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POLARIS SPORTSMAN 500 X2 EFI 2008 ATV Service Repair Manual

$16.99
$16.99
The 2008 Sportsman 500 X2 EFI is a versatile utility ATV renowned for its robust engineering and adaptability. As a key model in the esteemed Sportsman line, it offers a...
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Typ: Atv
Anbieter:
Polaris
Art.-Nr: 87012
Stichworte: 2008 ATV Misc Polaris Powersports SPORTSMAN 500 X2 EFI
POLARIS SPORTSMAN 500 X2 EFI 2008 ATV Service Repair Manual
The 2008 Sportsman 500 X2 EFI is a versatile utility ATV renowned for its robust engineering and adaptability. As a key model in the esteemed Sportsman line, it offers a unique X2 configuration, distinguishing itself with enhanced carrying capacity and passenger-carrying capabilities, bridging the gap between traditional ATVs and side-by-side vehicles. Its Electronic Fuel Injection (EFI) system ensures improved throttle response and reliable performance across various conditions. Built for demanding tasks and recreational adventures, the Sportsman 500 X2 EFI is powered by a 499cc liquid-cooled, SOHC engine, delivering approximately 30-32 horsepower and 28-30 lb-ft of torque, coupled with an On-Demand All-Wheel Drive system for superior traction. This comprehensive service repair manual provides essential information for maintaining and repairing the 2008 Sportsman 500 X2 EFI. It covers all major systems, including detailed engine overhaul procedures, EFI system diagnostics, PVT transmission maintenance, drivetrain components, suspension, brakes, and the electrical system. The manual includes step-by-step instructions for routine maintenance, troubleshooting common issues, component repair, and complete rebuilds. With in-depth coverage and clear explanations, this manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, longevity, and reliability of their Sportsman 500 X2 EFI.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 500 X2 EFI
Year:
2008
Product Type:
Service Repair Manual
Codes
Chassis Code Prefix:
A08
👋 Introduction
Market Position
Segment:
Utility ATV, known for versatility and carrying capacity due to the X2 designation.
Competitive Analysis
Competitors:
Yamaha Grizzly, Can-Am Outlander, Arctic Cat 500.
Key Features
X2 Design:
Unique X2 designation signifies its dual-purpose capability, often featuring a tilting rear dump bed or a second seat option for passenger carrying, enhancing its utility beyond typical single-seat ATVs.
Efi:
Electronic Fuel Injection provides improved throttle response, easier starting, and better performance in varying altitudes and temperatures compared to carbureted models.
📋 Manual Details
Coverage Areas
General Coverage:
Complete service and repair information for the 2008 Polaris Sportsman 500 X2 EFI ATV.
Page Count
Estimated Pages:
Hundreds (typical for comprehensive ATV service manuals)
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed engine overhaul, including top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (liquid-cooled), and timing.
Fuel System:
EFI (Electronic Fuel Injection) system diagnosis, components (throttle body, fuel pump, injectors, sensors), fuel filter replacement, and troubleshooting.
Transmission:
PVT (Polaris Variable Transmission) clutch system (primary and secondary), belt inspection and replacement, gearcase maintenance, and troubleshooting.
Drivetrain:
Front and rear drive shafts, differentials, CV joints, AWD system (On-Demand All-Wheel Drive) operation and maintenance, hub assemblies.
Suspension:
Front and rear independent suspension, shock absorbers, control arms, bushings, wheel bearings, alignment procedures.
Brakes:
Hydraulic disc brakes (front and rear), brake caliper service, master cylinder, brake lines, fluid replacement and bleeding, parking brake.
Electrical System:
Ignition system, charging system (stator, voltage regulator), battery maintenance, starter motor, lighting system (headlights, taillights, brake lights), wiring diagrams, fuses, relays, ECU (Engine Control Unit) diagnosis.
Steering:
Steering column, tie rods, steering rack, wheel alignment, and troubleshooting.
Body Chassis:
Frame inspection, body panels, seat removal, cargo rack system, front and rear bumpers, skid plates.
Cooling System:
Radiator, cooling fan, coolant hoses, coolant type and capacity, flushing and refilling procedures.
Exhaust System:
Muffler, exhaust pipes, heat shields, inspection and replacement.
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments, spark plug replacement, battery checks, tire pressure.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault codes, symptom-based troubleshooting guides, electrical diagnostics.
Repair:
Step-by-step instructions for component removal, installation, and repair across all major systems.
Rebuild:
Complete engine and transmission rebuild procedures, including torque specifications and clearances.
Diagnostics:
In-depth diagnostic procedures for the EFI system, electrical faults, and mechanical issues.
Technical Depth
Depth:
Comprehensive, from basic checks and adjustments to complete engine and drivetrain overhauls, including electrical system diagnostics and component-level repair.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text-based PDF for easy navigation.
Print Quality
Quality:
High-resolution scans or original factory files, ensuring clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, Single Cylinder
Displacement:
499cc
Bore X Stroke:
Approx. 92 mm x 76 mm (typical for 500cc Polaris single)
Cooling System:
Liquid-cooled
Valvetrain:
SOHC (Single Overhead Cam), 4 valves per cylinder
Compression Ratio:
Approx. 10.0:1
Performance
Horsepower:
Approx. 30-32 HP (typical for this engine size and configuration)
Torque:
Approx. 28-30 lb-ft (typical)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body
Fuel Type:
Unleaded gasoline, 87 octane or higher
Lubrication
Oil Type:
SAE 0W-40 or 5W-50 Synthetic ATV/Motorcycle Oil (refer to manual for specific Polaris recommendation)
Oil Capacity:
Approx. 2.0 US quarts (1.9 Liters) with filter change (verify in manual)
🔧 Transmission
Standard
Type:
Polaris Variable Transmission (PVT) with Engine Braking
Drive Modes:
Automatic (High, Low, Neutral, Reverse, Park)
Final Drive:
Shaft Drive (Front & Rear)
Features
AWD System:
On-Demand All-Wheel Drive (AWD)
Clutch System:
Primary and secondary centrifugal clutches with drive belt
Fluid Specifications
Gearcase Oil Type:
SAE 80W-90 Hypoid Gear Lubricant or Polaris Demand Drive Fluid (verify in manual)
Gearcase Oil Capacity:
Approx. 0.25 US quarts (0.24 Liters) for front/rear gearcases (verify in manual)
📐 Dimensions
Exterior
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 50 inches (127 cm)
Cargo
Front Rack Capacity:
Approx. 100 lbs (45 kg)
Rear Rack Capacity:
Approx. 200 lbs (90 kg) (or capacity of tilting bed)
Weights
Dry Weight:
Approx. 660 lbs (299 kg)
Ground Clearance:
Approx. 10.25 inches (26 cm)
Towing Capacity:
1500 lbs (680.4 kg)
Payload Capacity:
Approx. 450 lbs (204 kg) (combined rider and cargo)
🛡️ Safety Features
Ratings
Safety Certification:
Meets ANSI standards for recreational ATVs.
Active Features
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
AWD Engagement:
On-Demand AWD provides enhanced traction when needed.
Passive Features
Ergonomics:
Designed for rider comfort and control with accessible controls.
Lighting:
Dual headlights and a rear brake light for visibility.
💡 Technology Features
Infotainment
Dashboard:
Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and AWD indicator. May include diagnostic warning lights.
Driver Assistance
Auto Engage AWD:
The On-Demand AWD system automatically engages front wheel drive when rear wheels lose traction.
Connectivity
Diagnostic Ports:
Diagnostic port for connecting service tools to read fault codes and sensor data.
🔧 Maintenance
Service Intervals
Oil Change:
Every 100 hours or annually (whichever comes first).
Air Filter Cleaning:
Every 25 hours or more frequently in dusty conditions.
Spark Plug Inspection:
Every 100 hours or annually.
Clutch Belt Inspection:
Every 50 hours or annually; replace as needed based on wear.
Valve Adjustment:
Every 100 hours or annually.
Fluid Specifications
Coolant Type:
Polaris Premium Antifreeze or equivalent (50/50 mix with distilled water recommended).
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Known Issues
Drive Belt Wear:
Drive belts can wear prematurely if subjected to excessive slippage, heat, or incorrect tension. Regular inspection and replacement are key.
A-Arm Bushings:
Wear in A-arm bushings can lead to play in the suspension and steering. Manual details replacement procedures.
Efi Sensor Issues:
While generally reliable, sensors like the TPS (Throttle Position Sensor) or MAP sensor can sometimes require cleaning or replacement, often indicated by poor engine performance. The manual provides diagnostic steps.
📚 Vehicle History
Brand Heritage
Polar Heritage:
Polaris Industries is a long-standing American manufacturer of powersports vehicles, known for its innovation and robust utility ATVs.
Model Evolution
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris' ATV offerings for decades, evolving with new technologies and configurations like the X2 variant.
X2 Introduction:
The X2 models were introduced to cater to riders needing increased versatility, particularly for carrying passengers or hauling small loads, bridging the gap between traditional utility ATVs and side-by-sides.
Production
Manufacturing Location:
Typically manufactured in Spirit Lake, Iowa, USA (Polaris assembly plant).
🏆 Awards & Recognition
Recognitions
Market Perception:
The Polaris Sportsman 500 series is generally well-regarded in the utility ATV market for its power, reliability, and versatility, particularly in its X2 configuration for enhanced utility.
Ratings
Industry Reviews:
Often cited in industry reviews for its strong performance and comfort for its class.
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