Polaris Sportsman 500 (2009)
POLARIS SPORTSMAN 500 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
POLARIS SPORTSMAN 500 (2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual and Wiring Diagrams, to ATV Polaris Sportsman 500 (2009). CONTENTS: 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 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 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 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 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 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 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 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 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 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 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
Polaris Sportsman 500 (2009) - Repair, Workshop Manual and Electrical Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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