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Polaris Sportsman 500 Touring EFI 2008 Factory Service Manua

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This manual covers the 2008 Sportsman 500 Touring EFI, a versatile All-Terrain Vehicle (ATV) designed for both utility and recreational use. Known for its robust 500cc ProStar engine with Electronic...
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Taper: Atv
Distributeur:
Polaris
UGS: 59007
Mots clés: 2008 ATV Misc Polaris Powersports Sportsman 500 Touring EFI
Polaris Sportsman 500 Touring EFI 2008 Factory Service ManuaPolaris Sportsman 500 Touring EFI 2008 Factory Service ManuaPolaris Sportsman 500 Touring EFI 2008 Factory Service ManuaPolaris Sportsman 500 Touring EFI 2008 Factory Service Manua
This manual covers the 2008 Sportsman 500 Touring EFI, a versatile All-Terrain Vehicle (ATV) designed for both utility and recreational use. Known for its robust 500cc ProStar engine with Electronic Fuel Injection (EFI), it offers reliable power and responsive throttle control. The ATV features Independent Front and Rear Suspension (IRS) for enhanced ride comfort and handling, along with significant towing capacity for various tasks. Its dual seating designation highlights its touring capability, making it suitable for longer excursions with a passenger. The integrated front and rear storage racks further enhance its utility for carrying gear. This comprehensive factory service repair manual provides detailed information for the maintenance, diagnosis, and repair of your 2008 Sportsman 500 Touring EFI. It covers all essential systems, including the engine, fuel system, transmission, drivetrain, suspension, steering, brakes, and electrical system. The manual includes routine maintenance procedures, troubleshooting guides for common issues, step-by-step repair instructions, and complete overhaul procedures for major components. Additionally, it contains technical specifications, diagnostic flowcharts, and electrical wiring diagrams to assist owners, mechanics, and technicians in keeping the ATV in optimal working condition.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 500 Touring EFI
Year:
2008
Vehicle Type:
All-Terrain Vehicle (ATV)
Engine Type:
EFI (Electronic Fuel Injection)
Codes
Model Code:
Refer to manual for specific VIN and model codes
👋 Introduction
Market Position
Segment:
Premium utility/recreational ATV segment.
Competitive Analysis
Key Competitors:
Honda Foreman, Yamaha Grizzly, Can-Am Outlander.
Key Features
Powertrain:
Renowned Polaris 500cc ProStar engine with Electronic Fuel Injection for reliable power and throttle response.
Suspension:
Independent Front and Rear Suspension (IRS) for superior ride comfort and handling.
Towing Capacity:
Significant towing capacity suitable for work and recreation.
Storage:
Integrated front and rear storage racks for utility.
Comfort:
Dual seating ('Touring' designation) for passenger comfort.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service and repair
Page Count
Pages:
Hundreds (specific count not provided, but described as comprehensive)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Download PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine assembly, disassembly, diagnosis, tuning, and repair of all internal and external components.
Fuel System:
EFI system diagnosis, fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, and lines.
Transmission:
Automatic transmission, clutch, drive belts, and differential service.
Drivetrain:
Front and rear driveshafts, CV joints, U-joints, and wheel hub assemblies.
Suspension:
Front and rear suspension systems, shocks, springs, control arms, and bushings.
Steering:
Steering column, tie rods, steering rack, and linkages.
Brakes:
Hydraulic brake system, calipers, master cylinders, brake lines, pads, and rotors.
Electrical System:
Ignition system, charging system (stator, rectifier/regulator), battery, lighting, starter motor, and all wiring harnesses.
Cooling System:
Radiator, cooling fan, thermostat, water pump, and coolant lines.
Body And Frame:
Frame inspection and repair, body panels, fenders, seats, racks, and trim.
Lubrication System:
Oil pump, oil filter, and lubrication points.
Exhaust System:
Exhaust manifold, muffler, and pipes.
Procedures Included
Maintenance:
Routine maintenance tasks, lubrication, filter changes, and fluid checks.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common issues.
Repair:
Detailed step-by-step repair procedures for all major and minor components.
Overhaul:
Complete engine and transmission overhaul instructions.
Diagnostics:
EFI system diagnostics, fault code retrieval and interpretation.
Inspection:
Pre-ride inspections, scheduled inspections, and component wear checks.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for easy fault finding.
Technical Depth
Depth:
Full factory level, covering everything from basic adjustments to complete component rebuilds and advanced EFI diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Printable, allowing users to create a physical copy.
Binding Type
Suggested Binding:
Spiral or ring binding for lay-flat use in workshop environments (purchaser dependent).
Paper Type
Recommended Paper:
Durable, tear-resistant paper for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 2-valve, single-cylinder
Displacement:
499 cc
Bore X Stroke:
93.0 mm x 72.0 mm
Cooling System:
Liquid-cooled
Ignition System:
Electronic CDI
Performance
Horsepower:
Approx. 32 HP (specific figure may vary slightly by source, manual provides exact figures)
Torque:
Refer to manual for specific torque figures
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fluid Capacities
Engine Oil Capacity:
Refer to manual for exact capacity (typically ~1.7 liters with filter)
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified (refer to manual for precise specification)
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with engine braking
Drive Modes:
2WD/AWD On-Demand
Features
Gear Selection:
High, Low, Neutral, Reverse, Park
Fluid Specifications
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent (refer to manual for specific part number and alternative)
📐 Dimensions
Exterior
Length:
Approx. 83 in. (210.8 cm)
Width:
Approx. 46 in. (116.8 cm)
Height:
Approx. 47 in. (119.4 cm)
Weights
Dry Weight:
Approx. 660 lbs. (299.4 kg) (Refer to manual for exact weight with all fluids/options)
Towing Capacity:
1500 lbs. (680.4 kg)
Payload Capacity:
Approx. 260 lbs. (118 kg) (combined rider and cargo)
Cargo
Front Rack Capacity:
100 lbs. (45 kg)
Rear Rack Capacity:
200 lbs. (90 kg)
Wheels And Tires
Front Tire Size:
AT 25 x 8-12
Rear Tire Size:
AT 25 x 10-12
Wheelbase:
50.5 in. (128.3 cm)
Ground Clearance:
11.5 in. (29.2 cm)
🛡️ Safety Features
Ratings
Atv Safety Standards:
Complies with ANSI standards for recreational ATVs.
Active Features
Braking System:
Hydraulic disc brakes front and rear, engine braking.
Drive System:
On-Demand All-Wheel Drive (AWD) for enhanced traction.
Passive Features
Lighting:
Dual 50W headlights, 25/80W dual taillight/brake light.
Seat Belt Requirements:
Polaris strongly recommends wearing an approved helmet and appropriate safety gear. Seat belts are NOT a substitute for proper ATV operation and safety practices.
💡 Technology Features
Infotainment
Instrumentation:
Digital gauge cluster including speedometer, odometer, trip meter, tachometer, high beam, neutral, reverse, AWD indicator, and fuel level.
Driver Assistance
Electronic Features:
Electronic Fuel Injection (EFI) for optimized power delivery and cold starts. On-Demand AWD system.
Connectivity
Charging System:
12V DC output with 350W (or similar, refer to manual) stator for accessories and battery charging.
🔧 Maintenance
Service Intervals
Initial Service:
First service typically at 10 hours or 1 month for oil change, filter check, and lubrication.
Regular Oil Change:
Every 100 hours or 6 months for engine oil and filter.
Drive Belt Inspection:
Inspect drive belt for wear and tension every 50 hours or annually.
Spark Plug Replacement:
Replace spark plug every 100 hours or annually. (Refer to manual for specific part number, e.g., NGK CR9EIB-9 or similar)
Air Filter Cleaning Or Replacement:
Clean or replace air filter every 25 hours or as needed in dusty conditions.
Fluid Specifications
Brake Fluid Type:
DOT 4 hydraulic brake fluid (refer to manual for precise specification).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, minimum 50% concentration (refer to manual for specific Polaris brand or compatible type).
Known Issues
Common Wear Items:
Drive belts, ball joints, tie rod ends, wheel bearings, and brake pads are common wear items due to operational use. EFI sensors can occasionally require cleaning or replacement.
Electrical Connections:
Ensure all electrical connections are clean and tight to prevent intermittent faults. Corroded grounds are a common issue.
📚 Vehicle History
Brand Heritage
Brand Origin:
Polaris Industries Inc. is an American manufacturer founded in 1954, known for pioneering snowmobiles and later ATVs.
Model Evolution
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from basic utility models to more feature-rich recreational and touring variants. The 500cc engine has been a popular and reliable powerplant for many years within the lineup.
Production
Manufacturing Location:
Polaris ATVs are primarily manufactured in Spirit Lake, Iowa, USA and Roseau, Minnesota, USA.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2008 Sportsman 500 Touring EFI model are not readily published, the Polaris Sportsman line generally receives positive reviews for its utility, comfort, and capability within the ATV market.
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