2009 Polaris Scrambler 500 4x4, Scrambler 500 2x4 Factory Service Manual (P/N 9921777 / 9921778)

This 256-page PDF covers the 2009 Polaris Scrambler 500 Gen III platform: 4x4 models A09BG50AA and A09BG50FA, plus the 2x4 International model A09BA50FA. Vehicle identification uses the liquid-cooled SOHC four-stroke EH50PLE/EH500PLE designation; the engine chapter shortens it to EH50PL. It is suited to experienced owners for routine service, while steering and internal-engine repair call for advanced workshop skills and specified factory tools, and the manual expressly limits PVT repair to certified Polaris Master Service Dealer technicians.

• Organizes preventive service around pre-ride and interval charts, lubrication maps, oil and filter changes, valve-clearance adjustment, shift-linkage calibration, wheel alignment, AWD hub service, chain and sprocket care, brake inspection, and PVT drying.
• Takes engine repair beyond basic tune-up work with removal and installation, cooling-system bleeding and pressure testing, oil-pressure and pump-priming checks, cylinder-head and valve-seat service, cylinder and piston inspection, bottom-end disassembly, crankcase and bearing assembly, crankshaft and counterbalancer end-play checks, cam timing, and sealed-recoil service.
• Follows the Mikuni BST 40 carburetor through CV-system operation, jetting guidance, float and fuel-level adjustment, needle-and-seat leakage testing, cleaning, inspection, assembly, fuel-pump service, and troubleshooting. The non-EBS Polaris Variable Transmission (PVT) section covers belt inspection, clutch disassembly, bushing replacement, alignment and offset, and diagnosis.
• Separates the 4x4 driveline work into Hilliard front-hub, armature-plate and magnetic-coil service; CV axle and boot replacement; U-joint work; front-housing overhaul; and 4x4 transmission disassembly and reassembly. Rear axle, concentric-swingarm, A-arm, steering-post, ball-joint, and strut repair are covered in their own sections.
• Works through the hydraulic brake system from bleeding and fluid replacement to master-cylinder, front-caliper, rear-caliper, pad, and disc service, with inspection limits and brake-noise troubleshooting.
• Supports electrical fault isolation with PDM operation, fan and hot-light testing, thermistor checks, ETC testing, DC/CDI ignition diagnosis, charging and starter tests, reverse-limiter and No-AWD flowcharts, battery service, and a two-page 2009 wiring diagram with a wire-termination table.

4x4 vs. 2x4 Scope

The internal transmission exploded view, disassembly, and reassembly are labeled for the 4x4 transmission. The Hilliard hub, front drive axle, front housing, and No-AWD diagnostic material are likewise 4x4-specific; the 2x4 receives its own front-strut exploded view but no separate internal transmission-overhaul chapter.

The publication table cross-references Owner’s Manual 9921777 and Parts Manual 9921778 for both listed models. The service manual is arranged in 10 numbered chapters with section-level contents pages and end-of-manual wiring diagrams rather than a separate alphabetical index.

Factory Data, Tools, and Diagrams

Reference material includes assembly-specific torque tables and tightening patterns, fluid and lubricant data, clearances, wear and service limits, carburetor jetting and clutch setup charts, brake specifications, and electrical voltage, resistance, current-draw, and component test data. Factory-tool callouts include the PA-44689 valve/clutch adjuster, 2872105 water-pump mechanical-seal puller, 2200634 valve-seat reconditioning kit, 2870654 clutch offset alignment tool, 2870888 Hilliard garter-spring installation tool, and PV-43568 digital multimeter.

Key illustrations include the EH50PL engine oil-flow chart, Mikuni BST 40 exploded view, AWD front-hub exploded view, PDM control-circuit diagram, ignition-system testing flowchart, and the model-wide 2x4/4x4/International wiring diagram.

Scrambler-Specific Repair Cautions

The water-pump seal procedure warns that side-loading or misaligning the puller can bend the pump shaft, turning a seal repair into an engine-removal and crankcase-separation job. In the AWD hub, an incorrect or overstressed Hilliard garter spring can allow unwanted front-wheel engagement, while displaced armature-plate tabs can damage the roller clutch.

Cooling-system, brake, suspension, drivetrain, and PVT work should be performed with the ATV securely supported, the cooling system fully cooled, and the eye and hand protection specified by the manual.