Polaris Sportsman 500 Touring EFI 2008 Workshop Service Repair Manual

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Stichworte: 2008 ATV Misc Polaris Powersports Sportsman 500 Touring EFI

Produktvarianten

Beschreibung

Welcome to the comprehensive guide for your 2008 ATV. This robust all-terrain vehicle, powered by the ProStar 500 engine family, is engineered for versatility and performance, offering a comfortable and capable experience for extended rides and demanding terrain. Known for its reliability and user-friendly design, the Touring EFI combines advanced electronic fuel injection with a powerful liquid-cooled engine and an automatic transmission system, making it an ideal choice for both recreational use and utility tasks. This workshop service repair manual is an indispensable resource, providing detailed, step-by-step instructions for all aspects of maintenance, troubleshooting, and repair. Covering everything from routine service intervals and fluid specifications to in-depth engine overhauls, drivetrain service, electrical diagnostics, and bodywork, this manual is designed to empower owners and professional technicians alike. With over 700 pages of information, including comprehensive wiring diagrams and diagnostic flowcharts, you will find the precise technical data and procedures necessary to keep your 2008 ATV in optimal condition, ensuring its longevity and performance.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 Touring EFI

Year:

Vehicle Type:

ATV (All-Terrain Vehicle)

Trim:

Touring EFI

Codes

Engine Family:

ProStar 500

👋 Introduction

Market Position

Target Audience:

Polaris Sportsman 500 Touring EFI owners, independent mechanics, ATV repair shops.

Value Proposition:

An indispensable resource for maintaining and repairing the 2008 Polaris Sportsman 500 Touring EFI, saving time and money on dealership service.

Competitive Analysis

Manual Superiority:

Offers more detailed, step-by-step instructions and diagnostic information than generic repair guides.

Key Features

Primary Benefit:

Empowers users with the knowledge to perform complex repairs and routine maintenance themselves.

Diagnostic Focus:

Strong emphasis on EFI system diagnostics and troubleshooting.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive service and repair for the 2008 Polaris Sportsman 500 Touring EFI.

Page Count

Estimated Page Count:

Manual Type

Manual Classification:

Workshop Service Repair Manual

Language

Primary Language:

English

Format

Delivery Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine overhaul, troubleshooting, diagnostics, fuel injection system, ignition system, cooling system.

Drivetrain System:

Primary drive, secondary drive (PVT transmission), axles, CV joints, differentials (front and rear).

Electrical System:

Battery, charging system, starter, lighting, instrumentation, ignition system, EFI control unit, wiring diagrams.

Suspension System:

Front and rear suspension, shock absorbers, control arms, bushings, wheel bearings.

Braking System:

Hydraulic brake system, master cylinders, calipers, brake pads, rotors, bleeding procedures.

Steering System:

Handlebar, steering column, tie rods, steering linkage, wheel alignment.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, EFI control module (ECU).

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable).

Cooling System:

Radiator, fan, coolant hoses, thermostat, coolant specifications.

Body Chassis:

Frame, plastics, seating, racks, body panels, removal and installation.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, valve adjustments.

Troubleshooting Procedures:

Diagnostic flowcharts, symptom-based troubleshooting for common issues.

Repair Procedures:

Step-by-step repair instructions for all major components and systems.

Diagnostic Procedures:

EFI system diagnostics, fault code retrieval, component testing.

Electrical Troubleshooting:

Wiring diagrams, circuit testing, component troubleshooting.

Engine Rebuild:

Detailed procedures for engine disassembly, inspection, and reassembly.

Technical Depth

Diagnostic Capability:

Advanced diagnostics, including EFI system analysis and component-level testing.

Repair Scope:

From basic maintenance and fluid changes to complete engine and transmission rebuilds.

Specifications Detail:

Detailed torque specifications, clearances, and tolerances for all components.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Fully searchable text for quick access to information.

Print Quality

Digital Quality:

High-resolution digital format suitable for on-screen viewing or printing.

Binding Type

Digital Binding:

N/A (Digital download)

Paper Type

Digital Paper:

N/A (Digital download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, SOHC, 4-Valve

Engine Displacement:

499 cc

Bore X Stroke:

93 mm x 73.2 mm

Cooling System:

Liquid-Cooled

Compression Ratio:

10.2:1

Performance

Horsepower Estimate:

Approx. 30-35 HP (Manufacturer data varies, manual provides specific output)

Torque Estimate:

Approx. 30-35 lb-ft (Manufacturer data varies, manual provides specific output)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Throttle Body Size:

40 mm

Fuel Type:

Unleaded Gasoline, 87 Octane Minimum Recommended

Fuel Tank Capacity:

4.0 U.S. gal (15.1 L)

🔧 Transmission

Standard

Transmission Type:

Automatic (Polaris Variable Transmission - PVT)

Drive System:

Shaft Drive, On-Demand AWD/2WD

Features

Gear Selection:

High, Low, Reverse, Neutral, Park

Transmission Fluid Type:

Polaris ধর্ষণ Transmission Fluid (PVT Fluid) or equivalent specified in manual.

Fluid Capacity Transmission:

Refer to manual for precise capacity (typically under 1 quart)

📐 Dimensions

Exterior

Length:

83 in. (210.8 cm)

Width:

46 in. (116.8 cm)

Height:

54.5 in. (138.4 cm)

Wheelbase:

56 in. (142.2 cm)

Ground Clearance:

11.25 in. (28.6 cm)

Cargo

Front Rack Capacity:

100 lbs (45.4 kg)

Rear Rack Capacity:

200 lbs (90.7 kg)

Weights

Dry Weight:

630 lbs (286 kg)

Towing Capacity:

1,500 lbs (680.4 kg)

Payload Capacity:

N/A (typically not specified, but includes rider and cargo)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI and ATV safety standards.

Active Features

Braking System Type:

Hydraulic Disc Brakes (Front and Rear)

Parking Brake:

Hand-operated, mechanical.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Seat Belt Recommendation:

Not equipped with seat belts; helmet and protective gear mandatory.

💡 Technology Features

Infotainment

Instrumentation:

Digital speedometer, odometer, trip meter, tachometer, fuel gauge, engine hour meter, AWD/2WD indicator, clock.

Driver Assistance

Efi Control:

Engine Control Unit (ECU) manages fuel delivery, ignition timing, and other engine parameters for optimal performance and emissions.

Connectivity

Diagnostic Ports:

On-board diagnostic connector for fault code retrieval (covered in manual).

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 100 hours or annually, whichever comes first (consult manual for exact details).

Air Filter Cleaning:

Inspect every 25 hours, clean as needed, replace annually or sooner if damaged.

Spark Plug Replacement:

Replace every 100 hours or annually.

Valve Adjustment Interval:

Every 100 hours or annually.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Full Synthetic Engine Oil (or equivalent JASO MA certified 5W-50)

Engine Oil Capacity:

2.4 U.S. quarts (2.3 L) with filter change.

Coolant Type:

Polaris Premium Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors, 50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Common Wear Items:

Brake pads, wheel bearings, tie rod ends, drive belts (PVT).

Efi System Concerns:

Potential for clogged injectors or sensor issues if fuel quality is poor or maintenance is neglected.

Pvt Belt Wear:

Drive belt wear is normal; replacement is critical for performance and to prevent damage to clutch components.

📚 Vehicle History

Brand Heritage

Polaris Legacy:

Polaris has a long-standing reputation for innovation and performance in the powersports industry, particularly with its Sportsman line of ATVs.

Model Evolution

Sportsman 500 Lineage:

The Sportsman 500 is a foundational model in Polaris's ATV lineup, known for its versatility, comfort, and capability, with continuous updates over the years.

Touring Variant:

The 'Touring' designation signifies models equipped for longer rides and often include enhanced comfort features and storage.

Production

Manufacturing Plant:

Primarily manufactured in Roseau, Minnesota, USA.

🏆 Awards & Recognition

Recognitions

Atv Market Perception:

The Polaris Sportsman 500 line has consistently been recognized for its durability, comfort, and capability in various riding conditions.