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

2009 Polaris Sportsman 500 Family Workshop Documentation

• Covers 2009 Polaris Sportsman 500 H.O., 500 EFI, X2 500 EFI, and Touring 500 EFI variants with EH50PLE powertrain configurations
• Original OEM publication P/N 9921790, documenting service specifications for the 2009 model year range
• Contains 21 technical exploded-view diagrams and 39 detailed maintenance, engine, and drive system specification tables
• Accessible from your device as soon as the order is placed
• OCR text layer lets you jump to a torque spec by keyword
• Laid out for standard letter and A4 printing
• This 2009 edition provides the foundational mechanical build specs for the Sportsman 500 H.O. and EFI lineup including the X2 and Touring chassis variants

Technical and Maintenance Scope

The 2009 Polaris Sportsman 500 service publication provides detailed information for the engine, transmission, steering, and electrical subsystems. It details the maintenance intervals for periodic service, including lubrication requirements for the front gearcase, transmission, and ADC differential hydraulic circuit. The documentation outlines the procedures for checking engine compression, adjusting valve clearances, and maintaining the EFI or carbureted fuel delivery systems. It serves as an authoritative source for identifying sub-model differences, engine serial number locations, and essential calibration data for the EH50PLE power unit.

Specification Highlights

The 2009 Polaris Sportsman 500 data includes essential mechanical values for workshop review. Cylinder head bolt torque follows a specific sequence, while oil filter installation requires a 1/2-turn past gasket contact. Intake and exhaust valve clearance is documented at 0.006 in (0.15 mm) for the EH50PLE engine. Cylinder head warp limit is specified at 0.002 in (0.05 mm). Recommended transmission oil capacity is 32 oz (948 ml). Cooling system capacity is 2.7 qt (2.5 L). Auxiliary foot brake freeplay is 1/8–1/4 inch (3.2–6.35 mm). This document functions as an official 386-page Polaris workshop manual covering the 2009 Sportsman 500 H.O., 500 EFI, X2 500 EFI, and Touring 500 EFI models, documenting vital engine, chassis, and electrical specifications for these variants.