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POLARIS 2008 SPORTSMAN 500 Service Manual
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Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2008 Sub Model: EFI X2 Touring Sub Model Variant: 500 H.O. Introduction Market Position Segment: Utility ATV Target Audience: Recreational riders,...
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| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | Sportsman 500 |
| Year: | 2008 |
| Sub Model: | EFI X2 Touring |
| Sub Model Variant: | 500 H.O. |
| Introduction | |
| Market Position | |
| Segment: | Utility ATV |
| Target Audience: | Recreational riders, hunters, farmers, and utility users requiring a robust and versatile ATV. |
| Competitive Analysis | |
| Key Competitors: | Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rancher, Kawasaki Brute Force. |
| Key Features Vehicle | |
| Versatility: | The X2 variant offers a unique tilting rear cargo bed, increasing utility for hauling and dumping. |
| Engine Performance: | The 500 H.O. (High Output) engine provides strong low-end torque and reliable power for various tasks and terrains. |
| Drivetrain Technology: | Polaris's On-Demand AWD system offers excellent traction in challenging conditions. |
| Manual Utility | |
| Value Proposition: | This service manual is essential for owners and technicians seeking to maintain, diagnose, and repair the 2008 Sportsman 500 EFI X2 Touring and related 500 H.O. models. |
| Manual Details | |
| Coverage Areas | |
| Systems Covered: | Engine, Fuel System (EFI), Drivetrain (AWD/2WD), Transmission, Suspension, Steering, Brakes, Electrical System, Chassis, Bodywork, Accessories |
| Page Count | |
| Estimated Pages: | 700+ |
| Manual Type | |
| Type: | Factory Service Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Detailed disassembly, assembly, inspection, and repair of the 499cc liquid-cooled, SOHC, 4-valve, 4-stroke engine. |
| Fuel System: | Comprehensive coverage of the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, throttle body, sensors, and diagnostics. |
| Drivetrain: | Detailed information on the Polaris Variable Transmission (PVT), On-Demand All-Wheel Drive (AWD) system, viscous lockout, and drive shafts. |
| Suspension: | Front and rear suspension geometry, shock absorber adjustment and service, wheel bearing replacement, and alignment procedures. |
| Steering: | Steering column, tie rods, steering rack inspection and service, and potential Electronic Power Steering (EPS) system details if applicable to specific sub-models. |
| Brakes: | Hydraulic brake system, caliper service, master cylinder, brake pad replacement, fluid bleeding procedures, and disc inspection. |
| Electrical System: | Wiring diagrams, component testing (stator, rectifier, battery, starter, lighting), ignition system, diagnostic codes, and fuse/relay locations. |
| Chassis And Bodywork: | Frame inspection, body panel removal and installation, seat service, rack maintenance, and X2 specific tipping bed operation. |
| Procedures Included | |
| Maintenance: | Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel), spark plug service, coolant checks, and lubrication points. |
| Troubleshooting: | Systematic diagnostic procedures for common and uncommon issues, fault code interpretation, and diagnostic trees. |
| Repair: | Detailed step-by-step instructions for component repair and replacement across all covered systems. |
| Disassembly Assembly: | Complete guides for engine, transmission, suspension, and electrical component removal and reinstallation. |
| Technical Depth | |
| Depth: | Comprehensive, from basic rider maintenance to complete engine and transmission overhauls, electrical diagnostics, and chassis repairs. |
| Manual Specifications | |
| File Format | |
| Format: | Digital PDF |
| Searchability: | Searchable text enabled for quick information retrieval. |
| Printability: | Printable pages for hands-on workshop use. |
| Resolution: | High-resolution scans ensuring clarity of diagrams and text. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | 4-Stroke, SOHC, 4-Valve |
| Displacement: | 499cc |
| Bore X Stroke: | 92mm x 75.5mm |
| Cooling System: | Liquid-cooled |
| Compression Ratio: | 10.3:1 |
| Performance | |
| Horsepower Est: | 36 HP @ 6500 RPM (approximate) |
| Torque Est: | 30 lb-ft @ 5000 RPM (approximate) |
| Fuel System | |
| Fuel Delivery: | Electronic Fuel Injection (EFI) |
| Throttle Body Size: | 40mm |
| Recommended Fuel: | Unleaded gasoline, 87 octane minimum. |
| Ignition | |
| Ignition System: | Electronic Ignition (CDI) |
| Lubrication | |
| Oil Type: | SAE 5W-50 Synthetic Motorcycle Oil |
| Oil Capacity W Filter: | 2.1 US qt (2.0 L) |
| Transmission | |
| Standard | |
| Transmission Type: | Polaris Variable Transmission (PVT) with Engine Braking |
| Drive Selection: | 2WD / AWD (On-Demand Activation) |
| Gear Selection: | High, Low, Neutral, Reverse, Park |
| Features | |
| Clutch Type: | Dual centrifugal clutches (primary and secondary) |
| Final Drive: | Shaft Drive |
| Fluid Specifications | |
| Transmission Fluid Type: | Polaris AGL Synthetic Gearcase Lubricant (or equivalent 75W-90 synthetic gear oil) |
| Fluid Capacities | |
| Transmission Fluid Capacity: | 0.75 US qt (0.7 L) |
| Dimensions | |
| Exterior | |
| Length: | 83 in (210.8 cm) |
| Width: | 46 in (116.8 cm) |
| Height: | 47 in (119.4 cm) |
| Wheelbase: | 50.5 in (128.3 cm) |
| Ground Clearance: | 11.5 in (29.2 cm) |
| Weights | |
| Dry Weight Est: | 663 lbs (301 kg) |
| Towing Capacity: | 1500 lbs (680.4 kg) |
| Rack Capacity Front: | 100 lbs (45 kg) |
| Rack Capacity Rear X2: | 200 lbs (91 kg) + 400 lbs (181 kg) in tilting bed |
| Cargo | |
| X2 Bed Type: | Tilting Bed |
| Safety Features | |
| Ratings | |
| Atv Safety Standards: | Meets ANSI standard for recreational ATVs. |
| Active Features | |
| Braking System: | Hydraulic disc brakes, front and rear. |
| Engine Braking: | PVT provides engine braking for downhill control. |
| Passive Features | |
| Lighting: | Dual 35W headlights, 8W brake/taillight. |
| Operator Training: | Manual emphasizes proper operator training and safety gear (helmet, eye protection, gloves, etc.). |
| Technology Features | |
| Infotainment | |
| Instrumentation: | Digital odometer, speedometer, tachometer, fuel gauge, clock, trip meter, AWD indicator, hi/low gear indicator, and diagnostic fault codes. |
| Driver Assistance | |
| Efi Benefits: | Electronic Fuel Injection provides improved throttle response, easier starting in various conditions, and better fuel efficiency. |
| Connectivity | |
| Diagnostic Port: | Access to diagnostic codes via a dedicated port for service tools. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 100 hours or 6 months, whichever comes first. |
| Air Filter Service: | Inspect every 25 hours, clean/replace as needed. |
| Spark Plug Replacement: | Replace every 100 hours or annually. |
| Valve Lash Check: | Check every 500 hours or 2 years. |
| Fluid Specifications | |
| Coolant Type: | Ethylene Glycol based antifreeze (50/50 mix with distilled water recommended). |
| Brake Fluid Type: | DOT 3 or DOT 4 Hydraulic Brake Fluid. |
| Fluid Capacities | |
| Coolant Capacity: | 2.0 US qt (1.9 L) |
| Known Issues | |
| Common Wear Items: | Drive belts, wheel bearings, tie rod ends, brake pads are common wear items requiring periodic inspection and replacement. |
| Efi Diagnostics: | EFI system can be sensitive to fuel quality and cleanliness; troubleshooting often involves checking sensors and connections. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Polaris Industries, a long-standing American manufacturer of powersports vehicles. |
| Model Evolution | |
| Sportsman Lineage: | The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, capability, and utility since its introduction. |
| 2008 Updates: | The 2008 model year for the Sportsman 500 EFI X2 Touring benefited from Polaris's ongoing refinements in EFI technology, suspension tuning, and driveline components. |
| Production | |
| Manufacturing Location Est: | Primarily manufactured in Roseau, Minnesota, USA. |
| Awards & Recognition | |
| Recognitions | |
| Atv Industry Reputation: | Polaris Sportsman models consistently receive high marks for comfort, rider-friendliness, and capability in the utility ATV segment. |
| Ratings | |
| Consumer Reviews: | Generally positive consumer reviews highlight the versatility, power, and comfort of the Sportsman 500 platform. |