Target Audience:
Owners and independent repair shops seeking a professional-grade service manual for the 2008 Polaris Sportsman 500.
Value Proposition:
Provides the same in-depth technical information used by authorized Polaris dealerships, enabling cost-effective DIY repairs and maintenance.
Alternatives:
Owner's manuals (limited repair info), online forums (unverified information), third-party repair guides (variable quality).
Dealer Level Information:
Authentic service manual content mirroring dealership resources.
Instant Accessibility:
Immediate download allows for prompt access to critical repair data.
Comprehensive Coverage:
Covers all aspects of maintenance, troubleshooting, and repair.
Engine:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, crankshaft, camshaft, valves, etc.).
Fuel System:
Carburetor tuning, cleaning, and rebuilding; fuel pump inspection and replacement; fuel line routing and maintenance.
Ignition System:
Spark plug specifications, testing, and replacement; ignition coil testing; CDI unit diagnostics.
Cooling System:
Radiator service, fan operation, thermostat replacement, coolant specifications and flushing procedures.
Transmission:
Automatic transmission operation, maintenance, and repair; clutch pack inspection and replacement; torque converter service.
Drivetrain:
Drive shaft inspection and maintenance; CV joint service; differential overhaul and fluid specifications.
Suspension:
Front and rear suspension component inspection, replacement (shocks, springs, control arms); alignment specifications.
Steering:
Steering column, tie rod ends, and steering rack maintenance and repair; power steering system diagnostics (if applicable).
Braking System:
Hydraulic brake system service, caliper overhaul, brake pad and rotor replacement; bleeding procedures.
Electrical System:
Wiring diagrams, component testing (starter, alternator, battery), lighting system repair, fuse box identification and troubleshooting.
Bodywork And Frame:
Panel removal and installation, fairing repair, chassis inspection and maintenance.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, tire pressure checks, battery maintenance.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common mechanical and electrical issues.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Component Replacement:
Detailed guidance on replacing wear items and major components.
Performance Tuning:
Basic adjustments for optimal performance.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
Searchable:
Yes (text-based PDF, allowing for keyword searches)
Printable:
Yes (designed for printability, allowing users to print specific sections or the entire manual)
Digital Rights:
Instant Download - No physical shipping
Resolution:
High-resolution scans, ensuring clarity of text and diagrams.
Binding Description:
N/A (Digital format, no physical binding)
Paper Description:
N/A (Digital format, no physical paper type)
Engine Type:
4-stroke, SOHC, 4-valve
Bore X Stroke:
92mm x 76mm (approximate, requires manual confirmation for exact figures)
Cooling Method:
Liquid-cooled
Power Delivery:
Typically utilizes Polaris's PVT (Polaris Variable Transmission) system.
Horsepower:
Approximately 30-35 HP (requires manual confirmation for exact figure).
Torque:
Significant torque for off-road application (requires manual confirmation for exact figure).
Fuel Delivery:
Carbureted (likely Mikuni or Keihin, specific model to be confirmed in manual).
Fuel Type:
Unleaded gasoline
Transmission Type:
Automatic, Polaris Variable Transmission (PVT) with Engine Braking
Drive Modes:
2WD/4WD, often with locking front differential
Gear Reduction:
High and Low range
Clutch System:
Primary and secondary clutch system with belt drive.
Fluid Type:
Specific PVT fluid or SAE 10W-40 transmission oil (manual will specify exact type and capacity).
Length:
Approx. 83 in. (210.8 cm) (requires manual confirmation)
Width:
Approx. 46 in. (116.8 cm) (requires manual confirmation)
Height:
Approx. 48 in. (121.9 cm) (requires manual confirmation)
Wheelbase:
Approx. 50.5 in. (128.3 cm) (requires manual confirmation)
Ground Clearance:
Approx. 11 in. (27.9 cm) (requires manual confirmation)
Dry Weight:
Approx. 680 lbs (308 kg) (requires manual confirmation)
Towing Capacity:
Typically rated for 1,500 lbs (680 kg) (requires manual confirmation)
Rack Capacity Front:
Typically rated for 100 lbs (45 kg) (requires manual confirmation)
Rack Capacity Rear:
Typically rated for 200 lbs (90 kg) (requires manual confirmation)
Atv Classification:
All-Terrain Vehicle (ATV)
Braking System:
Hydraulic disc brakes front and rear.
Engine Braking:
Integrated engine braking through PVT system for downhill control.
Lighting:
Dual 25-watt headlights, single 8-watt taillight/brake light.
Instrumentation:
Digital odometer, speedometer, trip meter, tachometer, fuel gauge, engine hour meter, 4WD indicator, neutral/reverse indicator, high/low gear indicator.
Oil Change:
Typically every 100 hours or 6 months, whichever comes first. Manual to confirm exact interval and oil type.
Air Filter:
Inspect every 25 hours, clean or replace as needed. More frequent cleaning in dusty conditions.
Spark Plug:
Inspect and clean every 100 hours, replace as needed. Manual to confirm correct type and gap.
Transmission Fluid:
Check level regularly, change as specified (often annually or every 200 hours). Manual to confirm exact interval and fluid type.
Drive Belt:
Inspect for wear and damage at regular intervals (e.g., every 50 hours). Replace if any signs of damage or excessive wear are present.
Engine Oil:
Polaris recommends specific synthetic or semi-synthetic oil meeting certain viscosity grades (e.g., SAE 0W-40 or 10W-40, manual will specify exact API classification and viscosity based on temperature range).
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors. Manual will specify mixture ratio and type.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (manual will specify exact type).
Drive Belt Wear:
Regular inspection and replacement of the CVT belt is crucial to prevent breakage and ensure proper power transfer.
Carburetor Tuning:
Can require periodic adjustment due to altitude or fuel variations, especially with aftermarket modifications. Manual provides tuning procedures.
Suspension Bushings:
Wear on suspension bushings can lead to play and affect handling. Regular inspection and replacement are recommended.
Manufacturer:
Polaris Industries, Inc., a long-standing manufacturer of powersports vehicles.
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, known for its comfort, capability, and versatility. The 500cc engine has been a staple in their lineup for many years, with continuous refinements.
2008 Updates:
While major platform changes might not have occurred for 2008, model year updates typically include minor cosmetic refinements, component upgrades, and emissions compliance adjustments. Specific changes for 2008 will be detailed within the manual.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
