Market Segment:
Recreational ATV (All-Terrain Vehicle)
Target Audience:
Owners of the 2008 Polaris Sportsman 500 Touring EFI seeking to perform maintenance, repairs, and diagnostics.
Competitors 2008:
Can-Am Outlander, Arctic Cat 500, Yamaha Grizzly 550, Suzuki KingQuad 500.
Key Selling Points:
Comfortable seating for two, powerful 500cc engine, independent rear suspension (IRS), electronic fuel injection (EFI), robust storage capacity.
Manual Value Proposition:
Provides comprehensive technical information to maintain and repair the specific 2008 Sportsman 500 Touring EFI model, saving time and money on service.
Engine:
Complete engine overhaul, disassembly, assembly, tuning, lubrication system, cooling system, intake system, exhaust system.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, fuel filter, fuel tank, fuel lines.
Transmission:
PVT (Polaris Variable Transmission) clutch inspection, adjustment, and replacement; gearbox overhaul, lubrication, and fluid specifications.
Drivetrain:
Front and rear drive systems, differentials, drive shafts, CV joints, bearings, seals.
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system, starter motor, lighting, switches, relays, fuses, wiring diagrams, EFI control module.
Suspension:
Front and rear suspension components, shocks, springs, A-arms, bushings, alignment specifications, steering system.
Chassis Frame:
Frame inspection, welds, components, body panels, seat, handlebars, racks.
Cooling System:
Radiator, fan, coolant, hoses, thermostat.
Bodywork:
Body panel removal, installation, care.
Maintenance:
Routine maintenance tasks, oil changes, filter replacements, spark plug service, air filter cleaning/replacement, valve clearance checks, lubrication points.
Troubleshooting:
Diagnostic charts and procedures for common and uncommon problems, error codes, performance issues.
Repair:
Step-by-step repair instructions for all major and minor mechanical and electrical components.
Overhaul:
Complete engine and transmission overhaul procedures.
Disassembly Assembly:
Detailed instructions for component disassembly and reassembly.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for easy troubleshooting.
Depth Level:
Comprehensive; covers basic maintenance to complete engine and component rebuilds, including advanced diagnostics and EFI system troubleshooting.
Engine Type:
4-stroke, 2-cylinder, SOHC, liquid-cooled, fuel-injected
Engine Displacement:
499 cc (30.45 cubic inches)
Bore X Stroke:
70 mm x 64 mm
Engine Oil Type:
SAE 10W-40 Synthetic ATV Engine Oil (e.g., Polaris Synthetic 4T)
Engine Oil Capacity:
Approximately 2.3 quarts (2.2 liters) with filter change
Spark Plug Type:
NGK CR9EKB (or equivalent)
Idle Speed:
1200-1400 RPM (refer to manual for precise specification)
Horsepower Estimated:
Approximately 30-35 HP (actual figures can vary slightly)
Torque Estimated:
Approximately 30-35 lb-ft
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
4.0 gallons (15.1 liters)
Coolant Type:
Ethylene Glycol-based Antifreeze/Coolant (e.g., Polaris recommended mixture)
Coolant Capacity:
Approximately 1.7 quarts (1.6 liters)
Atv Safety Standards:
Complies with ANSI/SVIA standards where applicable. Manual provides safety guidelines.
Braking System:
Hydraulic disc brakes (front and rear), handlebar-mounted levers, foot brake.
Tire Type:
ATV specific, knobby tread for off-road traction.
Suspension Stability:
Independent Front Suspension (IFS) and Independent Rear Suspension (IRS) contribute to stability and rider comfort over uneven terrain.
Lighting:
Dual headlights, taillight, brake light for visibility.
Operator Controls:
Ergonomically designed handlebars, throttle, and brake controls.
Seat Design:
Comfortable, padded seat for rider and passenger.
Infotainment System:
N/A (ATV, not equipped with traditional infotainment)
Assistance Features:
N/A (ATV, not equipped with advanced driver assistance systems)
Connectivity Features:
N/A (ATV, basic electrical system)
Efi System:
Electronic Fuel Injection provides precise fuel delivery for improved throttle response, fuel efficiency, and altitude compensation.
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic timing advance.
Oil Change Interval:
Every 100 hours or 12 months, whichever comes first (refer to manual for specific conditions).
Air Filter Maintenance:
Inspect every 25 hours, clean or replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Service:
Inspect/replace every 100 hours or 12 months.
Valve Clearance Check:
Every 100 hours or 12 months.
Clutch Inspection:
Inspect primary and secondary clutches every 100 hours or 12 months. Check belt condition and alignment.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Coolant Mixture:
50/50 mix of ethylene glycol antifreeze and distilled water
Common Wear Items:
Drive belts, ball joints, tie rod ends, wheel bearings, brake pads, wheel bearings.
Efi System Considerations:
Potential for throttle body cleaning, injector maintenance, and ensuring proper battery voltage for optimal EFI performance.
Suspension Wear:
Bushing wear in A-arms and suspension pivot points can lead to looseness and alignment issues.
Polaris History:
Polaris Inc. is an American manufacturer of snowmobiles, ATVs, motorcycles, and electric/neighborhood vehicles, founded in 1954.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, utility, and off-road capability. The 500cc engine has been a popular choice for many years, evolving with features like EFI and IRS.
Model Year Significance 2008:
The 2008 model year for the Sportsman 500 Touring EFI represented a refinement of the popular touring platform, emphasizing rider comfort and utility for extended journeys.
