POLARIS SPORTSMAN 500 EFI X2 TOURING 500 H.O. Full Service & Repair Manual 2008

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The Polaris Sportsman 500 X2 Touring, produced in 2008, is a robust all-terrain vehicle designed for both utility and recreational riding. Featuring a powerful 500 H.O. engine with Electronic Fuel...

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Taper: Atv

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UGS: 58212

Mots clés: 2008 ATV Misc Polaris Powersports SPORTSMAN 500 EFI X2 TOURING SPORTSMAN 500 H.O.

Variantes de produits

Description

The Polaris Sportsman 500 X2 Touring, produced in 2008, is a robust all-terrain vehicle designed for both utility and recreational riding. Featuring a powerful 500 H.O. engine with Electronic Fuel Injection (EFI), Independent Rear Suspension (IRS), and a unique convertible cargo/passenger bed, this model offers exceptional versatility and comfort. Its on-demand all-wheel-drive system, hydraulic disc brakes, and accessory compatibility further enhance its capability for various tasks and terrains, making it a reliable choice for demanding environments. This comprehensive factory service manual provides detailed instructions for all aspects of the Polaris Sportsman 500 EFI X2 Touring. It covers a wide range of topics including routine maintenance, engine and transmission overhauls, suspension and brake system repairs, and in-depth electrical system diagnostics. With detailed troubleshooting guides, torque specifications, special tool requirements, and clear wiring diagrams, this manual is an essential resource for owners, mechanics, and technicians aiming to maintain, repair, and optimize the performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 EFI X2 Touring

Year:

Variant:

500 H.O.

👋 Introduction

Market Position

Positioning:

The Polaris Sportsman 500 X2 Touring represents a versatile utility and recreational ATV, designed for riders who need both work capability and comfortable two-up riding. This manual caters to owners and technicians who demand detailed, accurate information for maintaining and repairing this specific model.

Competitive Analysis

Comparison:

Competes with other mid-size, two-up capable ATVs from manufacturers like Can-Am (Outlander MAX), Yamaha (Grizzly 550/700), and Honda (Rancher/Foreman with accessories). The X2's unique convertible cargo/passenger bed is a key differentiator.

Key Features

Features:

500 H.O. engine, Electronic Fuel Injection (EFI), Independent Rear Suspension (IRS), Lock & Ride accessory system, convertible X2 cargo/passenger configuration, on-demand AWD, hydraulic disc brakes.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service, Repair, and Workshop

Scope:

All repairs, servicing, maintenance, troubleshooting, and diagnostics

Page Count

Estimated Pages:

Comprehensive (Specific count not provided, but implies full factory depth)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine assembly, disassembly, tuning, fuel system (EFI), ignition system, cooling system, lubrication system, exhaust system

Transmission:

Automatic transmission (PVT - Polaris Variable Transmission), clutch system, drive belts, gears, differentials (front and rear)

Drivetrain:

Driveshafts, CV joints, AWD system (if applicable), final drive, hub assemblies

Suspension:

Front and rear suspension components, shocks, springs, control arms, bushings, bearings, adjustments

Brakes:

Hydraulic brake system, master cylinder, calipers, brake pads, rotors, brake lines, bleeding procedures, parking brake

Electrical:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, ignition switch, sensors, wiring diagrams, diagnostic codes (DTCs)

Fuel System:

Electronic Fuel Injection (EFI) system, fuel pump, injectors, throttle body, fuel pressure regulator, sensors (MAP, TPS, IAT), troubleshooting EFI issues

Cooling System:

Radiator, fan, coolant hoses, thermostat, water pump, coolant specifications and flushing

Body And Chassis:

Frame, body panels, fenders, seat, handlebars, racks, cargo box, lighting fixtures, plastics

Ergonomics And Controls:

Handlebar controls, throttle, brake levers, shifter, seating position, passenger accommodations (X2 Touring)

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, chain/belt adjustments, lubrication points

Repair:

Component removal and installation, internal engine repair, transmission overhaul, suspension repair, brake component replacement, electrical component diagnosis and repair

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, error code interpretation

Diagnostics:

EFI diagnostic procedures, electrical system testing, mechanical component testing

Wiring Diagrams:

Detailed electrical schematics for all systems

Calibration:

EFI idle speed and TPS (Throttle Position Sensor) calibration procedures.

Overhaul:

Engine, transmission, and differential overhaul procedures.

Replacement:

Component replacement including major assemblies like the engine, transmission, suspension, and electrical components.

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics. Covers everything from routine maintenance to full engine rebuilds and complex electrical diagnostics.

Diagnostic Codes:

Detailed listing and interpretation of Diagnostic Trouble Codes (DTCs) for the EFI system and other vehicle electronics.

Torque Specifications:

Precise torque values for all fasteners and critical components.

Clearances And Tolerances:

Specifications for engine internal clearances, bearing preloads, and other critical tolerances.

Special Tools:

Listing and description of specialized tools required for specific repair or diagnostic procedures.

Wiring Diagrams Detail:

Color-coded wiring schematics with component identification and wire routing.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically searchable text within the PDF for quick information retrieval

Printability:

Printable pages for offline use

Print Quality

Quality:

High-resolution scans/digital creation ensuring clarity of text and diagrams

Binding Type

Binding:

Not applicable (Digital Download)

Paper Type

Paper:

Not applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single-cylinder, SOHC, 4-valve

Displacement:

499cc

Bore X Stroke:

92.0 mm x 75.6 mm

Cooling System:

Liquid-cooled

Fuel Induction:

Electronic Fuel Injection (EFI) with 44mm throttle body

Performance

Horsepower:

Approx. 30-33 HP (Estimates vary by tuning and source; manual provides precise specs)

Torque:

Not explicitly stated in product title, but manual will contain detailed torque specifications.

Fuel System

Fuel Type:

Unleaded gasoline, 87 octane minimum

Fuel Tank Capacity:

4.0 US gallons (15.1 L)

Ignition

Ignition Type:

CDI (Capacitor Discharge Ignition) with electronic advance

🔧 Transmission

Standard

Transmission Type:

Automatic, Polaris Variable Transmission (PVT) with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive System:

Shaft Drive, On-Demand True All-Wheel Drive (AWD)

Features

Clutch Type:

Dual clutch system (Primary and Secondary)

Belt Type:

Specific belt number (e.g., 3211077) will be detailed in the manual.

📐 Dimensions

Exterior

Length:

85.5 in. (217.2 cm)

Width:

47.2 in. (119.9 cm)

Height:

48 in. (121.9 cm)

Wheelbase:

57.5 in. (146.1 cm)

Ground Clearance:

11.0 in. (27.9 cm)

Weights

Dry Weight:

667 lbs (302.5 kg)

Payload Capacity:

Rear rack: 200 lbs (91 kg) / Passenger: 190 lbs (86 kg)

Towing Capacity:

1500 lbs (680 kg)

Cargo

Cargo Box Capacity:

Convertible X2 bed offers significant cargo space and can be converted to a 2-person seat.

Wheels And Tires

Front Tire:

AT 25 x 8-12

Rear Tire:

AT 25 x 10-12

Wheelbase Bolt Pattern:

4/110

🛡️ Safety Features

Ratings

Safety Certifications:

Typically meets industry safety standards for ATVs; specific ratings like NHTSA or IIHS are not applicable to this vehicle class.

Active Features

Braking System:

Hydraulic disc brakes front and rear; engine braking from PVT.

Drive Mode:

On-demand AWD provides enhanced traction.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Ergonomics:

Comfortable seating, intuitive controls designed for rider stability.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, tachometer, fuel gauge, AWD indicator, gear indicator, coolant temp warning. No advanced infotainment systems typically found on this model.

Driver Assistance

Assistance Features:

On-demand True AWD system for enhanced traction control.

Connectivity

Connectivity:

No modern connectivity features (Bluetooth, USB, smartphone integration).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 100 hours or 12 months (Refer to manual for precise interval and specific conditions).

Spark Plug Replacement:

Refer to manual for recommended interval, typically around 100-200 hours.

Air Filter Cleaning:

Recommended every 20-50 hours or as needed based on operating conditions.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Full Synthetic or equivalent API SG/SH/SJ certified oil (Manual will specify exact grade and API rating).

Engine Oil Capacity:

Approximately 2.5 US quarts (2.4 liters) with filter change (Refer to manual for exact capacity).

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Polaris Anti-Freeze/Coolant or equivalent meeting specified standards).

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 75W-90 gear oil (Manual will specify exact type and quantity).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (Manual will specify exact type).

Known Issues

Common Wear Items:

PVT belt wear, wheel bearing wear, CV joint boot tears, suspension bushings, starter solenoid reliability (common on many ATVs of this era).

Efi System:

Potential for throttle body contamination or sensor issues, though generally reliable. Manual provides detailed troubleshooting.

📚 Vehicle History

Brand Heritage

Heritage:

Polaris has a long history of producing off-road vehicles, including the highly successful Sportsman line, known for its utility, comfort, and innovation.

Model Evolution

Evolution:

The Sportsman 500 has been a cornerstone of Polaris's ATV lineup for years. The X2 variant, introduced in 2007, added the unique convertible 2-up/cargo bed, significantly enhancing its versatility.

Production

Production Years:

The Sportsman 500 platform has been in production for many years, with the X2 variant appearing from 2007 onwards. The 2008 model year represents a specific iteration of this popular platform.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for the 2008 Sportsman 500 X2 Touring are not widely documented, but the Polaris Sportsman line has consistently received praise for its utility, comfort, and reliability over many years.