2008 Polaris Sportsman 500 EFI X2 Touring Factory Manual

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Mots clés: 2008 ATV Misc Polaris Powersports Sportsman 500 EFI X2 Touring

Variantes de produits

Description

The 2008 Sportsman 500 EFI X2 Touring represents a robust and versatile sport/utility all-terrain vehicle, built for outdoor enthusiasts, recreational riders, and property owners. This model is powered by a 499cc liquid-cooled, SOHC, 4-valve, single-cylinder engine featuring Electronic Fuel Injection (EFI) for reliable starting and smooth power delivery, delivering approximately 33-36 horsepower. Its design emphasizes versatility, with the X2 and Touring configurations offering dual-seating capabilities and enhanced comfort for longer rides. The Sportsman 500 EFI X2 Touring is equipped with an Automatic PVT transmission with engine braking, on-demand All-Wheel Drive (AWD) for superior traction, and hydraulic disc brakes for dependable stopping power. With a towing capacity of 1,500 lbs and substantial rack capacity, it is well-suited for both work and recreational activities across various terrains. This comprehensive factory workshop and service manual provides detailed technical information for the 2008 Sportsman 500 EFI X2 Touring and 500 H.O. models, covering all aspects of maintenance, repair, and diagnostics. The manual delves into intricate details of major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical systems, along with the fuel system and bodywork. It outlines routine maintenance procedures, systematic troubleshooting guides for common issues, and step-by-step instructions for component repair and rebuilds. Owners and technicians will find essential information on diagnostic procedures, adjustment specifications, and technical data, ensuring the vehicle is maintained to optimal performance and safety standards.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 EFI X2 Touring

Model Variant:

X2, Touring, 500 H.O.

Year:

Codes

Product Name Code:

2008 Polaris Sportsman 500 EFI X2 Touring Factory Manual PDF Download

👋 Introduction

Market Position

Category:

Sport/Utility All-Terrain Vehicle (ATV)

Target Audience:

Outdoor enthusiasts, recreational riders, hunters, and property owners seeking a versatile, powerful, and comfortable ATV for various terrains and tasks.

Competitive Analysis

Competitors:

Yamaha Grizzly, Can-Am Outlander, Arctic Cat 500/550, Suzuki KingQuad, Honda Foreman/Rancher.

Key Features

Versatility:

The X2 model's dual-seating capability and the Touring model's comfort features make it a versatile option for both single-rider adventures and carrying a passenger.

Engine Power:

The 500 H.O. (High Output) engine provides robust power for hauling, towing, and trail riding.

Efi System:

Electronic Fuel Injection ensures reliable starting, smooth power delivery, and better altitude compensation compared to carbureted models.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete workshop and service information for the 2008 Polaris Sportsman 500 EFI X2 Touring and 500 H.O. models.

Secondary Coverage:

Includes information on X2 and Touring configurations.

Page Count

Estimated Pages:

High (typical factory service manuals for ATVs of this era are 500-1000+ pages)

Manual Type

Type:

Factory Workshop Manual / Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, and overhaul procedures for the 499cc liquid-cooled, SOHC, 4-valve, single-cylinder engine (500 H.O.). Covers fuel injection (EFI), ignition, cooling, lubrication, and exhaust systems.

Transmission:

Maintenance, troubleshooting, and repair of the Automatic PVT (Polaris Variable Transmission) with Engine Braking, including belt inspection, clutch service, and gearbox.

Drivetrain:

Service information for the AWD (All-Wheel Drive) system, including front differential, rear differential, drive shafts, CV joints, and hubs.

Suspension:

Front and rear suspension (e.g., MacPherson strut front, Independent Rear Suspension - IRS on X2/Touring models), shock absorbers, control arms, and bushings.

Brakes:

Hydraulic disc brakes (front and rear), brake system bleeding, pad replacement, caliper service, and master cylinder.

Electrical:

Complete electrical system schematics, wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, ignition switch, starter motor, and accessory circuits.

Fuel System:

EFI system components: fuel pump, fuel filter, injectors, throttle body, TPS (Throttle Position Sensor), and ECU (Engine Control Unit) diagnostics.

Bodywork And Chassis:

Frame, body panels, seats, racks, storage compartments, and the X2's unique Versa-Track dual-seating system.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug service, coolant flush, lubrication points, tire pressure checks, and battery maintenance.

Troubleshooting:

Systematic diagnostic procedures for common issues, error codes, and performance problems across all major systems.

Repair And Rebuild:

Step-by-step instructions for component disassembly, inspection, repair, and reassembly (e.g., engine rebuild, transmission overhaul, suspension component replacement).

Diagnostic Procedures:

Detailed methods for diagnosing electrical faults, engine performance issues, and driveability problems, often referencing specific tools or scan data.

Adjustment Procedures:

Calibration of sensors (e.g., TPS), throttle cable adjustment, brake adjustments, and suspension settings.

Technical Depth

Depth:

Comprehensive. Covers everything from basic owner maintenance to advanced engine rebuilds and complex electrical system diagnostics.

Diagnostic Tools:

References required diagnostic tools, specialized tools, and torque specifications for all procedures.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable, allowing for quick lookup of specific terms and procedures.

Print Quality

Quality:

Professional, dealer-level quality diagrams and illustrations.

Binding Type

Binding:

N/A (PDF Download)

Paper Type

Paper:

N/A (PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, SOHC, 4-Valve, Single Cylinder

Displacement:

499 cc

Bore X Stroke:

92 mm x 77 mm (typical for this engine)

Cooling System:

Liquid-Cooled

Ignition:

Electronic CDI with Digital Advance

Performance

Horsepower:

Approx. 33-36 HP (at flywheel, estimated for 2008 500 H.O.)

Torque:

N/A (Specific figures often not published by manufacturers for ATVs, but known to be strong low-end torque)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane minimum recommended)

Lubrication

Oil Type:

SAE 20W-50 Premium ATV Engine Oil

Oil Capacity:

Approx. 2.0 US qt (1.9 L) with filter change

🔧 Transmission

Standard

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking

Drive Selection:

2WD/AWD (All-Wheel Drive) selector

Features

Engine Braking:

Standard feature providing downhill control.

Clutch Type:

Dual Centrifugal Clutches (Primary and Secondary)

📐 Dimensions

Exterior

Length:

Approx. 83.0 in (210.8 cm)

Width:

Approx. 46.0 in (116.8 cm)

Height:

Approx. 47.0 in (119.4 cm)

Wheelbase:

Approx. 50.5 in (128.3 cm)

Weights

Dry Weight:

Approx. 630 lbs (286 kg)

Towing Capacity:

1,500 lbs (680.4 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

Cargo

Storage:

Front dry storage compartment, rear cargo box (X2 model features Versa-Track and folding bed).

🛡️ Safety Features

Ratings

Atv Safety:

Polaris emphasizes safe operating practices. This manual provides critical safety information and warnings as required by industry standards.

Active Features

AWD System:

Automatic All-Wheel Drive enhances traction and control.

Engine Braking:

Assists in maintaining control on descents.

Passive Features

Braking System:

Hydraulic disc brakes front and rear provide reliable stopping power.

Lighting:

Dual headlights, tail light, and brake light for visibility.

💡 Technology Features

Infotainment

Display Panel:

Digital instrument cluster featuring speedometer, odometer, trip meter, tachometer, fuel gauge, AWD indicator, and neutral/reverse indicators.

Driver Assistance

Electronic Fuel Injection provides optimized engine performance and starting.

AWD Engagement:

On-demand AWD system for enhanced traction when needed.

Connectivity

Accessories:

Pre-wired accessory connectors may be present for lights, winches, etc., though specific factory integration is limited.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months, whichever comes first. Check manual for specific usage conditions.

Air Filter Cleaning:

Check every 50 hours; clean or replace as needed. More frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 12 months or 100 hours.

Transmission Oil:

Check condition at every service; refer to manual for specific change intervals and procedures (often tied to hours or mileage).

Fluid Specifications

Coolant:

Polaris Premium 2-Stroke/4-Stroke Coolant or equivalent ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water).

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Known Issues

Drive Belt Wear:

PVT drive belts can wear over time and require periodic inspection and replacement. Aggressive riding or overloading accelerates wear.

Electrical Connections:

Corrosion in electrical connectors can lead to intermittent issues. Regular inspection and dielectric grease application are beneficial.

Efi Sensor Calibration:

Throttle Position Sensor (TPS) calibration may be necessary if performance issues arise. The manual will detail the procedure.

Rear Suspension Bushings:

Depending on mileage and usage, suspension bushings can wear, leading to a clunky feel or alignment issues.

📚 Vehicle History

Brand Heritage

Polarissporting:

Polaris Industries is a long-standing American manufacturer known for snowmobiles, ATVs, and personal watercraft, with a strong reputation for innovation and performance.

Model Evolution

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, evolving through various engine sizes and configurations, including the popular 500 H.O. series.

X2 Touring Development:

The X2 and Touring variants were introduced to cater to riders seeking greater versatility and passenger comfort, building upon the established Sportsman platform.

Production

Production Era:

The 500 H.O. engine was a dominant force in Polaris's ATV lineup throughout the early to late 2000s.

🏆 Awards & Recognition

Recognitions

General Reputation:

The Polaris Sportsman 500 H.O. platform was highly regarded in its class for its combination of power, reliability, and versatility, often receiving positive reviews from ATV publications.

Ratings

Owner Satisfaction:

Typically strong owner satisfaction for its work and recreational capabilities.