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
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
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
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 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
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
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
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.
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).
