This manual covers the 2008 Sportsman 500 Touring EFI, a high-performance utility All-Terrain Vehicle (ATV) designed for extended riding comfort and capability. As a cornerstone of ATV offerings, the Sportsman line is recognized for its versatility and durability. This touring variant, in particular, emphasizes a comfortable riding experience, often featuring a longer wheelbase and accommodating seating. The Electronic Fuel Injection (EFI) system ensures improved throttle response, fuel efficiency, and altitude compensation, making it a capable choice for various off-road adventures.
This comprehensive Factory Service Repair Manual provides essential data for maintaining and repairing the Sportsman 500 Touring EFI. It covers general information, detailed maintenance procedures, engine and fuel system specifics, bodywork, suspension, clutch, transmission, final drive, and the complete electrical system, including wiring diagrams. The manual includes step-by-step repair instructions, disassembly and assembly procedures, and critical torque specifications. Its extensive factory-level detail empowers owners and technicians to perform scheduled maintenance, diagnose issues, and execute repairs, ensuring the vehicle's optimal performance and longevity.
Model:
Sportsman 500 Touring EFI
Product Type:
Service Repair Manual
Segment:
High-performance utility All-Terrain Vehicle (ATV)
Competitors:
Can-Am Outlander, Arctic Cat TRV, Yamaha Grizzly, Suzuki KingQuad
Touring Capability:
Designed for longer rides and comfort, often with enhanced seating or storage
Efi System:
Electronic Fuel Injection for improved throttle response, fuel efficiency, and altitude compensation
Manual Benefit:
Provides the same essential repair and maintenance data used by authorized Polaris service centers, empowering owners with comprehensive knowledge.
Estimated Pages:
Extensive (Factory Service Manual Scope)
Type:
Factory Service Repair Manual
Delivery Format:
PDF / WINRAR
Operating Systems:
Win95/98/ME/XP/vista/7/Linux/MAC
Searchability:
Fully searchable text
Bookmarking:
Completely bookmarked
Printability:
All pages printable
Source:
Factory files (not scans)
Powertrain:
Engine, Fuel System, Clutch, Transmission, Final Drive
Chassis:
Suspension, Brakes, Bodywork
Electrical:
Full Electrical System Diagnosis and Wiring Diagrams
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements
Troubleshooting:
Diagnostic procedures for common and complex issues, fault code interpretation
Repair:
Component removal, inspection, repair, and reinstallation for all systems
Disassembly Assembly:
Step-by-step instructions for major component overhauls
Torque Specifications:
All critical torque values for assembly and disassembly
Depth:
Comprehensive factory-level detail, suitable for dealership technicians and advanced DIYers
Format:
PDF/WINRAR Archive
Quality:
High resolution, clear and legible text and diagrams
Type:
Digital Download (No physical binding)
Type:
Not Applicable (Digital Format)
Engine Type:
4-Stroke Single Cylinder SOHC
Bore X Stroke:
92mm x 75.6mm
Cooling System:
Liquid-Cooled
Ignition:
Electronic CDI with Throttle Position Sensor (TPS)
Horsepower Approx:
32-34 HP (Estimate, varies with conditions)
Torque Approx:
30-32 lb-ft (Estimate, varies with conditions)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Control:
Electronic Throttle Body (ETB) with TPS
Fuel Type:
Unleaded Gasoline (91 Octane Recommended)
Oil Type:
SAE 5W-50 Synthetic or Polaris PS-4 Full Synthetic 5W-50
Oil Capacity:
Approx. 2.2 L (2.3 US qt) with filter change
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Drive Modes:
High, Low, Neutral, Reverse, Park
Deceleration Braking:
Engine braking provided by the PVT system
Fluid Specification:
Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent API GL-4 SAE 75W-90
Length:
85.2 in (2164 mm)
Height:
50.5 in (1283 mm)
Dry Weight Approx:
655 lbs (297 kg)
Ground Clearance:
11.25 in (286 mm)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
300 lbs (136 kg)
Rack Capacity Rear:
150 lbs (68 kg)
Wheelbase:
56 in (1422 mm)
Rollover Protection:
Not applicable (ATV design) - Operator safety relies on proper usage and protective gear.
Braking System:
Hydraulic Disc Brakes (Front and Rear), Park Brake
Operator Awareness:
Manual emphasizes the importance of wearing appropriate PPE (helmet, eye protection, etc.) and following safe operating practices.
Features:
Basic instrumentation: Speedometer, Odometer, Tripmeter, Tachometer, Fuel Gauge, Gear Indicator, AWD Indicator, High/Low Temp.
Efi:
Electronic Fuel Injection with Throttle Position Sensor (TPS) for optimized fuel/air mixture.
Features:
None (typical for ATVs of this era).
Oil Change:
Every 100 hours or 6 months (whichever comes first)
Air Filter:
Inspect every 25 hours, clean/replace as needed
Spark Plug:
Replace every 100 hours or 1 year
Transmission Fluid:
Change every 100 hours or 1 year
Brake Fluid:
Flush and replace every 2 years
Engine Oil Viscosity:
SAE 5W-50
Transmission Fluid Type:
Polaris AGL or SAE 75W-90 GL-4
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Efi Calibration:
Potential need for EFI re-calibration under extreme temperature or altitude changes (covered in manual).
Clutch Maintenance:
Importance of keeping clutch sheaves clean and free of debris for optimal performance, detailed in manual.
Electrical Connections:
Corrosion on connectors can be an issue; manual provides guidance on inspection and protection.
Manufacturer:
Polaris Industries Inc.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its versatility, comfort, and capability.
Touring Variant:
The 'Touring' designation signifies models optimized for extended riding comfort, often featuring a longer wheelbase and more accommodating seating compared to standard models.
Manufacturing Location:
Primarily USA (Roseau, Minnesota)
Brand Reputation:
Polaris consistently ranks high in ATV market share and owner satisfaction for its durable and capable off-road vehicles.
