2008 Polaris Sportsman 500 All Service Repair Manual Instant

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Tipo: Atv

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SKU: 53861

Etiquetas: 2008 ATV Polaris Powersports Sportsman 500 Sportsman Series

Variantes de producto

Descripción

This manual covers the 2008 Polaris Sportsman 500, a versatile all-terrain vehicle renowned for its robust engineering and reliable performance. Designed for both utility and recreational use, the Sportsman 500 series, including variants such as the Sportsman 500 EFI, Sportsman 500 HO, and the Sportsman Touring 500 EFI, offers a powerful 4-stroke, liquid-cooled 499cc engine. Key features include an automatic CVT transmission, On-Demand All-Wheel Drive, hydraulic disc brakes, and a comfortable suspension system. A long-standing American manufacturer, has consistently refined the Sportsman line, and the 2008 models represent a mature generation with updated systems for enhanced capability. This comprehensive service repair manual provides detailed information for the maintenance and repair of your 2008 Polaris Sportsman 500. It covers all essential systems, including the engine, fuel system (EFI and carbureted), transmission, final drive, brakes, and electrical components, along with bodywork, steering, and suspension. The manual includes step-by-step procedures for routine maintenance, diagnostics, troubleshooting, and complete rebuilds, supported by high-resolution diagrams and wiring schematics. This resource is designed to empower owners and technicians alike, offering dealership-level repair information to ensure optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500

Year:

Model Variants:

Sportsman 500 EFI, Sportsman 500 EFI Scandinavian, Sportsman 500 HO, Sportsman Touring 500 EFI, Sportsman Touring 500 EFI Quadricycle

Generation

Generation Code:

Third Generation Sportsman (2005-2008)

Codes

Vin Decoder Location:

Refer to manual for VIN location and interpretation

👋 Introduction

Market Position

Target Audience:

Owners of 2008 Polaris Sportsman 500 models seeking to perform maintenance and repairs.

Competitive Analysis

Value Proposition:

Provides dealership-level repair information at a fraction of the cost, enabling self-sufficiency and cost savings.

Key Features

Delivery Method:

Instant PDF download, eliminating shipping costs and delays.

Content Quality:

High-resolution diagrams and easy-to-read text for efficient repair processes.

Searchability:

Searchable PDF format allows quick access to specific information.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service and repair for all listed 2008 Polaris Sportsman 500 models.

Secondary Coverage:

Specific sections for EFI X2 / Touring Quadricycle variants.

Page Count

Estimated Pages:

Hundreds (exact number not specified but implies comprehensive coverage)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, diagnostics, and repair.

Fuel System:

EFI system diagnostics, fuel pump, injectors, pressure regulator, and related components.

Body Steering Suspension:

Bodywork, steering system components (rack, tie rods), front and rear suspension (shocks, arms, bushings).

Clutch:

Primary and secondary clutch inspection, maintenance, and replacement.

Transmission:

Transmission disassembly, assembly, and repair procedures.

Final Drive:

Front and rear differential, driveshafts, and axle components.

Brakes:

Hydraulic brake system, calipers, master cylinders, brake lines, and bleeding procedures.

Electrical:

Complete electrical system diagnostics, battery, charging system, ignition, lighting, starter, and accessories.

Wiring Diagrams:

Detailed wiring schematics for all electrical systems.

Procedures Included

Maintenance:

Oil changes, filter replacements, lubrication, spark plug service, air filter cleaning/replacement.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon issues.

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly.

Rebuilds:

Comprehensive procedures for engine, transmission, and differential rebuilds.

Technical Depth

Depth:

Professional technical service level, suitable for both DIY enthusiasts and experienced mechanics.

📊 Manual Specifications

File Format

Format Details:

High-resolution PDF, allowing for clear printing of individual pages.

Compatibility:

Compatible with all PC Windows operating systems and Mac OS.

Requirements:

Adobe PDF Reader and WinZip (for extraction if compressed).

Print Quality

Print Clarity:

High resolution, ensuring excellent quality when printing necessary pages.

Binding Type

Binding:

Digital Download (printable from PDF).

Paper Type

Digital Format:

N/A (Digital PDF).

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke Single-Cylinder

Engine Displacement:

499cc

Cooling System:

Liquid-cooled

Bore X Stroke:

92.0 mm x 75.0 mm (Refer to manual for exact specifications for HO/EFI variants)

Performance

Horsepower:

Approximately 30-35 HP (exact figures vary by specific model and tune)

Torque:

Refer to manual for specific torque figures.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) for EFI models; Carbureted for HO models (refer to manual for specific carburetor details if applicable to certain variants).

Fuel Type:

Unleaded gasoline, minimum 87 octane.

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

On-Demand All-Wheel Drive (AWD) / 2WD

Features

Gear Selection:

High, Low, Neutral, Reverse, Park

Transmission Fluid:

Refer to manual for specific Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent.

📐 Dimensions

Exterior

Wheelbase:

Approx. 50.5 inches (128.3 cm) (Refer to manual for specific model variations)

Ground Clearance:

Approx. 10.25 inches (26.0 cm) (Refer to manual for specific model variations)

Weights

Dry Weight:

Approx. 600 lbs (272 kg) (Refer to manual for specific model variations)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI standards for ATVs.

Active Features

Braking System:

Hydraulic disc brakes (front and rear).

Engine Braking:

Integrated engine braking through the CVT.

Passive Features

Lighting:

Dual 50W headlights, taillight/brake light.

Roll Over Protection:

Not applicable for ATVs; emphasis on operator responsibility and terrain awareness.

💡 Technology Features

Infotainment

Infotainment System:

Basic analog instrumentation (speedometer, odometer, fuel gauge), indicator lights.

Driver Assistance

Assistance Features:

On-Demand AWD system provides enhanced traction.

Connectivity

Connectivity Options:

N/A (No integrated connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 100 hours or 6 months (refer to manual for exact intervals based on usage type).

Air Filter Cleaning:

Every 25 hours or 3 months, or more frequently in dusty conditions.

Spark Plug Replacement:

Refer to manual for specific mileage or time interval.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 Extreme Duty 5W-50 Synthetic Oil or equivalent API SG/SH/SJ rated oil.

Engine Oil Capacity:

Refer to manual for exact capacity (typically around 2.5 quarts / 2.4 liters).

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mixture with distilled water).

Known Issues

Common Wear Items:

CVT belt wear, suspension bushings, tie rod ends, brake pads.

Efi System Considerations:

Occasional check for fuel injector cleanliness and sensor calibration for optimal performance.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, a long-standing American manufacturer of powersports vehicles.

Model Evolution

Sportsman Line:

The Sportsman line is known for its comfort, capability, and versatility, consistently evolving since its introduction.

2008 Updates:

The 2008 models represent a mature generation of the Sportsman 500, incorporating refinements from previous years, including updated EFI systems and chassis improvements.

🏆 Awards & Recognition

Recognitions

Atv Industry Awards:

Polaris Sportsman series has historically received numerous accolades for utility and recreational capabilities from industry publications and consumer surveys.