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

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The 2008 Sportsman 500 EFI X2 EFI Touring is a versatile All-Terrain Vehicle (ATV) designed for a wide range of applications, from recreational trail riding and hunting to demanding utility...

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Type: Atv

Vendor:

Sku: 58214

Tags: 2008 ATV Misc Polaris Powersports SPORTSMAN 500 SPORTSMAN 500 EFI SPORTSMAN TOURING SPORTSMAN X2 EFI

Product variants

Description

The 2008 Sportsman 500 EFI X2 EFI Touring is a versatile All-Terrain Vehicle (ATV) designed for a wide range of applications, from recreational trail riding and hunting to demanding utility tasks. Known for its robust 499cc liquid-cooled, single-cylinder engine with Electronic Fuel Injection (EFI), this model offers reliable power and efficient performance. Key features include its dual-seat capability, a practical tilting cargo bed with a substantial payload capacity, and an On-Demand All-Wheel Drive system for superior traction in challenging terrain. Built with a reputation for engineering quality and durability, the Sportsman 500 EFI X2 EFI Touring provides a comfortable ride and dependable operation, making it a strong contender in the utility ATV segment. This comprehensive factory service repair workshop manual provides detailed information essential for the maintenance, diagnosis, and repair of your 2008 Sportsman 500 EFI X2 EFI Touring. It covers all major systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical system, offering step-by-step instructions, troubleshooting guides, and factory specifications. The manual is designed to assist owners, mechanics, and technicians in performing everything from routine scheduled maintenance, such as oil changes and filter replacements, to complex overhauls and diagnostics. With factory-level technical depth and clear procedures, this manual is an invaluable resource for ensuring the longevity, performance, and safe operation of your vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 EFI X2 EFI Touring

Model Variant:

X2 EFI Touring

Year:

Codes

Engine Code:

Not specified in product info, but typically 500cc class EFI

Chassis Code:

Not specified in product info, standard Sportsman 500 X2 chassis

👋 Introduction

Market Position

Segment:

Utility ATV (All-Terrain Vehicle)

Target User:

Hobbyists, farmers, hunters, recreational riders, and professional service technicians.

Competitive Analysis

Competitors:

Competitors from brands like Yamaha (Grizzly), Can-Am (Outlander), Arctic Cat (TRV), and Honda (Rancher/Foreman).

Key Features

Vehicle Features:

Dual-seat capability (X2), versatile cargo bed, robust 500cc EFI engine, capable AWD system.

Manual Value

Value Proposition:

Provides essential technical data for maintaining and repairing the specific 2008 Polaris Sportsman 500 EFI X2 EFI Touring model, crucial for longevity and performance.

📋 Manual Details

Coverage Areas

Manual Type:

Complete Factory Service Repair Workshop Manual

Language:

English

Format:

PDF Download

Availability:

Instant Download, No Expiry Dates, No Extra Fees

Page Count

Page Count:

Estimated 300-500 pages (typical for full service manuals of this era and complexity)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, diagnostics, and component specifications.

Fuel System:

EFI system diagnosis, fuel pump, injectors, throttle body, sensors, and ECU operations.

Transmission:

CVT system (Primary and Secondary Clutch), gearcase maintenance, lubrication, and troubleshooting.

Drivetrain:

Front and rear differentials, driveshafts, U-joints, and AWD engagement system.

Suspension:

Front and rear suspension components, shock absorbers, springs, A-arms, bushings, and alignment procedures.

Brakes:

Hydraulic brake system, caliper servicing, master cylinder, brake lines, fluid replacement, and bleeding procedures.

Electrical System:

Wiring diagrams, lighting, ignition system, charging system (stator, regulator/rectifier), battery, starter, and ECU troubleshooting.

Cooling System:

Radiator, fan, thermostat, water pump, coolant flushing and replacement.

Body And Frame:

Body panel removal and installation, frame inspection, seating, cargo bed mechanisms (X2 specific).

Controls:

Handlebar controls, throttle, brake levers, shifter operation, and pedal systems.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, and spark plug servicing.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for common issues, error code interpretation.

Repair:

Step-by-step repair instructions for all major components and systems.

Overhaul:

Complete engine and transmission overhaul procedures with detailed torque specifications.

Diagnostics:

EFI system diagnostics, electrical system testing, and mechanical fault finding.

Wiring Diagrams:

Comprehensive electrical wiring schematics with component identification.

Technical Depth

Depth:

Factory-level technical depth, suitable for professional mechanics and advanced DIY enthusiasts.

Detail Level:

Detailed disassembly, reassembly, measurement specifications, and tolerances.

📊 Manual Specifications

File Format

File Format:

Portable Document Format (PDF)

Searchability:

Likely text-searchable, allowing quick access to specific information.

Printability:

Printable, enabling users to create physical copies for workshop use.

Print Quality

Resolution:

Assumed high-resolution for clear diagrams and text, typical of factory manuals.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve, single-cylinder

Displacement:

499cc

Bore X Stroke:

Not specified in product info, typically around 92mm x 75mm for this engine family

Cooling System:

Liquid-cooled

Compression Ratio:

Not specified in product info, typically around 9.0:1 to 10.0:1

Performance

Horsepower:

Approx. 29-30 HP (at flywheel)

Torque:

Not specified in product info, but typically strong low-end torque

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline, Octane rating 87 or higher

Lubrication

Oil Type:

Polaris recommends SAE 0W-40 Synthetic or SAE 10W-40 API SG or higher.

Oil Capacity:

Approx. 2.0 L (2.1 US qt) with filter change.

Ignition

Ignition System:

Electronic Ignition (CDI)

Spark Plug Type:

NGK CR7HSA or equivalent

Spark Plug Gap:

0.6 - 0.7 mm (0.024 - 0.028 in)

🔧 Transmission

Standard

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Arctic Cat APV System

Drive System:

On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector

Features

Gear Reduction:

High and Low range gears plus Reverse.

Clutch Type:

Dual centrifugal clutch system (Primary and Secondary)

Gearcase Oil

Gearcase Oil Type:

Polaris AGL Premium Synthetic Gearcase Lubricant or SAE 80W-90 GL-4 Gear Oil.

Gearcase Oil Capacity:

Approx. 0.56 L (0.59 US qt)

📐 Dimensions

Exterior

Length:

215.9 cm (85 in)

Width:

116.8 cm (46 in)

Height:

115.6 cm (45.5 in)

Wheelbase:

132.1 cm (52 in)

Ground Clearance:

25.4 cm (10 in)

Cargo

Cargo Bed Capacity:

Tilt Bed: 181.4 kg (400 lbs)

Towing Capacity:

657.7 kg (1450 lbs)

Weights

Dry Weight:

Approx. 308 kg (680 lbs)

Fuel Capacity:

17.0 L (4.5 US gal)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI standard ATVA-1 (2008) for ATVs.

Active Features

Braking System:

Hydraulic disc brakes on all wheels, parking brake.

Passive Features

Rollover Protection:

Handlebars and footrests provide primary rider control and stability; ROPS not standard on this model.

Lighting:

Dual 50W headlights, brake light, taillight.

💡 Technology Features

Infotainment

Display Panel:

Digital gauge cluster with speedometer, odometer, trip meter, RPM indicator, 4WD indicator, fuel level, and warning lights.

Driver Assistance

Engine Management:

ECU controlled EFI provides optimal fuel and spark timing for various conditions.

Connectivity

Diagnostic Ports:

Diagnostic port for connecting service tools to read fault codes and monitor engine parameters.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically at 10-20 hours or 1 month, focusing on oil change and inspection.

Engine Oil Change:

Every 100 hours or 6 months, whichever comes first.

Gearcase Oil Change:

Every 200 hours or 12 months.

Air Filter Cleaning:

Inspect and clean every 50 hours, replace as needed.

Spark Plug Replacement:

Every 100 hours or 12 months.

Fluid Specifications

Coolant Type:

Polaris Premium Antifreeze/Coolant or equivalent ethylene glycol based coolant with corrosion inhibitors (typically a 50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Common Wear Items:

CV joints, bushings, wheel bearings, and drive belts (CVT) are common wear items on ATVs of this vintage and usage type.

Efi System Concerns:

Fuel pump reliability, sensor function (TPS, MAP, temp), and throttle body cleanliness can affect EFI performance.

Suspension Durability:

Regular inspection and lubrication of suspension components are key to preventing premature wear.

📚 Vehicle History

Brand Heritage

Brand Origins:

Polaris Industries Inc., founded in 1954, a major manufacturer of powersports vehicles.

Model Evolution

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, with various iterations and features added over time.

X2 Variant Introduction:

The X2 model introduced dual-seating and a versatile tilting cargo bed, enhancing utility for riders needing to carry a passenger and haul gear.

Production

Production Years:

The Sportsman 500 was produced for many years, with the X2 variant appearing in the mid-2000s. The 2008 model represents a mature iteration of this platform.

🏆 Awards & Recognition

Recognitions

Atv Segment Performance:

Polaris Sportsman models are consistently rated highly for comfort, ride quality, and utility in their class by automotive and powersports publications.

Manual Quality:

Factory service manuals are the industry standard for accuracy and completeness, ensuring quality repairs and maintenance.