Positioning:
The Polaris Sportsman 500 EFI X2 Touring 500 HO was positioned as a versatile, multi-purpose ATV offering utility for work and comfort for recreational two-up riding.
Competitors:
Competed with models from brands like Can-Am (Outlander MAX), Arctic Cat (Prowler), and Yamaha (Grizzly) in the mid-size utility ATV segment, particularly those offering two-up capability.
Features:
Unique X2 dual-mode functionality (switchable between single-rider utility with tilting cargo bed and two-up touring), independent rear suspension (IRS), electronic fuel injection (EFI), On-Demand All-Wheel Drive (AWD).
Value:
Empowers owners to perform their own maintenance and repairs, significantly reducing labor costs associated with dealership service departments.
Engine:
Detailed diagnostics, overhaul, component testing, and repair of the 499cc ProStar 4-stroke engine.
Fuel System:
EFI system, fuel pump, injectors, throttle body, fuel tank, lines, and pressure testing.
Cooling System:
Radiator, fan, coolant, hoses, thermostat, and water pump.
Exhaust System:
Muffler, pipes, catalytic converter (if applicable), and gasket replacement.
Transmission:
PVT (Polaris Variable Transmission) including belt inspection/replacement, clutch service (primary and secondary), and gearbox maintenance.
Drivetrain:
Front and rear drive shafts, CV joints, differential (front and rear), AWD system operation and service.
Suspension:
Front and rear independent suspension systems, shock absorbers, springs, control arms, bushings, and alignment.
Brakes:
Hydraulic disc brakes (front and rear), caliper service, pad replacement, fluid bleeding, master cylinder, and parking brake.
Steering:
Handlebar, steering stem, tie rods, steering linkage, and EPS (Electronic Power Steering) system diagnosis and repair (if equipped).
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, and wiring diagrams.
Bodywork:
Fenders, racks, seat, body panels, hood, cargo bed, and chassis components.
X2 Features:
Actuator for the rear dump bed conversion, seating mechanism, and associated components.
Touring Features:
Passenger seat, floorboards, and any specific touring package components.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, and pre-ride inspections.
Troubleshooting:
Diagnostic charts, common problem identification, and step-by-step solutions for various issues.
Repair:
Detailed instructions for disassembly, repair, reassembly, and adjustment of all major components.
Rebuild:
Engine and transmission rebuild procedures, including specifications and tolerances.
Wiring Diagrams:
Comprehensive electrical schematics for all systems, aiding in diagnosis and repair.
Depth:
Comprehensive, covering everything from basic adjustments and fluid changes to complete engine overhauls and advanced electrical diagnostics.
Engine Type:
4-stroke, SOHC, 4-valve, Single Cylinder
Displacement:
499 cc (30.4 cubic inches)
Bore X Stroke:
92 mm x 76 mm (3.62 in x 2.99 in)
Cooling System:
Liquid-cooled
Compression Ratio:
10.2:1
Horsepower:
Approx. 30-33 HP (varies slightly by source and testing conditions)
Torque:
Approx. 29-31 lb-ft
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body size typically around 40mm.
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition Type:
CDI (Capacitor Discharge Ignition)
Engine Oil Type:
SAE 5W-50 Synthetic (check manual for exact specification, API SG or higher)
Engine Oil Capacity:
Approx. 2.0 L (2.1 US qt) with filter change
Transmission Type:
Polaris Variable Transmission (PVT) Automatic
Drive Modes:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft Drive, On-Demand All-Wheel Drive (AWD)
Primary Clutch:
Roller Sheave Design
Secondary Clutch:
High Engagement
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 GL-5)
Gearcase Oil Capacity:
Approx. 0.6 L (0.63 US qt)
Length:
Approx. 85.5 inches (217.2 cm)
Width:
Approx. 45.8 inches (116.3 cm)
Height:
Approx. 47.5 inches (120.7 cm)
Wheelbase:
Approx. 56.0 inches (142.2 cm)
Ground Clearance:
Approx. 11.25 inches (28.6 cm)
Dry Weight:
Approx. 690 lbs (313 kg)
Payload Capacity:
Approx. 450 lbs (204 kg) total, 100 lbs (45 kg) on front rack, 200 lbs (90 kg) on rear bed.
Towing Capacity:
1500 lbs (680 kg)
Front Rack Capacity:
100 lbs (45 kg)
Rear Bed Capacity:
200 lbs (90 kg), converts to passenger seat.
Fuel Capacity:
4.0 US gallons (15.1 L) with a 1.0 gallon (3.8 L) reserve
Rollover Protection:
Not applicable to ATVs in the same way as cars. Operator training and adherence to safety guidelines are paramount.
Braking System:
Hydraulic disc brakes front and rear, engine braking via PVT.
AWD System:
On-Demand AWD enhances traction and control.
Lighting:
Dual halogen headlights, dual taillights/brake lights.
Ergonomics:
Handlebar design, seating position optimized for rider control and comfort.
Infotainment System:
Basic LCD display for speed, odometer, trip meter, fuel level, AWD indicator, and basic warning lights. No integrated audio or advanced infotainment.
Eps:
Optional Electronic Power Steering (EPS) was available on some trims, reducing steering effort, especially at low speeds.
Connectivity:
No external connectivity features like Bluetooth or USB ports standard.
Oil Change:
Every 100 hours or 12 months, whichever comes first (check manual for specific break-in service).
Air Filter:
Inspect every 50 hours, clean/replace as needed. Replace at 100 hours or annually.
Spark Plug:
Replace every 100 hours or 24 months. Check gap at 50 hours.
Transmission Oil Change:
Every 200 hours or 24 months.
Drive Belt Inspection:
Inspect every 50 hours, replace as recommended (typically around 200-300 hours or if damaged).
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Coolant:
Ethylene Glycol based antifreeze/coolant (50/50 mix with distilled water), typically a green type.
Common Issues:
Belt slippage due to contamination or wear, starter solenoid failure, CV joint boot tears, potential for some electrical gremlins if not properly maintained, rear differential bearing wear under heavy use.
Heritage:
Polaris Industries, founded in 1954, has a long history in powersports, particularly in snowmobiles and ATVs, known for innovation and off-road performance.
Evolution:
The Sportsman 500 platform has been a cornerstone for Polaris for many years, with the X2 variant introduced to address the growing demand for two-up ATVs with added utility. The 2008 model represents a mature iteration of this design.
Manufacturing Location:
Primarily manufactured in Roseau, Minnesota, USA.
