Category:
All-Terrain Vehicle (ATV) - Utility/Recreational
Target User:
Owners and technicians performing maintenance, repairs, and diagnostics on the 2008 Polaris Sportsman 500 Touring EFI.
Competitors 2008:
Can-Am Outlander, Yamaha Grizzly, Arctic Cat 500/550, Kawasaki Brute Force, Suzuki KingQuad.
Touring Capability:
Designed for extended rides with comfortable seating for two and ample storage, suitable for recreational touring and utility tasks.
Completeness:
Provides exhaustive technical information directly from the manufacturer, ensuring accuracy and completeness for all service procedures.
Engine Systems:
Engine disassembly, assembly, troubleshooting, performance tuning, fuel injection system, ignition system, cooling system, lubrication system.
Drivetrain Systems:
Transmission, final drive, differential, axle shafts, drive shafts, CV joints.
Chassis Systems:
Frame, suspension (front and rear), steering system, brakes (hydraulic, calipers, master cylinder, lines), wheels, tires.
Electrical Systems:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation, ignition switch, wiring diagrams, EFI sensors.
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, coolant checks and flushes, brake fluid replacement, lubrication points, valve adjustments.
Repair Procedures:
Engine rebuilds, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and replacement, fuel system cleaning and repair.
Troubleshooting Guidelines:
Diagnostic charts for common problems, symptom-based troubleshooting, error code interpretation (if applicable for EFI system).
Wiring Diagrams:
Detailed electrical system wiring diagrams for troubleshooting and repair.
Torque Specifications:
Specific torque values for all critical fasteners and engine components.
Special Tools:
Identification and usage instructions for any specialized tools required for specific repair procedures.
Depth:
Comprehensive, suitable for both amateur mechanics and professional technicians. Covers basic maintenance to complete overhauls and diagnostics.
Document Type:
Factory Service Manual / Repair Manual
Engine Type:
4-Stroke, Liquid-Cooled, SOHC, Single-Cylinder
Displacement:
499 cc (30.45 cu. in.)
Bore X Stroke:
92 mm x 76 mm (3.62 in. x 2.99 in.)
Horsepower:
Approx. 30 HP (Actual figures vary slightly based on tuning and conditions, manual will provide precise figures)
Torque:
Approx. 28 lb-ft (Actual figures vary slightly, manual will provide precise figures)
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin 40mm throttle body
Fuel Type:
Unleaded Gasoline, 87 Octane minimum
Coolant Type:
Polaris Premium 2-Stroke Premix (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors - manual specifies exact type and mix ratio)
Oil Type:
SAE 5W-50 Synthetic or Polaris Premium 4 Synthetic (manual specifies exact viscosity and API rating)
Oil Capacity:
Approx. 2.1 US quarts (2.0 L) with filter change (manual specifies exact capacity)
Type:
Electronic Ignition (CDI)
Type And Gap:
NGK CR7E or equivalent, 0.028-0.031 in. (0.7-0.8 mm) gap (manual specifies exact part number and gap)
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Drive System:
Shaft Drive, On-Demand AWD/2WD
Gear Selection:
High, Low, Neutral, Reverse, Park
Transmission Fluid:
Polaris AGL Premium Synthetic Gearcase Lubricant (manual specifies exact type and capacity)
Capacity:
Approx. 20 oz. (0.6 L) (manual specifies exact capacity)
Length:
Approx. 85.0 in. (215.9 cm)
Width:
Approx. 46.0 in. (116.8 cm)
Height:
Approx. 47.0 in. (119.4 cm)
Wheelbase:
Approx. 50.5 in. (128.3 cm)
Ground Clearance:
Approx. 10.25 in. (26.0 cm)
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Dry Weight:
Approx. 662 lbs (300 kg) (manual may specify specific configurations)
Towing Capacity:
1500 lbs (680.4 kg)
Payload Capacity:
N/A (Refer to rack capacities and specific user weight limits in manual)
Fuel Capacity:
4.25 US gallons (16.1 L) with reserve
Atv Safety Standards:
Adheres to American National Standards Institute (ANSI) standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear. Engine braking via PVT system.
Suspension Stability:
Independent front and rear suspension contributes to ride stability and control.
Seat Belts Roll Cage:
Not equipped with seat belts or roll cage; designed for operation with helmet and protective gear.
Hand Grips Throttle:
Ergonomic hand grips and thumb throttle for control.
Protective Gear Requirements:
Manual emphasizes the necessity of wearing a helmet, eye protection, gloves, boots, and protective clothing.
Instrument Cluster:
Digital LCD display with speedometer, tachometer, odometer, trip meter, fuel gauge, clock, high beam, neutral, reverse, AWD indicators, and engine hour meter.
Efi Performance:
Electronic Fuel Injection provides optimized fuel delivery for improved throttle response, cold starts, and fuel efficiency.
On Demand AWD:
On-Demand All-Wheel Drive system automatically engages front wheels when rear wheel traction is lost, enhancing off-road capability.
Diagnostic Ports:
Potential for diagnostic data access via specific connectors, detailed in the manual for advanced troubleshooting.
Initial Service:
First service typically at 10 hours or 1 month (refer to manual for exact break-in procedure).
Engine Oil Change:
Every 100 hours or 6 months (manual specifies based on usage conditions).
Air Filter Cleaning:
Every 25 hours or 3 months, clean or replace as needed (more frequently in dusty conditions).
Spark Plug Inspection:
Every 100 hours or 12 months.
Valve Adjustment:
Every 100 hours or 12 months (manual specifies procedure and tolerances).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid (manual specifies exact type and replacement interval).
Coolant Specifications:
Polaris Premium 2-Stroke Premix or specified ethylene glycol-based antifreeze. Manual details correct mix ratio for optimal freeze and corrosion protection.
Common Wear Items:
Drive belts, brake pads, tie rod ends, suspension bushings are common wear items. Manual provides inspection guidelines.
Efi System Maintenance:
Throttle body cleaning and sensor checks may be required over time. Manual guides diagnostics for EFI issues.
Polaris History:
Polaris Industries is a long-standing American manufacturer known for its innovation in snowmobiles, ATVs, and other powersports vehicles since its founding in 1954.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving over decades to incorporate advanced features like EFI, independent suspension, and improved comfort for touring.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States, with plants in Minnesota and Iowa.
Model Year Specifics:
The 2008 model year represents a mature iteration of the Sportsman 500 platform, featuring the EFI system for improved performance and emissions.
