2008 Polaris Sportsman 500 ATV Repair Manual

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Tipo: Atv

Proveedor:

SKU: 53327

Etiquetas: 2008 ATV Polaris Powersports Sportsman 500 Sportsman Series

Variantes de producto

Descripción

This manual covers the 2008 Sportsman 500 ATV, a versatile and rugged vehicle renowned for its capability in various terrains. Engineered with a 499cc 4-stroke engine, available in both fuel-injected and carbureted variants, the Sportsman 500 is designed for a wide range of applications, from utility work to recreational trail riding. Its robust construction, automatic Variable Transmission (PVT), and selectable All-Wheel Drive (AWD) system provide reliable performance and user-friendly operation, making it a trusted choice for owners and operators. This comprehensive service manual provides detailed instructions for the maintenance, repair, and troubleshooting of your 2008 Sportsman 500. It encompasses all major systems, including engine management, powertrain, chassis, suspension, and electrical components. Inside, you will find step-by-step procedures for routine maintenance, engine overhaul, component rebuilding, and advanced diagnostic techniques. This manual is an essential resource for owners and professional technicians alike, ensuring the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500

Year:

Product Name:

2008 Polaris Sportsman 500 ATV Repair Manual PDF Download

Generation

Atv Platform:

Polaris Sportsman

Codes

Vin Code Engine:

500cc (exact code dependent on sub-model)

👋 Introduction

Market Position

Target Audience:

Polaris Sportsman 500 ATV owners and independent repair shops.

Competitive Analysis

Vendor Strength:

GearHead Manuals positions itself as the sole source for reliable repair and service manual downloads.

Key Features

Convenience:

Instant, downloadable PDF format eliminates shipping delays and physical storage issues.

Usability:

Designed for easy use in the field or workshop, printable on demand.

Accessibility:

Accessible on smart devices for on-the-spot troubleshooting and repair.

📋 Manual Details

Coverage Areas

Covered Models:

2008 Polaris Sportsman 500 6x6 ATV, 2008 Polaris Sportsman 500 EFI ATV, 2008 Polaris Sportsman 500 EFI LE ATV, 2008 Polaris Sportsman 500 EFI Touring ATV, 2008 Polaris Sportsman 500 EFI X2 ATV, 2008 Polaris Sportsman 500 HO ATV

Page Count

Estimated Page Count:

Varies by specific sub-model, but comprehensive manuals typically range from 300-600 pages.

Manual Type

Primary Manual Type:

Repair Manual / Service Manual / Workshop Manual

Secondary Manual Type:

Owner's Manual, Parts Catalog (implied by description)

Language

Language:

English

Format

File Format:

PDF (Direct Download)

📖 Manual Coverage

Systems Covered

Engine Management:

Includes fuel system, lubrication, cooling system, engine specifications, intake, and exhaust.

Powertrain:

Covers transmission, drive chain, and sprockets.

Chassis And Suspension:

Details steering system and shocks.

Electrical And Electronics:

Comprehensive coverage of the electrical system, including troubleshooting.

Bodywork And Cosmetics:

Includes information on body work.

Procedures Included

Routine Maintenance:

Detailed steps for all routine maintenance tasks.

Engine Repair:

Engine removal and installation, along with internal engine procedures.

Troubleshooting:

Advanced troubleshooting guides for diagnosing and resolving issues.

Component Overhaul:

Procedures for disassembling, inspecting, and rebuilding major components.

Technical Depth

Diagnostic Capabilities:

Provides diagnostic procedures for identifying common and complex problems.

Repair Complexity:

Covers everything from basic adjustments to complete engine and transmission rebuilds.

Information Scope:

Comprehensive information for both novice and experienced mechanics.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable PDF for easy navigation and printing.

File Structure:

Single, integrated PDF file; no compression or additional software required.

Print Quality

Printable Pages:

Designed for printing specific pages as needed, without degrading the digital copy.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital Download)

Download Features

Download Speed:

Instant download post-payment.

Shipping Cost:

No shipping cost.

Support Policy

Loss Damage Policy:

Lifetime Protection Policy for lost or damaged downloads.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, 4-Valve, SOHC

Displacement:

499cc (for most 500 models)

Bore X Stroke:

93.3 mm x 71.9 mm (typical for 500 HO)

Performance

Horsepower:

Approx. 30-34 HP (varies by sub-model and tuning)

Torque:

Approx. 27-30 ft-lbs (varies by sub-model)

Fuel System

Fuel Delivery:

Fuel Injection (EFI) for EFI and EFI LE, EFI Touring, EFI X2 models; Carbureted for HO and potentially base 500 models.

Fuel Type:

Unleaded gasoline (87 octane or higher recommended)

Lubrication

Oil Type:

Polaris recommends SAE 0W-40 or SAE 5W-50, API CI-4 Synthetic

Cooling System

Coolant Type:

Ethylene Glycol based antifreeze/coolant

🔧 Transmission

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission)

Drive System:

Shaft Drive (AWD/2WD selectable on most models, 6x6 features 6-wheel drive)

Features

Gear Selection:

High, Low, Neutral, Reverse, Park

Clutch Type:

Primary and Secondary Clutch System

Fluid Requirements

Transmission Oil Type:

Polaris Synthetic Gearcase Lubricant (SAE 80W-90)

📐 Dimensions

Exterior

Length:

Approx. 83-85 inches (varies by sub-model, 6x6 and Touring will be longer)

Width:

Approx. 46-48 inches (varies by sub-model)

Height:

Approx. 48-50 inches (varies by sub-model)

Weights

Dry Weight:

Approx. 600-700 lbs (varies significantly by sub-model, 6x6 and X2 will be heavier)

Ground Clearance:

Approx. 8-10.5 inches (varies by sub-model)

Cargo

Rack Capacity Front:

100 lbs

Rack Capacity Rear:

200 lbs (except X2 which has a tilt bed)

Towing Capacity:

1500 lbs

🛡️ Safety Features

Ratings

Atv Safety Standards:

Follows industry standards for ATV safety.

Active Features

Braking System:

Hydraulic Disc Brakes (Front and Rear, often dual-rotor front)

Parking Brake:

Hand-operated lever or integrated into transmission park position.

Passive Features

Lighting:

Headlights, Taillight, Brake Light

Throttle Limiter:

Adjustable throttle stop for new riders (if equipped).

💡 Technology Features

Infotainment

Display Panel:

Digital LCD display showing speed, RPM, odometer, fuel level, gear indicator, AWD status.

Driver Assistance

AWD System:

On-Demand All-Wheel Drive (AWD) system, which engages automatically when rear wheel slip is detected.

Connectivity

Diagnostics Port:

Diagnostic port for connecting scan tools to read fault codes and monitor engine parameters.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 50-100 hours or annually.

Air Filter Cleaning:

Check every 25 hours, clean/replace as needed based on conditions.

Spark Plug Replacement:

Check and gap every 100 hours, replace every 200 hours (typical).

Valve Adjustment:

Every 100-200 hours or as per manual specification.

Fluid Specifications

Engine Oil Spec:

SAE 0W-40 or SAE 5W-50, API CI-4 Synthetic

Gearcase Oil Spec:

Polaris Synthetic Gearcase Lubricant (SAE 80W-90)

Coolant Spec:

Ethylene Glycol based antifreeze/coolant, 50/50 mix with distilled water

Known Issues

Common Wear Items:

Drive belts (PVT), wheel bearings, tie rod ends, brake pads.

Potential Failures:

EFI sensor issues, starter solenoid, fuel pump (on EFI models).

Maintenance Schedule Summary

Pre Ride Checks:

Tires, fluids, controls, lights, brakes.

📚 Vehicle History

Brand Heritage

Polaristracks:

Polaris has a long history in motorsports and off-road vehicles, known for innovation and ruggedness.

Model Evolution

Sportsman Legacy:

The Sportsman line is Polaris's flagship ATV series, known for comfort, capability, and versatility since its introduction.

Production

Manufacturing Location:

Typically manufactured in the USA (e.g., Roseau, Minnesota).

🏆 Awards & Recognition

Recognitions

Model Reputation:

The 2008 Sportsman 500 is generally regarded as a reliable and capable workhorse ATV within its class.