The 2008 Sportsman 500 Touring EFI is a versatile All-Terrain Vehicle (ATV) designed for both sport and utility riding, offering comfort for extended excursions. Known for its robust engineering and reliable performance, this model features Electronic Fuel Injection (EFI) for consistent power delivery, independent rear suspension for a smoother ride, and a powerful 499cc liquid-cooled engine. Its design prioritizes rider comfort and capability, making it a capable companion for various off-road adventures and demanding tasks, reflecting a heritage in the powersports industry.
This comprehensive workshop repair manual provides essential information for the maintenance, diagnosis, and repair of the 2008 Sportsman 500 Touring EFI. It covers a wide array of systems, including the engine, fuel system, drivetrain, suspension, brakes, and electrical components. Detailed procedures for disassembly, inspection, rebuilding, and assembly are included, along with troubleshooting guides, diagnostic flowcharts, and technical specifications. This manual is an indispensable resource for owners and technicians aiming to ensure the optimal performance, longevity, and safe operation of their vehicle.
Model:
Sportsman 500 Touring EFI
Vehicle Type:
All-Terrain Vehicle (ATV)
Segment:
Sport/Touring ATV
Market Position:
The Polaris Sportsman 500 Touring EFI was a popular choice in the 2008 ATV market, known for its comfort, versatility, and capability for longer rides and utility tasks.
Competitive Analysis:
Competed against models from Can-Am (Outlander), Yamaha (Grizzly), and Honda (Foreman/Rancher) in the 500cc-class utility and sport-touring ATV segment.
Key Features:
Electronic Fuel Injection (EFI) for consistent performance, independent rear suspension (IRS) for a smoother ride, active descent control, powerful engine, and comfortable seating for two.
Manual Value Proposition:
This workshop manual is essential for owners and technicians seeking to maintain, diagnose, and repair the 2008 Polaris Sportsman 500 Touring EFI, providing authorized procedures for optimal performance and longevity.
Coverage Areas:
General, Maintenance, Engine, Fuel System, Body, Suspension, Clutch, Transmission, Final Drive, Brakes, Electrical, International
Estimated Page Count:
Refer to actual manual (typically 300-600 pages for full workshop manuals)
Manual Type:
Workshop Repair Manual
File Format:
PDF / WinZip
Delivery Method:
Instant Download via Email
Operating System Compatibility:
All versions of operating systems
Systems Covered:
Engine mechanical, fuel injection system, cooling system, drivetrain components (clutch, transmission, final drive), suspension system (front and rear), braking system, electrical system (wiring diagrams, ignition, lighting, charging), chassis, bodywork, and more.
Procedures Included:
Disassembly, inspection, cleaning, rebuilding, assembly, troubleshooting, diagnostics, routine maintenance, adjustments, repair procedures for all major components.
Technical Depth:
Comprehensive from beginner to advanced mechanic, covering detailed step-by-step repair instructions, diagnostic flowcharts, torque specifications, and component tolerances.
Applicable Models:
Specifically for the 2008 Polaris Sportsman 500 Touring EFI model.
File Format Details:
PDF for widespread compatibility, likely compressed with WinZip for efficient download.
Print Quality:
High-resolution digital format, suitable for printing high-quality pages.
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Type:
4-Stroke, Single Cylinder
Horsepower:
Approx. 31 HP (This is an estimate, actual may vary by tune)
Torque:
Refer to manual for specific torque figures.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Cooling Method:
Liquid-Cooled
Ignition System:
Electronic CDI (Capacitor Discharge Ignition)
Valvetrain Type:
SOHC (Single Overhead Camshaft), 4 Valves
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
High, Low, Neutral, Reverse, Park
Transmission Features:
Engine Braking System (EBS) for controlled downhill descents.
Drivetrain Type:
Shaft Drive (AWD/2WD Selectable)
Length:
Approx. 83 in (210.8 cm)
Width:
Approx. 46 in (116.8 cm)
Height:
Approx. 49.5 in (125.7 cm)
Dry Weight:
Approx. 653 lbs (296 kg)
Ground Clearance:
Approx. 11.25 in (28.6 cm)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
Front Tire Size:
AT 25 x 8-12
Rear Tire Size:
AT 25 x 10-12
Wheelbase:
Approx. 50.5 in (128.3 cm)
Safety Ratings:
ATV safety standards adherence (e.g., ANSI).
Active Safety Features:
On-Demand All-Wheel Drive (AWD), Engine Braking System (EBS).
Passive Safety Features:
Handguards, ergonomic seating, secure footwells.
Infotainment System:
Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, gear indicator, AWD indicator, 4x4 indicator, engine hour meter.
Driver Assistance:
Engine Braking System (EBS), On-Demand AWD.
Lighting System:
Dual halogen headlights, LED taillight/brake light.
Initial Service:
Typically at 10 hours or 1 month for break-in service (oil change, filter check, adjustments).
Regular Maintenance:
Refer to manual for detailed intervals (e.g., oil changes every 100 hours/6 months, spark plug replacement, air filter service).
Engine Oil:
Polaris PS-4 Synthetic 5W-50 (or equivalent SAE 5W-50 API SG or higher synthetic oil).
Coolant:
Ethylene glycol-based antifreeze (e.g., Polaris Premium Antifreeze) mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Oil:
Polaris PVT Fluid (or SAE 10W-30 gear oil for older models - consult manual for exact spec).
Common Issues To Look For:
Potential issues might include wear on suspension components, drive belt wear in the PVT system, starter solenoid issues, or charging system problems. The manual will detail specific diagnostics for these.
Oil Filter Part Number:
Refer to manual for exact P/N. Common Polaris filters: 3089233, 3089999.
Air Filter Part Number:
Refer to manual for exact P/N. Common Polaris filters: 7080582, 3089934.
Brand Heritage:
Polaris Industries has a long-standing reputation in the powersports industry, particularly for its ATV and snowmobile products, known for innovation and off-road performance.
Model Evolution:
The Sportsman 500 series has been a flagship line for Polaris, evolving over years with significant updates like the introduction of EFI, IRS, and touring capabilities.
Production Years:
The Sportsman 500 model line has been in production for many years, with the Touring EFI variant being a specific configuration for models like 2008.
Awards And Recognitions:
Polaris Sportsman models have consistently received praise for their utility and performance from industry publications and riders.
