Vehicle Type:
All-Terrain Vehicle (ATV)
Target Audience:
Owners, mechanics, and enthusiasts seeking in-depth repair and maintenance knowledge for the 2008 Polaris Sportsman 500 models.
Manual Value Proposition:
Provides authoritative, detailed instructions to empower users to perform their own maintenance and repairs, saving time and money compared to dealership service.
Manual Benefits:
Enables proactive maintenance, efficient troubleshooting, and confident execution of repairs, leading to extended vehicle lifespan and optimal performance.
Major Sections:
General Information, Maintenance, Engine, Fuel System, Body/Suspension, Clutch, Transmission, Final Drive, Brakes, Electrical, International Models
Estimated Page Count:
400+
Type:
Workshop Repair Service Manual
Operating Systems:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Engine Systems:
Engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, cooling system, lubrication system
Fuel System:
Fuel injection system (EFI), fuel pump, fuel injectors, throttle body, fuel tank, fuel lines
Drivetrain:
Clutch (primary and secondary), transmission, final drive, driveshafts, differential, AWD system (if applicable)
Suspension And Steering:
Front and rear suspension components, shock absorbers, A-arms, steering system, tie rods, wheel bearings
Brakes:
Brake system overhaul, hydraulic lines, calipers, master cylinder, brake pads, rotors, bleeding procedures
Electrical System:
Ignition system, battery, charging system (stator, regulator/rectifier), lighting, starter motor, wiring diagrams, sensors, ECU
Body And Frame:
Body panels, plastic components, seat assembly, rack systems, chassis components, frame inspection
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, lubrication, valve adjustments, belt inspection/replacement
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation, common problem diagnosis, electrical diagnostics
Repair Procedures:
Step-by-step repair instructions for all major systems, component removal and installation, torque specifications
Overhaul Procedures:
Complete engine rebuild, transmission overhaul, differential rebuild
Depth Of Information:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Engine Type:
4-stroke, Liquid-Cooled, SOHC, 2-Valve
Bore X Stroke:
92mm x 75mm
Cooling System:
Liquid-Cooled with Fan
Horsepower Estimate:
Approx. 32-34 HP (Varies by specific sub-model and tuning)
Torque Estimate:
Approx. 30-32 lb-ft (Varies by specific sub-model and tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Electronic Ignition with Digital CDI
Oil Type Recommended:
SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher)
Oil Capacity W Filter:
Approx. 2.1 quarts (2.0 liters)
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Drive System:
On-Demand All-Wheel Drive (AWD)
Gear Reduction:
Shaft Drive to Front and Rear
Transmission Fluid:
Polaris PVT Fluid or equivalent SAE 20W-50 API GL-5 Gearcase Lube
Length:
Approx. 81 inches (205.7 cm) (Varies slightly by sub-model)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm) (Varies by sub-model)
Dry Weight:
Approx. 675 lbs (306 kg) (Varies by sub-model)
Ground Clearance:
Approx. 11.25 inches (28.6 cm)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg) (Or more on X2/Touring models)
Fuel Capacity:
4.0 gallons (15.1 L)
Safety Certification:
ATV Safety Institute (ASI) Recommended Practices
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Engine Braking:
Standard on PVT transmission for controlled descents
Handlebars:
Handlebar with integrated handguards for protection
Operator Protection:
Recommended use of helmet, eye protection, gloves, and sturdy footwear
Infotainment Features:
Basic LCD display for speed, RPM, odometer, trip meter, fuel level, and engine warning indicators.
Throttle Control:
Electronic Fuel Injection (EFI) for precise throttle response and smoother power delivery.
Diagnostic Ports:
On-board diagnostic system with connectors for service tools/computers (covered in the manual).
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Air Filter Cleaning:
Inspect every 25 hours, clean as needed. Replace if damaged.
Spark Plug Replacement:
Every 200 hours or 24 months.
Clutch Belt Inspection:
Inspect every 100 hours for wear, cracks, or damage. Replace as needed.
Transmission Fluid Change:
Every 200 hours or 24 months.
Engine Oil Specification:
SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher)
Cooling System Coolant:
Polaris Premium Antifreeze/Coolant or equivalent (50/50 mix of ethylene glycol and distilled water).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Gearcase Lubricant:
Polaris PVT Fluid or SAE 20W-50 API GL-5 Gearcase Lube
Common Wear Items:
Drive belt, tie rod ends, wheel bearings, brake pads, shock absorber bushings.
Potential Efi Issues:
Throttle body cleaning, fuel injector clogging, TPS sensor calibration.
Cooling System Maintenance:
Regular coolant flushes and ensuring proper fan operation are critical to prevent overheating.
Manufacturer:
Polaris Industries Inc.
Brand Focus:
Specialty vehicles, including snowmobiles, ATVs, and utility vehicles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its versatility, comfort, and capable performance since its introduction.
2008 Updates:
The 2008 model year saw continued refinement of the Sportsman 500 platform, including improvements in EFI systems for better throttle response and reliability across its various configurations (EFI, X2, Touring).
Manufacturing Location:
Likely manufactured in the USA by Polaris Industries.
