Market Segment:
Premium touring ATV, designed for comfort and utility over long distances and varied terrain.
Key Competitors:
Can-Am Outlander, Arctic Cat 500 TRV, Yamaha Grizzly.
Touring Focus:
Features like extended passenger seat, floorboards, and comfortable ergonomics for two-up riding.
Engine Performance:
EFI system for consistent power delivery and throttle response across changing altitudes and temperatures.
Primary Focus:
Service, Repair, and Maintenance
Vehicle Variants:
Polaris Sportsman 500 Touring EFI 2008
Estimated Pages:
Approx. 300-500 pages (typical for comprehensive service manuals of this era).
Type:
Factory Service Manual (FSM) / Repair Manual
Format:
Downloadable Digital Format (PDF)
Engine Mechanical:
Engine assembly, disassembly, inspection, and repair of all internal components.
Engine Fuel System:
EFI system troubleshooting, injector cleaning, fuel pump, pressure regulator, and throttle body.
Engine Ignition System:
Ignition coil, CDI unit, spark plugs, and timing procedures.
Cooling System:
Radiator, fan, hoses, thermostat, and coolant specifications.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) operation, belt inspection/replacement, clutch service, and final drive maintenance.
Suspension Steering:
Front and rear suspension components, shock absorber adjustment/replacement, steering linkage, and wheel alignment.
Brakes:
Hydraulic brake system, caliper service, pad replacement, fluid flush, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (stator, voltage regulator), starter motor, lighting, and accessory circuits.
Chassis Frame:
Frame inspection, body panel removal/installation, and seat service.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) if applicable for the EFI system, and common fault analysis.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, and general inspection checklists.
Component Rebuilds:
Detailed instructions for engine, transmission, and differential rebuilds.
Troubleshooting Fault Finding:
Systematic approaches to diagnose and resolve issues across all vehicle systems.
Torque Specifications:
Precise torque values for critical fasteners.
Special Tools:
Identification and usage of any specialized tools required for specific procedures.
Depth:
Comprehensive, from basic owner maintenance to advanced mechanical and electrical repair.
Engine Type:
4-stroke, SOHC, 2-valve, Single Cylinder
Bore X Stroke:
92mm x 76mm (approx.)
Cooling System:
Liquid-cooled
Horsepower:
Approx. 30-35 HP (estimated, actual figures may vary).
Torque:
Approx. 30-35 lb-ft (estimated, actual figures may vary).
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch or similar system.
Fuel Type:
Unleaded Gasoline, 87 Octane (minimum)
Transmission Type:
Automatic Polaris Variable Transmission (PVT) with Hi/Lo range, Neutral, and Reverse.
Optional Gearbox:
N/A (PVT is standard)
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector.
Differentials:
Front: Polaris ADC (Active Descent Control) compatible with AWD engagement. Rear: Locked.
Gear Reduction:
Included within the PVT and final drive units.
Length:
Approx. 85.5 inches (217.2 cm)
Width:
Approx. 45.2 inches (114.8 cm)
Height:
Approx. 48.5 inches (123.2 cm) to handlebars
Wheelbase:
Approx. 57 inches (144.8 cm)
Ground Clearance:
Approx. 11.25 inches (28.6 cm)
Front Rack Capacity:
Approx. 100 lbs (45 kg)
Rear Rack Capacity:
Approx. 200 lbs (91 kg)
Dry Weight:
Approx. 660 lbs (299 kg)
Towing Capacity:
Approx. 1500 lbs (680.4 kg)
Payload Capacity:
Approx. 475 lbs (215.5 kg)
Atv Safety Standards:
Complies with ANSI standards for recreational ATVs.
Braking System:
Hydraulic disc brakes front and rear with park brake.
Engine Braking:
Engine braking provided by the PVT system.
All Wheel Drive:
On-demand AWD system for enhanced traction.
Lighting:
Dual 50W headlights, 35W brake/taillight.
Ergonomics:
Ergonomic seating and controls for rider comfort and control.
Hand Guards:
Standard handguards for rider protection from elements and debris.
Instrument Cluster:
Digital odometer, speedometer, trip meter, tachometer, fuel gauge, AWD indicator, and gear indicator.
Adc:
Active Descent Control (ADC) assists with downhill control.
Charging Port:
12V auxiliary outlet for charging accessories.
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first. (Refer to manual for specific API rating).
Air Filter Cleaning:
Check every 25 hours, clean/replace as needed. More frequent in dusty conditions.
Spark Plug Replacement:
Recommended every 200 hours or as needed based on condition.
Brake Fluid Flush:
Recommended every 24 months or as needed.
Pvt Belt Inspection:
Inspect every 100 hours. Replace if worn, cracked, or damaged.
Engine Oil Type:
SAE 10W-40, API SG or higher (Check manual for exact API/JASO specification).
Engine Oil Capacity:
Approx. 2.0 US quarts (1.9 L) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Gearcase Oil Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 80W-90.
Common Problems:
Potential for premature wear on PVT belt if not maintained, occasional EFI sensor issues, and common electrical connection corrosion if not protected.
Maintenance Tips:
Regular cleaning of air filter and critical electrical connectors, proper PVT belt tension and inspection are key to longevity.
Brand Focus:
Polaris is a long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving significantly in performance, comfort, and technology.
Touring Variant:
The Touring models, like the 500 Touring EFI, were specifically developed to enhance the rider and passenger experience for longer excursions.
Manufacturing Origin:
Typically manufactured in North America (e.g., USA).
