Vehicle Segment:
Mid-size All-Terrain Vehicle (ATV)
Target Audience:
Recreational riders, utility users, farmers, hunters, and those seeking a capable off-road vehicle.
Key Competitors 2008:
Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Kawasaki Prairie/Brute Force, Can-Am Outlander.
Vehicle Strengths:
Reliability, powerful engine for its class, comfortable ride, capable off-road performance, versatility for work and play.
Manual Benefit:
Essential resource for maintaining and repairing the 2008 Polaris Sportsman 500, enabling owners to perform tasks efficiently and correctly, saving time and money.
Overall Coverage:
Comprehensive service and repair information for the 2008 Polaris Sportsman 500.
Specific Coverage Points:
Engine, drivetrain, suspension, brakes, electrical system, body, chassis, maintenance, troubleshooting, and specifications.
Type:
Factory Service Manual / Workshop Manual
Format:
Digital Download (PDF)
Engine System:
Detailed diagnosis, repair, and overhaul of the 499cc liquid-cooled, 4-stroke, SOHC engine.
Fuel System:
Carburetor (Mikuni BSR 40), fuel pump, fuel lines, and related components.
Ignition System:
CDI ignition, spark plug specifications, timing.
Exhaust System:
Exhaust pipe, muffler, heat shields.
Cooling System:
Radiator, fan, coolant, hoses, thermostat.
Transmission System:
PVT (Polaris Variable Transmission) automatic transmission, belt inspection and replacement, clutch service.
Drivetrain System:
Shafts, U-joints, differentials (front and rear), drive axles, and gear cases.
Suspension System:
Front and rear independent suspension, shock absorbers, bushings, control arms, ball joints.
Brake System:
Hydraulic disc brakes (front and rear), brake fluid specifications, caliper service, master cylinder, brake lines.
Steering System:
Handlebars, steering shaft, tie rods, steering rack (if applicable).
Electrical System:
Battery, starter, alternator/stator, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays, switches.
Body And Chassis:
Frame, fenders, racks, seats, body panels, decals.
Wheels And Tires:
Tire sizes, inflation pressures, wheel specifications.
Maintenance Procedures:
Regular servicing, lubrication, oil changes, filter replacements, valve adjustments, belt inspection/replacement, brake bleeding.
Diagnostic Procedures:
Troubleshooting guides for common issues, fault code interpretation (if applicable), systematic diagnostic steps for various systems.
Repair Procedures:
Detailed, step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components.
Overhaul Procedures:
Complete engine and transmission rebuild procedures.
Wiring Diagrams:
Detailed electrical schematics for all circuits.
Depth Level:
Factory-level technical information, suitable for professional mechanics and advanced DIY enthusiasts.
Detail Level:
Includes torque specifications, clearances, tolerances, and detailed assembly instructions.
Engine Type:
4-Stroke, Single Cylinder, SOHC
Cooling System:
Liquid-cooled
Bore X Stroke:
92mm x 75mm
Horsepower Est:
~30 HP @ 6000 RPM (estimate based on model year and displacement)
Torque Est:
~28 lb-ft @ 4500 RPM (estimate based on model year and displacement)
Carburetor Model:
Mikuni BSR 40
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Oil Type Spec:
SAE 5W-50 or 10W-40, Polaris 4-Stroke Oil or equivalent JASO MA certified oil.
Oil Capacity:
Approx. 2.1 L (2.2 US qt) with filter change.
Transmission Type:
Polaris Variable Transmission (PVT) Automatic
Optional Transmission:
N/A
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Drive System:
Shaft Drive, On-Demand All-Wheel Drive (AWD)
Final Drive Ratio:
Refer to manual for specific gear ratios (typically around 3.00:1 for rear differential)
Transmission Fluid Type:
Polaris Synthetic Gearcase Lubricant or equivalent GL-5 75W-90.
Rear Gearcase Capacity:
Approx. 0.23 L (0.25 US qt)
Clutch Type:
Primary and Secondary Clutch System (CVT)
Infotainment Features:
N/A (Basic ATV without advanced infotainment systems).
Driver Assistance Features:
N/A (No electronic driver assistance systems like traction control, ABS, etc.).
Connectivity Features:
N/A
Electronic Features:
Keyed ignition, electric start, basic indicator lights (neutral, reverse, oil).
Initial Break In:
First service at 10 hours or 100 miles, including oil change, filter inspection, and general inspection.
Regular Oil Change:
Every 100 hours or 1000 miles, or annually, whichever comes first.
Air Filter Cleaning:
Inspect every 25 hours, clean or replace as needed, or every 6 months.
Spark Plug Replacement:
Replace every 100 hours or annually.
Belt Inspection:
Inspect every 50 hours or annually for wear and damage. Replace as needed.
Engine Oil Spec:
SAE 5W-50 or 10W-40, Polaris 4-Stroke Oil or equivalent JASO MA certified.
Gearcase Fluid Spec:
Polaris Synthetic Gearcase Lubricant or equivalent GL-5 75W-90.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Spec:
Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water).
Common Wear Items:
Drive belts, wheel bearings, tie rod ends, bushings, and ball joints are common wear items on ATVs of this era and usage.
Potential Maintenance Focus:
Regular inspection and maintenance of the PVT system (clutch alignment, belt condition) and cooling system are crucial for longevity.
Polarisfabrication:
Polaris Industries Inc. has a long history in powersports, founded in 1954, known for innovation in snowmobiles, ATVs, and UTVs.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving over decades to become a benchmark for comfort, utility, and performance.
Sportsman 500 Development:
The 500cc engine platform has been a popular choice for Polaris, offering a balance of power and efficiency, with continuous refinements in suspension, ergonomics, and driveline.
Production Location:
Primarily manufactured in Roseau, Minnesota, USA.
