Segment:
Premium Utility ATV (All-Terrain Vehicle)
Target Audience:
Recreational riders, hunters, farmers, and professionals requiring a robust, comfortable, and capable ATV for extended use and varying terrain.
Key Competitors:
Can-Am Outlander, Arctic Cat 500/550, Honda Foreman/Rancher, Yamaha Kodiak/Grizzly.
Touring Comfort:
Features extended seating for two passengers, comfort-tuned suspension, and ergonomic design for longer rides.
Engine Performance:
Powerful 500cc class engine known for its reliable torque and consistent power delivery.
Bfs Suspension:
Dual-A arm front and rear suspension with Polaris's Bear Foot System (BFS) for improved ground clearance and handling.
Efi Technology:
Electronic Fuel Injection for improved throttle response, easier cold starts, and optimal performance in varying altitudes.
Manual Purpose:
To provide comprehensive diagnostic, repair, maintenance, and troubleshooting information for the 2008 Polaris Sportsman 500 EFI Touring, enabling users to perform most service tasks.
Manual Benefit:
Empowers owners and technicians with the knowledge to maintain peak performance, extend the vehicle's lifespan, and accurately diagnose and repair issues.
Systems Covered:
Engine, Fuel System, Ignition System, Drivetrain, Transmission, Suspension, Steering, Brakes, Electrical System, Bodywork, Chassis, Maintenance, Troubleshooting, Specifications
Estimated Pages:
High (typical for a complete service manual, often 300+ pages for this model/type)
Type:
Workshop Service Manual
Engine Mechanical:
Complete disassembly, inspection, assembly, and torque specifications for engine components (cylinder, piston, crankshaft, camshaft, valves, etc.).
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, pressure regulator, throttle body, fuel tank, and lines. Includes diagnostic procedures.
Ignition System:
Ignition coils, spark plugs, ECU control, and troubleshooting for ignition timing and spark generation.
Drivetrain Transmission:
CVT (Continuously Variable Transmission) system, drive belts, clutch assembly (primary and secondary), gearcase, and final drive. Includes maintenance and repair of AWD system.
Suspension Steering:
Front and rear suspension components (shocks, springs, control arms), steering system (handlebar, tie rods, rack and pinion), and wheel alignment procedures.
Braking System:
Hydraulic brake system, brake calipers, master cylinders, brake lines, rotors, pads, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting, instrumentation, ECU, sensors, fuses, relays, and common electrical troubleshooting.
Bodywork Chassis:
Frame, body panels, fenders, racks, seat, and general assembly/disassembly procedures.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter service, lubrication points, and valve adjustments.
Troubleshooting Diagnostics:
Step-by-step diagnostic charts and procedures for identifying and resolving common performance issues and system faults.
Engine Rebuild:
Detailed instructions for engine overhaul, including component measurements, tolerances, and rebuilding procedures.
Transmission Repair:
CVT belt inspection/replacement, clutch adjustment, gearcase servicing, and repair of the AWD engagement system.
Electrical Diagnostics:
Testing of sensors, actuators, charging system, starting system, and troubleshooting of electrical faults using wiring diagrams.
Brake System Service:
Brake pad replacement, caliper servicing, rotor inspection, brake fluid bleeding, and master cylinder maintenance.
Suspension Steering Adjustment:
Shock absorber adjustments, tie rod end replacement, and wheel alignment checks.
Level Of Detail:
Comprehensive, covering all aspects from basic maintenance to complete engine and drivetrain overhauls. Designed for professional technicians but accessible for advanced DIYers.
Diagnostic Capability:
Advanced diagnostic procedures, including fault codes (if applicable via diagnostic tool connection) and component testing methods.
Wiring Diagrams:
Includes detailed, color-coded electrical wiring diagrams for easy troubleshooting.
Engine Type:
4-Stroke Single Cylinder
Displacement:
499cc (30.4 cubic inches)
Bore X Stroke:
93.0 mm x 73.0 mm (3.66 in x 2.87 in)
Cooling System:
Liquid-Cooled
Valvetrain:
SOHC (Single Overhead Cam), 4 Valves
Compression Ratio:
10.0:1
Horsepower Estimated:
Approximately 30-35 HP (Horsepower) - specific figures vary by test conditions and region.
Torque Estimated:
Approximately 30-35 ft-lbs (Foot-Pounds) - specific figures vary.
Fuel Delivery:
Electronic Fuel Injection (EFI) - typically a single throttle body with one injector.
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Fuel Tank Capacity:
5.25 US Gallons (19.9 Liters)
Oil Type:
SAE 5W-50 Synthetic Motorcycle Oil (refer to manual for exact specification)
Oil Capacity:
Approximately 2.1 US Quarts (2.0 Liters) with filter change
Crash Test Ratings:
N/A (ATVs are not typically rated by organizations like NHTSA or IIHS; safety relies on design and rider operation)
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
AWD System:
On-Demand All-Wheel Drive provides enhanced traction in challenging conditions.
Engine Braking:
CVT provides engine braking for controlled descents.
Handlebars:
Ergonomically designed handlebars with grips for secure control.
Seating:
Comfortable, extended seating for two with grab handles for passenger security.
Lighting:
Dual headlights and tail/brake lights for visibility.
Footwells:
Spacious footwells with floorboard guards for foot protection.
Engine Oil Change:
Every 100 hours or annually, whichever comes first. (Consult manual for precise intervals and conditions).
Air Filter Cleaning:
Inspect every 50 hours, clean or replace as needed. More frequent cleaning may be required in dusty conditions.
Spark Plug Inspection:
Inspect every 100 hours. Replace as needed.
Cvt Belt Inspection:
Inspect every 100 hours. Replace if worn, damaged, or if a specific length is exceeded.
Gearcase Oil Change:
Every 100 hours or annually.
Engine Oil:
Polaris Premium 4 5W-50 Synthetic (or equivalent API SG or higher, JASO MA certified)
Gearcase Oil:
Polaris Demand Drive Fluid or equivalent SAE 75W-90 Synthetic Gear Lubricant
Coolant:
Polaris Coolant or equivalent ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water).
Brake Fluid:
DOT 3 Hydraulic Brake Fluid
Cvt Belt Wear:
CVT belts can wear prematurely if subjected to excessive heat, slippage, or incorrect tension. Regular inspection and replacement are crucial.
Efi System Issues:
While generally reliable, issues can arise from clogged injectors, faulty sensors (e.g., TPS, MAP), or fuel pump problems. The manual provides diagnostics for these.
Suspension Bushings:
Over time and with heavy use, suspension bushings can wear out, leading to play and affecting handling. The manual details replacement procedures.
Electrical Connections:
Corrosion or loose electrical connections, especially in wet environments, can cause intermittent faults. Manual's wiring diagrams are key to diagnosis.
Polaris Atv Legacy:
Polaris is a pioneer and leader in the ATV industry, known for innovation and robust utility vehicles.
Sportsman Lineage:
The Sportsman line has been a cornerstone for Polaris for decades, evolving from basic utility to feature-rich recreational and touring models.
500 Engine Development:
The 500cc engine platform has been a staple, with continuous improvements in EFI, cooling, and emissions over the years.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States, including facilities in Minnesota and Iowa.
Model Introduction Year:
The Sportsman 500 model line was introduced in the mid-1990s. The Touring variant emerged as the ATV market grew and demand for two-up riding increased.
