🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 500

Year:

2008

Vehicle Type:

All-Terrain Vehicle (ATV)

Chassis Code:

A08CH50AA (typical for 2008 500 HO model)

👋 Introduction

Segment:

Mid-size utility ATV segment, known for its versatility and power

Competitors:

Competes with models like the Can-Am Outlander 400, Yamaha Grizzly 450/550, Suzuki KingQuad 450/500, Kawasaki Brute Force 300/400

Powertrain:

Proven Polaris 499cc liquid-cooled engine, robust PVT automatic transmission with on-demand AWD

Suspension:

Long-travel independent front and rear suspension for comfort and capability

Braking:

Hydraulic disc brakes on all wheels for consistent stopping power

Utility:

Front and rear racks with substantial weight-carrying capacity, factory-installed tow hitch

📋 Manual Details

Models Covered:

2008 Polaris Sportsman 500 (Specific variations may apply; manual states 'See below for models covered' which implies broader applicability within the Sportsman 500 range for that year, and potentially other years)

Estimated Page Count:

Highly comprehensive, likely 300+ pages (typical for a full factory service manual)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanics:

Complete teardown and rebuild, internal component specifications, timing, valve adjustment, cooling system

Fuel System:

Fuel injection (EFI) system diagnosis and repair, fuel pump, injectors, throttle body, fuel filter

Powertrain:

Transmission (PVT - Polaris Variable Transmission) operation, belt inspection and replacement, clutch service, differential service, drive shafts, U-joints

Electrical System:

Ignition system, starting system, charging system (stator, rectifier/regulator), battery, lighting, wiring diagrams, diagnostic codes

Brakes:

Hydraulic brake system, caliper service, master cylinder, brake lines, bleeding procedures, parking brake

Suspension Steering:

Front and rear suspension components, shocks, bushings, steering linkage, tie rods, wheel alignment

Chassis Body:

Frame inspection, body panel removal and installation, seat, racks, fenders

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication points, pre-ride inspections

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides

Repair Rebuild:

Step-by-step instructions for complete disassembly and reassembly of major components

Technical Data:

Torque specifications for all fasteners, clearances, measurements

Special Tools:

Identification and usage of specialized tools required for specific procedures

Depth:

Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts

📊 Manual Specifications

Quality:

High-resolution PDF, likely searchable text

Printability:

Printable for physical use in a workshop environment

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, 4-valve, Single Cylinder

Displacement:

499 cc (30.4 cu. in.)

Bore X Stroke:

93.0 mm x 72.0 mm (3.66 in x 2.83 in)

Cooling System:

Liquid-cooled

Compression Ratio:

10.2:1 (typical)

Ignition System:

Electronic Ignition (CDI)

Valve Adjustment:

Requires periodic adjustment; specific clearances detailed in manual

Horsepower:

Approximately 35-38 HP (claimed; actual may vary)

Torque:

Specific torque figures for engine components are crucial and detailed in manual

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

3.25 US gallons (12.3 L)

Oil Type:

SAE 0W-40 Synthetic Motor Oil (Polaris Premium 4)

Oil Capacity:

2.1 US quarts (2.0 L) with filter change

🔧 Transmission

Type:

Polaris Variable Transmission (PVT) - Automatic

Drive Selection:

2WD/4WD (On-Demand)

Gear Selection:

High, Low, Neutral, Reverse, Park

Clutch System:

Adjustable primary and secondary clutches for optimal power delivery across RPM range

Belt Maintenance:

Regular inspection and replacement of the drive belt recommended; specific wear limits and replacement procedures in manual

Gear Reduction:

High and low gear ranges for versatile performance

📐 Dimensions

Length:

81 in. (205.7 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)

Dry Weight:

644 lbs (292 kg)

Payload Capacity:

Front Rack: 50 lbs (22.7 kg), Rear Rack: 100 lbs (45.4 kg)

Towing Capacity:

1,500 lbs (680.4 kg)

Front Tire Size:

AT 25 x 8-12

Rear Tire Size:

AT 25 x 10-12

Wheel Bolt Pattern:

4x110mm (typical for Polaris)

🛡️ Safety Features

Crash Test Results:

N/A for ATVs; safety is based on design, features, and operator responsibility.

Braking System:

Front and rear hydraulic disc brakes

4Wd System:

On-Demand All-Wheel Drive (AWD) enhances traction and control

Lighting:

Dual 37.5W headlights, dual 20W taillights/brake lights

Ergonomics:

Handlebar-mounted throttle and brake controls, comfortable seating position

💡 Technology Features

Features:

N/A (Basic Utility ATV; focus is on function over features)

Traction Control:

On-Demand AWD system provides enhanced traction

Features:

N/A

🔧 Maintenance

Engine Oil Change:

Every 50 hours or 6 months (whichever comes first); consult manual for specific conditions.

Transmission Clutch Inspection:

Every 100 hours or annually; belt condition and alignment are critical.

Air Filter Cleaning Replacement:

Every 50 hours or more frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 12 months or 100 hours.

Valve Clearance Check:

Typically at 250 hours or annually; critical for engine performance and longevity.

Engine Oil:

SAE 0W-40 Synthetic (Polaris Premium 4 or equivalent)

Coolant:

Polaris Premium 2-Stroke Synthetic Oil or equivalent antifreeze/coolant rated for -34°F (-37°C) to 260°F (126°C), 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Gearcase Oil:

Polaris AGMA 7 Synthetic Gearcase Lube or equivalent SAE 80W-90 GL-5 gear oil.

Drive Belt Wear:

PVT drive belts can wear over time and require periodic inspection and replacement. Proper alignment is key.

Idle Air Control Valve Iacv:

Can become dirty or fail, leading to rough idle or stalling issues.

Electrical Connections:

Corrosion or loose connections, particularly in wet environments, can cause intermittent electrical problems.

Suspension Bushings:

Wear on control arm bushings can lead to play and affect handling.

📚 Vehicle History

Manufacturer:

Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV series, known for its comfort, capability, and durability. The 500cc engine has been a staple for years, evolving with fuel injection and updated suspension.

Manufacturing Location:

Polaris ATVs are primarily manufactured in the United States (e.g., Roseau, Minnesota; Spirit Lake, Iowa).

🏆 Awards & Recognition

Market Reputation:

Polaris Sportsman models are generally well-regarded for their comfort, handling, and utility in the ATV market. The 500 is a workhorse.