Positioning:
The Polaris Sportsman 500 Touring EFI was positioned as a versatile and capable utility ATV, offering enhanced comfort for longer rides and tandem operation.
Competitors:
Competed against similar offerings from brands like Can-Am (Outlander), Arctic Cat ( a comparable model), and Yamaha (Grizzly).
Features:
Electronic Fuel Injection (EFI) for improved throttle response and cold starts, independent rear suspension (IRS) for a smoother ride, power steering (on some trims), and comfortable seating for two.
Engine Service:
Detailed disassembly, inspection, repair, and reassembly of the engine, including top-end and bottom-end components.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, fuel lines, and fuel tank service.
Transmission Drivetrain:
CVT system service, drive clutch, driven clutch, belt inspection and replacement, final drive, differential, and driveshaft maintenance.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter system, and accessory circuits.
Suspension Steering:
Front and rear suspension components, shocks, A-arms, bushings, steering system, tie rods, and hub maintenance.
Braking System:
Hydraulic brake system, master cylinders, calipers, brake pads, brake lines, and rear brake system service.
Cooling System:
Radiator, cooling fan, thermostat, hoses, and coolant specifications.
Chassis Body:
Frame, plastic body panels, racks, seat, and general chassis maintenance.
Wheels Tires:
Tire pressure, replacement, and wheel hub service.
Routine Maintenance:
Oil changes, filter replacements, air filter service, spark plug replacement, and general inspections.
Troubleshooting:
Diagnostic procedures for common issues, fault codes (if applicable), and step-by-step troubleshooting guides.
Repair Procedures:
Detailed instructions for component replacement, adjustments, and repairs across all covered systems.
Overhaul:
Complete engine and transmission overhaul procedures.
Calibration Adjustments:
Adjustment procedures for linkages, clutches, and other relevant components.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds.
Diagnostic Level:
Advanced diagnostics, including EFI system analysis and electrical troubleshooting.
Engine Type:
4-stroke, Single Cylinder, SOHC
Cooling System:
Liquid-cooled
Horsepower Estimate:
Approximately 30-35 HP (actual figures may vary slightly).
Torque Estimate:
Estimated torque output for strong low-end pulling power.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Engine Family:
Polaris ProStar (specific variant for the 500)
Transmission Type:
Automatic, Continuously Variable Transmission (CVT) with High/Low range and Reverse.
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector.
Optional Transmissions:
N/A for this model/year.
Clutch System:
Primary and Secondary CVT clutches, belt-driven.
Gear Reduction:
Internal reduction gears within the transmission and final drive units.
Length:
Approximately 85 inches (2159 mm)
Width:
Approximately 46 inches (1168 mm)
Height:
Approximately 45 inches (1143 mm)
Wheelbase:
Approximately 50.5 inches (1283 mm)
Ground Clearance:
Approximately 11 inches (279 mm)
Seating Capacity:
2 (Rider and Passenger)
Front Rack Capacity:
Typically around 100 lbs (45 kg).
Rear Rack Capacity:
Typically around 200 lbs (90 kg).
Dry Weight Estimate:
Around 650-700 lbs (295-318 kg).
Towing Capacity:
Typically 1,500 lbs (680 kg).
Tongue Weight Capacity:
Typically 150 lbs (68 kg).
Atv Safety Standards:
Complies with ANSI and BRP standards for ATVs.
Braking System:
Hydraulic disc brakes on all wheels, engine braking through CVT.
Lighting:
Dual 50W headlights, brake light/taillight.
Rollover Protection:
N/A (standard ATV design, operator training crucial)
Seat Belt:
N/A (standard ATV design, helmet and protective gear required)
Infotainment System:
N/A (basic instrumentation: speedometer, odometer, trip meter, fuel gauge, warning lights).
Driver Assistance:
Power steering (if equipped on the specific trim) enhances maneuverability and reduces rider fatigue.
Connectivity Features:
N/A (no modern connectivity features like Bluetooth or USB ports on this model).
Engine Oil Change:
Typically every 100 hours or annually, whichever comes first. Consult manual for exact mileage/hour recommendation.
Air Filter Service:
Regular inspection and cleaning, replacement as needed based on operating conditions (e.g., dusty environments require more frequent attention).
Spark Plug Replacement:
Typically at 1,000-2,000 mile intervals or as specified by the manufacturer.
Cv Belt Inspection:
Inspect every 50-100 hours. Replacement interval varies based on usage and conditions, typically 2,000-3,000 miles if conditions are moderate.
Engine Oil Type:
Polaris PS-4 5W-50 Synthetic (or equivalent API SG, JASO MA certified oil).
Engine Oil Capacity:
Approximately 2.1 quarts (2.0 liters) with filter change.
Transmission Gearcase Oil:
Polaris Demand Drive Fluid (front differential) and Polaris Synthetic Gearcase Lubricant (rear differential/transmission).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Polaris Premium All-Season Coolant).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, brake pads.
Potential Electrical Issues:
While EFI enhances reliability, aging electrical components like the regulator/rectifier or stator can be points of failure.
Fuel System Maintenance:
Maintaining clean fuel and fuel filters is crucial for EFI system longevity.
Brand Legacy:
Polaris has a long-standing reputation in the powersports industry, particularly with its Sportsman line of ATVs, known for utility and off-road capability.
Sportsman Line:
The Sportsman 500 platform has been a cornerstone for Polaris, evolving significantly over the years with advancements in engine technology, suspension, and features like EFI and IRS.
Production Era:
The 2008 model represents a mature iteration of the 500cc Sportsman, benefiting from several years of development and refinement.
Manufacturing Location:
Typically manufactured in Polaris facilities in the USA.
