Positioning:
The Polaris Sportsman 500 Touring EFI 2008 was positioned as a capable and versatile all-terrain vehicle for recreational use, trail riding, and light utility tasks, offering a balance of power and comfort for longer rides.
Competitors:
Competed with other leading 500cc-class ATVs from brands like Can-Am (Outlander 500), Arctic Cat (500 TRV), and Yamaha (Grizzly 550).
Touring Focus:
The 'Touring' designation highlights features aimed at rider comfort and extended use, such as a longer wheelbase, comfortable seating for two, and potentially larger storage options.
Efi:
Electronic Fuel Injection (EFI) provides improved throttle response, easier starting in various conditions, and better fuel efficiency compared to carbureted models.
Value Proposition:
This factory service manual is indispensable for owners and technicians seeking accurate, comprehensive repair and maintenance information directly from the manufacturer. It ensures correct procedures are followed, preserving vehicle integrity and performance.
Engine:
Complete overhaul, troubleshooting, diagnostics, fuel injection system (EFI), ignition system, cooling system, lubrication system
Transmission:
PVT (Polaris Variable Transmission) service, belt inspection/replacement, roller inspection, clutch service, final drive
Drivetrain:
AWD system, driveshafts, CV joints, differential service, rear axle
Suspension:
Front and rear suspension components, shocks, A-arms, bushings, wheel bearings
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake lines, bleeding procedures, rotor/pad replacement
Electrical:
Wiring diagrams, lighting systems, battery, starter, charging system, ECU, sensor diagnostics, accessory circuits
Steering:
Handlebar, steering shaft, tie rods, steering rack, potential EPS (Electric Power Steering) diagnostics if applicable to this model variant
Frame And Body:
Chassis inspection, body panel removal/installation, plastics, seat, rack systems
Routine Maintenance:
Oil changes, filter replacements, lubrication points, spark plug checks, tire pressure, coolant checks
Troubleshooting:
Systematic diagnostic flowcharts for common and uncommon issues
Repair:
Detailed step-by-step repair instructions for all major and minor components
Disassembly And Assembly:
Complete instructions for component removal, inspection, repair, and reinstallation
Special Tools:
Identification and usage of required special tools
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds; dealer-level diagnostic information
Searchability:
Likely text-searchable, enabling quick navigation to specific topics
Quality:
High-resolution images, clear text, suitable for printing by the user
Type:
N/A (Digital Download - PDF)
Type:
N/A (Digital Download - PDF)
Engine Type:
4-stroke, Single Cylinder
Displacement:
499cc (approx.)
Bore X Stroke:
Specifics available within the manual (typical for Polaris 500cc single)
Cooling System:
Liquid-cooled
Valvetrain:
SOHC (Single Overhead Cam), 4 valves
Horsepower:
Typically in the range of 30-35 HP (exact rating in manual)
Torque:
Specific torque figures and curves detailed in the manual
System:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Type:
Electronic Ignition
Type:
Polaris Variable Transmission (PVT) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive Modes:
On-Demand All-Wheel Drive (AWD)
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant or equivalent (refer to manual for precise specification)
Gearcase Capacity:
Specific capacity detailed in the manual (typically around 1.5-2 liters)
Length:
Approx. 85.5 inches (217.2 cm)
Width:
Approx. 48 inches (121.9 cm)
Height:
Approx. 50 inches (127 cm) to handlebars
Wheelbase:
Approx. 57 inches (144.8 cm)
Ground Clearance:
Approx. 11.25 inches (28.6 cm)
Dry Weight:
Approx. 715 lbs (324 kg)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
Storage:
Locking front storage compartment, rear rack with integrated tie-down points.
Atv Classification:
Not applicable for crash ratings in the same manner as automobiles; focus is on operational safety and handling.
Braking System:
Hydraulic disc brakes front and rear, sealed hydraulic rear brake pedal.
Engine Braking:
Standard on PVT for downhill control.
AWD System:
On-Demand AWD for enhanced traction.
Lighting:
Dual 35W headlights, 35W tail/stop light.
Ergonomics:
Comfortable seating for two, ergonomic handlebar placement.
Protective Gear:
Helmet, eye protection, gloves, long pants, long-sleeved shirt, sturdy boots are strongly recommended (detailed in owner's manual).
Instrumentation:
Digital odometer, speedometer, tachometer, trip meter, fuel gauge, AWD indicator, high-beam indicator, neutral indicator, reverse indicator, oil/temp warning lights. Specific dashboard layout details in manual.
Efi Management:
The EFI system itself is a technological advancement, providing precise fuel metering and optimizing performance across varying conditions. Diagnostic codes may be accessible through a diagnostic port.
Accessory Ports:
Provision for 12V accessory outlets for charging devices or powering accessories.
Oil Change:
Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact intervals).
Air Filter:
Inspection every 25 hours, cleaning/replacement as needed, more frequently in dusty conditions.
Spark Plug:
Check and clean at 50 hours, replace at 100 hours or as needed.
Transmission Fluid:
Check level periodically, change at recommended intervals (e.g., annually or every 200 hours).
Engine Oil:
Polaris PS-4 Full Synthetic 5W-50 or equivalent (specific API service classification will be in the manual).
Engine Oil Capacity:
Approximately 2.5 quarts (2.4 liters) with filter change (verify in manual).
Coolant:
Permanent type antifreeze/coolant, 50/50 mix with distilled water (specific type and color in manual).
Common Wear Items:
PVT belt wear, wheel bearings, ball joints, tie rod ends, bushings are common wear items on ATVs and are well-documented for inspection and replacement in the manual.
Efi Diagnostics:
EFI systems can be complex; the manual's diagnostic section is crucial for identifying sensor issues (e.g., throttle position sensor, oxygen sensor) or fuel delivery problems.
Engine Mounts:
Specific torque values for critical fasteners (e.g., cylinder head, exhaust) are provided.
Wheel Lug Nuts:
Torque specifications for wheel mounting are essential for safety.
Polaris Legacy:
Polaris Industries has a long history in powersports, known for innovation in snowmobiles and later ATVs, building a reputation for ruggedness and performance.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from basic models to feature-rich, multi-passenger and utility-focused machines. The 500cc engine has been a popular displacement for this series for many years.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States, with assembly plants in Minnesota and South Dakota.
2008 Enhancements:
While specific details for 2008 are best confirmed by the manual, Polaris typically refined its models annually, potentially including suspension tweaks, styling updates, and EFI system improvements.
