Sub Models Covered:
Sportsman 500, Sportsman 500 EFI, Sportsman X2 500 EFI, Sportsman Touring 500 EFI
Vehicle Type:
All-Terrain Vehicle (ATV)
Generation Identifier:
Fifth Generation Sportsman (2005-2009)
Positioning:
The Polaris Sportsman 500 series in 2008 was positioned as a versatile and capable utility ATV, popular for trail riding, hunting, and farm work due to its robust design and power.
Competitors:
Competed against models like the Can-Am Outlander 500, Arctic Cat 500 TRV, and Yamaha Kodiak 450/Grizzly 550.
Features:
Known for its independent rear suspension (IRS), powerful 499cc engine, selectable 2WD/AWD, and comfortable seating for extended use. The EFI models offered improved throttle response and cold-weather starting.
Primary Coverage:
Service, repair, assembly, disassembly, wiring diagrams
Secondary Coverage:
Maintenance procedures, troubleshooting, specifications
Estimated Page Count:
Comprehensive (exact count not provided but implied to be extensive)
Type:
Service Repair Manual
Engine:
Includes detailed service and repair procedures for the engine assembly.
Fuel System:
Covers fuel delivery, carburetor/EFI system, fuel pump, fuel tank, and lines.
Transmission:
Detailed coverage of the transmission system, including gears, bearings, and seals.
Final Drive:
Procedures for servicing the front and rear final drive units, including differentials and axles.
Brakes:
Comprehensive information on hydraulic brake systems, including caliper, master cylinder, and bleeding procedures.
Electrical:
Includes detailed wiring diagrams, troubleshooting for electrical components, ignition system, charging system, and lighting.
Body Suspension:
Covers body panels, fenders, seat, handlebars, front and rear suspension components (shocks, A-arms, bushings).
Clutch:
Details on the clutch system, including primary and secondary clutch maintenance and service.
General:
Includes general information, torque specifications, special tools, and safety precautions.
Maintenance:
Provides scheduled maintenance tasks, fluid changes, and inspection procedures.
International:
Indicates potential coverage for international models or specifications, though details are not explicitly listed.
Frame Chassis:
Includes inspection and repair of the ATV's frame and chassis components.
Steering:
Covers steering column, tie rods, and steering linkage.
Disassembly Assembly:
Step-by-step instructions for taking apart and reassembling all major vehicle components.
Troubleshooting:
Diagnostic procedures and solutions for common and uncommon issues.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Torque Specifications:
Provides critical torque values for fasteners to ensure correct assembly and prevent component failure.
Special Tools:
Lists specialized tools required for various repair and maintenance procedures.
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics, covering everything from basic maintenance to major component overhauls.
Engine Type:
4-Stroke DOHC Twin Cylinder
Bore X Stroke:
Not explicitly provided in product info, but typically around 83 mm x 92 mm for this engine.
Cooling System:
Liquid-Cooled
Ignition:
Electronic Ignition
Starting System:
Electric Start
Horsepower:
Approximately 30-32 HP (actual figures may vary slightly by model and tuning)
Torque:
Not explicitly provided, but sufficient for utility tasks and trail performance.
Carburetor:
Mikuni BST40 (on non-EFI models)
Efi:
Electronic Fuel Injection (Bosch or similar system on EFI models)
Fuel Type:
Unleaded Gasoline
Fuel Capacity:
Typically 3.25 gallons (12.3 liters)
Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
H (High), L (Low), N (Neutral), R (Reverse), P (Park)
Engine Braking:
Equipped with engine braking for controlled descents.
Pv T Fluid:
Polaris AGL (API GL-4) Gearcase Lubricant or equivalent.
Pv T Capacity:
Approximately 0.75 quarts (0.71 L) for the transmission/final drive case.
Length:
Approximately 81-83 inches (205.7-210.8 cm) depending on specific model variant.
Width:
Approximately 46 inches (116.8 cm).
Height:
Approximately 48 inches (121.9 cm).
Dry Weight:
Approximately 600-650 lbs (272-295 kg) depending on model.
Payload Capacity:
Typically around 200 lbs (90.7 kg) on racks.
Towing Capacity:
Typically 1,500 lbs (680.4 kg).
Wheelbase:
Approximately 50.5 inches (128.3 cm).
Ground Clearance:
Typically around 10.25 inches (26 cm).
Safety Compliance:
Designed to meet ANSI/SVIA standards for recreational ATVs.
Braking System:
Hydraulic disc brakes front and rear, providing strong stopping power.
AWD:
On-Demand All-Wheel Drive system for enhanced traction.
Lighting:
Dual halogen headlights and tail/brake lights for visibility.
Ergonomics:
Designed for rider comfort and control with comfortable seating and intuitive controls.
Oil Change Engine:
Recommended every 100 hours or annually. Check manual for specific recommendations.
Air Filter Cleaning:
Check every 50 hours, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Inspection:
Inspect every 100 hours or annually.
Belt Inspection:
Inspect PVT belt every 50 hours for wear and damage.
Engine Oil:
Polaris Synthetic 2W-50 or SAE 5W-50 API SG or higher.
Engine Oil Capacity:
Approximately 2.5 quarts (2.4 L) with filter change.
Coolant:
Polaris Premium 2-Stroke Oil (for pre-mix) or recommended coolant for radiator.
Common Wear Items:
PVT belt wear, wheel bearing issues, ball joint wear, and occasional starter solenoid problems are noted on this generation. Fuel pump issues can occur on EFI models with age.
Maintenance Focus:
Regular maintenance, especially PVT belt inspection and correct fluid levels, is crucial for longevity. Addressing suspension component wear promptly ensures proper handling.
Polar Heritage:
Polaris Industries has a long history of innovation in the powersports industry, particularly with its pioneering work in snowmobiles and the development of the modern ATV.
Sportsman Lineage:
The Sportsman line, introduced in the early 1990s, became a benchmark for utility ATVs, emphasizing comfort, capability, and rider-friendly features. The 500cc engine has been a mainstay, evolving over generations.
Manufacturing Location:
Typically manufactured in Spirit Lake, Iowa, USA.
Production Period:
The 500 engine platform has been in continuous production for many years, with the 2008 model belonging to the '05-'09 generation.
