Positioning:
The Polaris Sportsman 500 Touring EFI was positioned as a versatile, comfortable, and capable two-up ATV for recreational riding, trail exploration, and light utility work. It aimed to blend the performance of the Sportsman line with the comfort for a passenger.
Competitors:
Competed with other 500cc-class two-up ATVs from brands like Can-Am (Outlander Max), Arctic Cat (Prowler), and Yamaha (Grizzly). Key selling points were its established Polaris reputation, comfort features for a passenger, and the EFI system for consistent performance.
Features:
Electronic Fuel Injection (EFI) for improved throttle response and cold starts, Independent Rear Suspension (IRS) for superior ride comfort and handling, True On-Demand All-Wheel Drive (AWD), powerful 500cc engine, comfortable two-up seating with passenger backrest and floorboards, front and rear racks for cargo.
Coverage:
Comprehensive repair, maintenance, troubleshooting, and diagnostics for the Polaris Sportsman 500 Touring EFI 2008 model.
Page Count:
Detailed page count not specified in product information, but described as 'very detailed'.
Type:
Full Service Repair Manual
Language:
English (presumed, standard for this type of manual)
Format:
Digital (likely PDF, common for online sales of service manuals).
Engine:
Engine overhaul, disassembly, assembly, tuning, fuel system (EFI), ignition system, cooling system, lubrication.
Transmission:
Automatic transmission (CVT) maintenance, repair, belt replacement, clutch inspection.
Drivetrain:
All-Wheel Drive (AWD) system, front differential, rear differential, drive shafts, U-joints, CV joints.
Suspension:
Front and rear suspension components, shocks, springs, control arms, bushings, wheel bearings.
Brakes:
Hydraulic brake system, brake caliper service, pad replacement, rotor inspection, bleeding procedures, parking brake.
Electrical:
Wiring diagrams, starter system, charging system (alternator/stator), battery maintenance, lighting, instrumentation, EFI control module (ECU).
Bodywork:
Body panel removal and installation, fairings, seat, handlebars, rack systems, cosmetic repairs.
Chassis:
Frame inspection, steering system, wheel alignment.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, tire pressure checks, lubrication points.
Troubleshooting:
Diagnostic flowcharts for common problems, electrical troubleshooting, engine performance issues, starting difficulties.
Repair:
Step-by-step instructions for all major component repairs and replacements, including engine rebuilds, suspension overhaul, and brake system service.
Diagnostics:
EFI system diagnostics, sensor testing, actuator testing, fault code interpretation (if applicable).
Installation:
Instructions for installing genuine Polaris accessories or common aftermarket upgrades.
Depth:
Comprehensive, covering from basic scheduled maintenance to full engine and transmission rebuilds, including electrical diagnostics and component-level repair.
Engine Type:
4-stroke, SOHC, 2-valve, Single Cylinder, Liquid-Cooled
Displacement:
499cc (Actual displacement may vary slightly based on specific engine revisions, but commonly listed as 499cc or 498cc)
Bore X Stroke:
Typical for this engine family: 93.0 mm x 73.0 mm
Compression Ratio:
Typically around 10.0:1
Engine Cooling:
Liquid-Cooled
Horsepower:
Approximately 30-33 HP (figures vary slightly by source and specific tune)
Torque:
Around 28-30 lb-ft (figures vary slightly by source and specific tune)
Fuel Delivery:
Electronic Fuel Injection (EFI) with a throttle body size typically around 40mm.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with electronic advance.
Oil Type:
Typically SAE 5W-50 or 10W-50 API SG or higher, JASO MA certified synthetic or semi-synthetic motorcycle oil.
Type:
Automatic Polaris Variable Transmission (PVT) with all-wheel engine braking.
Gear Selection:
High, Low, Neutral, Reverse, Park.
Drive System:
Shaft Drive, True On-Demand All-Wheel Drive (AWD).
Clutch:
Primary and secondary clutch system with belt drive for CVT operation.
Differential:
Front: Limited-slip or lockable differential. Rear: Locked differential.
Length:
Approximately 85.5 inches (2172 mm)
Width:
Approximately 46 inches (1168 mm)
Height:
Approximately 47.5 inches (1207 mm)
Wheelbase:
Approximately 56.5 inches (1435 mm)
Ground Clearance:
Approximately 11.25 inches (286 mm)
Dry Weight:
Approximately 670 lbs (304 kg)
Payload Capacity:
Front Rack: 100 lbs (45 kg), Rear Rack: 200 lbs (90 kg), Total Payload: 300 lbs (135 kg)
Towing Capacity:
1500 lbs (680 kg)
Wheel Bolt Pattern:
Common for Polaris ATVs of this era, typically 4x110mm or similar, though not explicitly stated in product info.
Crash Test Ratings:
N/A (ATVs are not typically rated by organizations like NHTSA or IIHS for crash safety as passenger vehicles are).
Braking System:
Hydraulic disc brakes front and rear, sealed single-lever hydraulic disc front brakes, hydraulic rear foot brake. Parking brake mechanism.
A W D System:
True On-Demand AWD system for enhanced traction in varied conditions.
Operator Controls:
Handlebar steering, throttle lever, brake levers, gear selector, ignition switch, kill switch.
Passenger Features:
Comfortable two-up seating with integrated backrest, passenger handholds, floorboards.
Infotainment System:
Basic instrumentation includes speedometer, odometer, trip meter, fuel gauge, and indicator lights. No advanced infotainment features.
Assistance Features:
On-Demand AWD system provides enhanced traction. Engine braking for downhill control.
Connectivity Options:
N/A (No Bluetooth, USB, or smart device integration on this model year).
Oil Change Interval:
Typically every 100 hours or 12 months, whichever comes first. Always consult the specific manual for exact recommendations.
Air Filter Service:
Clean every 25 hours, replace every 100 hours or as needed based on operating conditions.
Spark Plug Replacement:
Typically every 100 hours or 12 months. Specific plug part number (e.g., NGK CR9EB) should be confirmed in manual.
Cv Belt Inspection:
Inspect at 50 hours, replace as needed based on wear and tear. Belts are a common wear item.
Engine Oil Capacity:
Approximately 2.0 US quarts (1.9 liters) with filter change.
Transmission Fluid:
Refer to manual for specific type, often a specific Polaris brand or a high-quality gear oil/ATF for the reduction gearbox.
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Specify type (e.g., Polaris Bluecoolant).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
CV joint boots, drive belts, wheel bearings, tie rod ends, suspension bushings. Regular inspection and lubrication are key.
Efi System:
While generally reliable, EFI systems can be sensitive to fuel quality and contamination. Fuel pump, injectors, and sensors may require diagnostic checks.
Suspension And Steering:
Bushings and ball joints can wear over time, especially with heavy use or rough terrain, leading to play and potential alignment issues.
Heritage:
Polaris Industries, founded in 1954, is a long-standing American manufacturer known for its innovation in powersports vehicles, including snowmobiles, ATVs, and UTVs. The Sportsman line has been a cornerstone of their ATV offerings for decades, renowned for its durability and capability.
Evolution:
The Sportsman 500 model has undergone numerous iterations since its introduction. The 'Touring' designation specifically highlights the focus on passenger comfort and extended riding. The addition of EFI in later models like the 2008 version marked a significant upgrade over carbureted versions, improving performance and efficiency.
Production Period:
The 500cc Sportsman platform has been in production for many years, with the Touring EFI variant being a prominent model in the mid-2000s to early 2010s.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
Awards:
While specific awards for the 2008 Sportsman 500 Touring EFI might not be widely publicized, the Sportsman line consistently receives accolades and positive reviews from ATV publications for its performance, comfort, and value in the utility and recreational ATV segments.
Industry Perception:
Polaris Sportsman models are generally regarded as reliable, capable, and user-friendly ATVs, making them a popular choice for a wide range of riders.
