🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 500 EFI X2 EFI Touring

Year:

2008

Model Code:

Likely includes specific Polaris VIN prefixes and model identifiers for the 2008 Sportsman 500 EFI X2 EFI Touring range. Actual codes would be detailed within the manual.

👋 Introduction

Market Position:

The Polaris Sportsman 500 EFI X2 EFI Touring was positioned as a versatile and capable all-terrain vehicle (ATV) for recreational and utility use, emphasizing comfort for two riders and cargo carrying capacity. This manual caters to owners and mechanics needing in-depth repair and maintenance information for this specific model year.

Competitive Analysis:

Competed against other premium 500cc-class ATVs from brands like Can-Am (Outlander), Arctic Cat (TRV), and Yamaha (Grizzly) in the dual-seat, touring-oriented segment. Key differentiators often included Polaris's independent rear suspension, powerful EFI engine, and specialized features like the X2's convertibility. This manual provides the specialized knowledge needed to maintain these competitive advantages.

Key Features:

Features a 499cc liquid-cooled, SOHC, 4-valve, single-cylinder engine with electronic fuel injection (EFI) for improved throttle response and fuel efficiency. The 'X2' designation typically implies a versatile design, potentially allowing for conversion to a single-seater with a dump bed. 'Touring' indicates comfort features for two riders. AWD/2WD selectable traction system is a hallmark.

📋 Manual Details

Coverage Areas:

Comprehensive service and repair for all aspects of the 2008 Polaris Sportsman 500 EFI X2 EFI Touring model. Includes mechanical, electrical, and bodywork components. Likely covers specific sub-models or configurations within the 2008 lineup.

Page Count:

Detailed page count not explicitly provided, but described as 'highly detailed' and covering 'every service and repair job,' suggesting a substantial number of pages (likely 500+).

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine (2WD/AWD systems, ignition, fuel injection, lubrication, cooling), Drivetrain (transmission, drive shafts, differentials, CV joints), Suspension (front and rear, shocks, control arms), Steering, Brakes (hydraulic, parking brake), Electrical System (lighting, battery, charging system, starter, ECU, wiring diagrams), Fuel System (tank, pump, injectors), Exhaust System, Frame, Body Panels, Seat, Controls, Accessories.

Procedures Included:

Routine maintenance (oil changes, filter replacements, spark plugs, air filters, lubrication), diagnostic procedures, troubleshooting guides, component removal and installation, complete engine rebuilds, transmission overhaul, brake system service, electrical system repair, suspension alignment and adjustment, body panel repair and replacement, carburetor adjustments (if applicable to specific EFI variants), fuel system cleaning and testing.

Technical Depth:

Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed exploded views, torque specifications, electrical schematics, diagnostic trouble codes (DTCs), and step-by-step repair instructions for all major components.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, designed for clear printing of all diagrams, illustrations, and text. Likely supports searchable text functionality.

Binding Type:

N/A (Digital Download - PDF)

Paper Type:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, 4-valve Single Cylinder

Displacement:

499cc (30.4 cu. in.)

Cooling System:

Liquid-Cooled

Bore X Stroke:

92 mm x 75 mm (Approximate, specific figures in manual)

Compression Ratio:

10.2:1 (Typical for this engine family)

Ignition:

Electronic CDI with Digital Coil Induction

Valve Lash Adjustment:

Specific cold lash values provided in manual (e.g., Intake: 0.003-0.005 in., Exhaust: 0.004-0.006 in.)

Horsepower:

Approx. 30-35 HP (Varies based on tuning and exact configuration)

Torque:

Specific Nm/lb-ft figures provided in manual.

Fuel Delivery:

Electronic Fuel Injection (EFI) - Likely a throttle body injection system.

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

Approx. 4.0 US gallons (15.1 L)

Engine Oil Type:

Polaris Synthetic 2W-50 or equivalent API SG or higher motorcycle oil.

Engine Oil Capacity:

Approx. 2.4 US quarts (2.3 L) with filter change.

Coolant Type:

Ethylene Glycol based antifreeze with corrosion inhibitors (e.g., Polaris Genuine Coolant or equivalent).

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system.

Gear Selection:

High (H), Low (L), Neutral (N), Reverse (R), Park (P).

Drive System:

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

Final Drive:

Shaft Drive (Front and Rear)

Cvt Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent.

Cvt Fluid Capacity:

Approx. 0.47 US quarts (0.44 L)

📐 Dimensions

Length:

Approx. 83 in. (210.8 cm)

Width:

Approx. 46 in. (116.8 cm)

Height:

Approx. 47 in. (119.4 cm)

Wheelbase:

Approx. 50.5 in. (128.3 cm)

Ground Clearance:

Approx. 11.25 in. (28.6 cm)

Dry Weight:

Approx. 670 lbs (304 kg)

Payload Capacity:

Approx. 250 lbs (113 kg) for rear rack; X2 seat conversion increases payload.

Towing Capacity:

1500 lbs (680 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Front Rack Capacity:

100 lbs (45 kg)

🛡️ Safety Features

Safety Ratings:

ATVs are not subject to formal automotive crash test ratings like cars. Safety is determined by design, rider skill, and adherence to recommended operating procedures, all detailed within this manual.

Active Features:

On-Demand AWD, powerful hydraulic disc brakes (front and rear), engine braking, thumb throttle with safety lock.

Passive Features:

Handguards, comfortable seating for two, integrated lighting system, robust chassis and suspension.

💡 Technology Features

Infotainment System:

Basic instrumentation cluster including speedometer, odometer, trip meter, fuel gauge, and indicator lights for AWD, oil pressure, and engine status. No advanced infotainment system typically present on this model.

Driver Assistance Features:

On-Demand AWD system provides enhanced traction. Engine braking system assists in downhill descents. No electronic driver aids like ABS or traction control beyond the AWD system.

Connectivity Features:

No integrated connectivity features like Bluetooth or smartphone integration.

🔧 Maintenance

Initial Service:

First service typically recommended at 20 hours or 100 miles (160 km).

Engine Oil Change:

Every 100 hours or 1000 miles (1600 km), or annually, whichever comes first.

Air Filter Cleaning:

Inspect every 20 hours, clean/replace as needed. More frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 100 hours or annually.

Belt Inspection:

Inspect CVT belt every 50 hours for wear and damage. Replace if thickness is reduced by more than 1/16 inch (1.6 mm) or if damaged.

Brake Fluid Flush:

Recommended every 2 years or as needed based on inspection.

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Grease Type:

Lithium-based grease for chassis lubrication points (refer to manual for specific types).

Known Issues:

Potential issues common to ATVs of this era and type may include CVT belt wear, suspension component wear (bushings, ball joints), front differential issues if proper maintenance is neglected, and occasional EFI sensor problems. The manual provides detailed diagnostic and repair procedures for these.

Air Filter Part Number:

Specific Polaris part number for the 2008 Sportsman 500 EFI (e.g., 7072403, but verify within manual).

Oil Filter Part Number:

Specific Polaris part number for the 2008 Sportsman 500 EFI (e.g., 2408405 or 3083200, verify within manual).

Spark Plug Part Number:

NGK CR9EKB or equivalent (verify within manual).

📚 Vehicle History

Brand Heritage:

Polaris Industries, founded in 1954, is a leading manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles. They have a long-standing reputation for innovation and performance in the off-road vehicle market.

Model Evolution:

The Polaris Sportsman 500 line has been a cornerstone of the Polaris ATV lineup for many years. The 500 EFI model represented a significant upgrade with the adoption of fuel injection, offering improved reliability and performance over carbureted versions. The X2 and Touring variants were introduced to cater to riders seeking greater versatility and comfort for longer rides or carrying passengers/cargo.

Production Years For 500 Efi:

The 500 EFI engine was utilized in various Polaris Sportsman models from the mid-2000s onwards, with the 2008 model being a specific iteration within this popular series.

🏆 Awards & Recognition

Recognitions:

While specific awards for the 2008 Sportsman 500 EFI X2 EFI Touring may not be publicly cataloged, the Polaris Sportsman line consistently received accolades from industry publications and consumer reviews for its performance, comfort, and durability throughout its production runs.

Consumer Ratings:

Generally well-regarded by owners for its utility and versatility, though like any machine, specific ownership experiences vary. This manual empowers owners to maintain it to optimal standards.