER
            Removal
            Installation
        FRONT BRAKES
            Pad Removal
            Assembly
            Brake Burnishing Procedure
        FRONT BRAKE DISC
            Inspection
            Removal / Replacement
        FRONT CALIPER
            Removal
            Inspection
            Reassembly
            Installation
        REAR BRAKE PAD
            X2, Touring Pad Removal
            X2, Touring Pad Installation
            Sportsman Rear Pad Removal
            Sportsman Rear Pad Installation
            Brake Burnishing Procedure
        X2, TOURING REAR CALIPER
            Removal
            Inspection
            Reassembly
        SPORTSMAN REAR CALIPER
            Removal and Inspection
            Assembly
        REAR BRAKE DISC
            Inspection
        REAR MASTER CYLINDER
            X2, Touring Exploded View
            Overview
            X2, Touring Rear Master Cylinder Removal and Installation
            Sportsman Rear Master Cylinder Removal / Installation
            Pedal Removal and Installation
        TROUBLESHOOTING
            Brakes Squeal
            Poor Brake Performance
            Lever Vibration
            Caliper Overheats (Brakes Drag)
            Brakes Lock
            
9921790_CH 10-ELECTRICAL
    TABLE OF CONTENTS
        GENERAL INFORMATION
            Special Tools
            Ignition System / Basic Electrical Components
            Electrical Service Notes
            Troubleshooting
        INSTRUMENT CLUSTER
            Overview
            Instrument Cluster Diagnostic Mode
            Setting A New Service Interval
            EFI Diagnostic Mode 
            Speedometer Removal
            Speedometer Installation
        ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING
            TEST 1 - No All Wheel Drive
            TEST 2 - No Speedometer Display
            TEST 3 - No Reverse Speed Limit
            TEST 4 - No AWD Hub Safety Limit
            TEST 5 - Reverse Speed Limiter Activated In Forward Gear
            TEST 6 - Wheel Speed Sensor
            TEST 7 - Fuel Gauge Display Not Working
            TEST 8 - Shift Indicator Not Working
        ACTIVE DESCENT CONTROL (ADC) COIL
            Operation Overview - EFI Only
            Diagnosing System Failures
        ALL WHEEL DRIVE (AWD) COIL
            Operation Overview
            Diagnosing System Failures
        COOLING SYSTEM COMPONENTS
            Fan Control Circuit Operation
            Fan Control Bypass Test - EFI 
            Fan Control Bypass Test - H.O. 
            Fan Motor Current Draw Test
            Coolant Temperature Sensor - EFI
            Coolant Temperature Fan Switch - H.O.
        GEAR POSITION INDICATOR SWITCH
            Test Diagram
        ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
            Operation Overview
            ETC Test
        IGNITION SYSTEM
            Overview
            Components of Alternator and DC / CDI Ignition System
            EFI Ignition System Testing Flow Chart
            Crankshaft Position Sensor Gap
            Ignition Troubleshooting
            Ignition Output Test Using Gap Tester
        CHARGING SYSTEM
            Current Draw - Key Off
            Break Even Test
            Alternator Output Test
            Charging System Testing Diagrams
        RELAYS
            Operation
        FUSES/Circuit Breaker
            Operation
        DIFFERENTIAL SOLENOID
            Overview - X2 and Touring
            Testing
            Replacement
            Differential Solenoid Diagram - X2 and Touring
        LIGHTING
            High Beam Headlight Bulb Replacement
            Headlight Housing Relacement
            High Beam Headlight Adjustment 
            Lower Headlamp Removal / Installation
            Low Beam Headlight Adjustment
            Headlamp Switch Test
            Work Light / Differential Lockout Switch
            Brake Light / Work Light Replacement
            Brake Light Switch Test
        SPEED SENSOR
            Testing
            Replacement
        FUEL SENDER
            Testing
        ACCESSORY POWER
            Wire Connections
        STARTER SYSTEM 
            Troubleshooting
            VOLTAGE DROP TEST
            Starter Lockout Troubleshooting- EFI 
            Starter Lockout Troubleshooting- H.O. 
            Starter Lockout Diagram- EFI
            Starter Lockout Diagram- H.O.
            Starter Motor Removal / Disassembly
            Brush Inspection / Replacement
            Armature Testing
            Starter Reassembly
            Starter Solenoid Bench Test
            Starter Exploded View
        STARTER DRIVE
            Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
        STARTER SYSTEM TESTING FLOW CHART
            Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing...
        BASIC WINCH WIRING
            Pre-Wired Models
        BATTERY
            Battery Identification
            Battery Activation
            Terminal Preparation
            Battery Removal
            Battery Installation
            Off Season Storage
            Low Maintenance Battery Off-Season Storage
            Battery Testing
            Conventional Battery OCV - Open Circuit Voltage Test
            Conventional Battery Specific Gravity Test
            Battery Load Test
            Charging Procedure
            Low Maintenance Battery Check:
            Low Maintenance Battery Charging
            Low Maintenance Battery - OCV- Open Circuit Voltage Test
            Low Maintenance Battery Load Test
            Low Maintenance Battery Charging Procedure
        TROUBLESHOOTING DIAGRAMS
            All Wheel Drive - EFI
            Fuel Pump and Ignition Coil - EFI
            Reverse Override - EFI
            Fan Control - EFI
            
9921790_CH_11-500 EFI X2 / TOURING QUADRICYCLE
    TABLE OF CONTENTS
        500 EFI X2 / TOURING QUADRICYCLE BRAKE SYSTEM
            Overview
            Exploded View
        500 EFI X2 / TOURING QUADRICYCLE STEERING POST AND LOCK
            Steering Assembly Exploded View
        500 EFI QUADRICYCLE EMISSIONS SYSTEM
            Overview
        500 QUADRICYCLE ELECTRICAL
            Turn / Hazard Signal Diagram
            
9921790_WIRE DIAGRAMS

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