Polaris Sportsman 500 EFI X2 Touring 500 H.O. Complete Workshop Service Repair Manual 2008

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The 2008 Sportsman 500 EFI X2 Touring 500 H.O. is a versatile utility All-Terrain Vehicle (ATV) engineered for a wide range of applications, from recreational riding and hunting to farm...

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类型: Atv

斯库: 97252

标签: 2008 ATV Misc Polaris Powersports Sportsman 500 EFI X2 Touring Sportsman 500 H.O.

产品多属性

Description

The 2008 Sportsman 500 EFI X2 Touring 500 H.O. is a versatile utility All-Terrain Vehicle (ATV) engineered for a wide range of applications, from recreational riding and hunting to farm work and general utility tasks. This model is distinguished by its powerful 500 High Output (H.O.) engine featuring Electronic Fuel Injection (EFI) for optimal performance and efficiency, coupled with a Variable Transmission (PVT) for seamless power delivery and engine braking. The X2 Touring designation suggests enhanced comfort and versatility, potentially including a convertible seating arrangement for two-up riding or increased cargo capacity. Renowned for its robust build and capable all-wheel-drive system, the Sportsman 500 line has consistently been recognized for its reliability and all-terrain prowess. This comprehensive workshop service repair manual provides detailed guidance for the maintenance, troubleshooting, and repair of your 2008 Sportsman 500 EFI X2 Touring 500 H.O. It covers all essential systems, including the engine mechanical and fuel systems, ignition, transmission and drivetrain, brakes, suspension, and electrical systems. With approximately 400-500 pages of information, the manual offers step-by-step procedures for scheduled maintenance, detailed diagnostic flowcharts, component overhauls, and critical technical specifications such as torque values and fluid capacities. This resource is an indispensable tool for owners and technicians seeking to ensure the longevity, performance, and safe operation of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 EFI X2 Touring 500 H.O.

Year:

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Utility ATV (All-Terrain Vehicle)

Target Audience:

Recreational riders, hunters, farmers, utility users.

Competitive Analysis

Key Competitors:

Arctic Cat 500, Can-Am Outlander 500, Yamaha Kodiak 450/500, Suzuki KingQuad 450/500.

Key Features

Model Variant:

X2 Touring (indicates a 2-up seating capability or specialized touring features).

Engine Type:

500 H.O. (High Output) engine, EFI (Electronic Fuel Injection).

Drivetrain:

Often features AWD (All-Wheel Drive) engagement with 2WD/AWD modes.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Repair, Overhaul, Specifications

Page Count

Estimated Pages:

400-500

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, valves, pistons, crankshaft, camshaft, lubrication system, cooling system.

Engine Fuel System:

EFI (Electronic Fuel Injection) system, fuel pump, injectors, throttle body, sensors, fuel pressure regulator, fuel tank.

Engine Ignition System:

Ignition coil, spark plugs, ECU control, timing.

Transmission Drivetrain:

PVT (Polaris Variable Transmission) clutch system (primary and secondary), belt maintenance, gearcase, differentials (front and rear), driveshafts, CV joints.

Brakes:

Hydraulic brake system, front and rear calipers, master cylinder, brake lines, brake pads, rotor specifications.

Suspension:

Front and rear suspension systems, shock absorbers, A-arms, bushings, wheel bearings, alignment specifications.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, brake lights), wiring diagrams, fuses, relays, ECM (Engine Control Module).

Chassis Frame:

Frame inspection, body panel removal and installation, seat removal, steering system (handlebar, steering post, tie rods).

Cooling System:

Radiator, coolant, fan, hoses, thermostat.

Exhaust System:

Muffler, exhaust pipe, heat shields.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, clutch inspection, chain/belt adjustments (where applicable), lubrication points.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), symptom-based troubleshooting guides.

Engine Repair:

Engine disassembly and reassembly, piston ring replacement, valve adjustments, bearing inspection and replacement, gasket replacement.

Transmission Repair:

PVT belt replacement, clutch service and replacement, gearcase seal replacement, differential service.

Electrical Diagnostics:

Wiring harness troubleshooting, component testing (sensors, actuators), charging system diagnosis, starter motor testing.

Brake Service:

Brake pad replacement, caliper service, brake fluid flush and bleed, master cylinder replacement.

Suspension Service:

Shock absorber replacement, bushing replacement, wheel bearing replacement, steering component alignment.

Body Panel Repair:

Removal and installation of fenders, racks, plastics, and seat.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine and transmission rebuilds).

Diagnostic Focus:

Detailed diagnostic flowcharts and symptom-based troubleshooting.

Specification Detail:

Torque specifications, clearances, fluid capacities, electrical resistance values.

Diagrams Illustrations:

Extensive use of diagrams, schematics, and step-by-step illustrations for clarity.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams.

Binding Type

Binding:

Not applicable (downloadable PDF).

Paper Type

Paper Quality:

Not applicable (downloadable PDF).

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Single Cylinder, SOHC

Displacement:

499 cc

Bore X Stroke:

92 mm x 75 mm

Cooling System:

Liquid-Cooled

Performance

Horsepower Estimate:

Approx. 30-35 HP (varies slightly by source)

Torque Estimate:

Approx. 30-35 lb-ft

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), throttle body size ~40mm

Fuel Type:

Unleaded Gasoline, 87 Octane (Minimum)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition) with Electronic Advance

Spark Plug:

NGK CR7E (Typical, verify with manual)

🔧 Transmission

Standard

Transmission Type:

Polaris Variable Transmission (PVT) with Engine Braking

Gears:

High, Low, Neutral, Reverse, Park

Drive:

Shaft Drive (AWD/2WD)

Features

Clutch System:

Dual Clutch - Primary and Secondary

Belt Service Interval:

Inspect every 1000 miles or 12 months; replace as needed. Consult manual for specific wear limits.

📐 Dimensions

Exterior

Length:

Approx. 81 inches (205.7 cm)

Width:

Approx. 46 inches (116.8 cm)

Height:

Approx. 47 inches (119.4 cm)

Wheelbase:

Approx. 50.5 inches (128.3 cm)

Cargo

Front Rack Capacity:

Approx. 100 lbs (45 kg)

Rear Rack Capacity:

Approx. 200 lbs (90 kg)

Weights

Dry Weight:

Approx. 690 lbs (313 kg)

Towing Capacity:

1500 lbs (680 kg)

Payload Capacity:

Not explicitly stated, but implied by rack capacities and chassis strength.

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI standards.

Active Features

Braking System:

Hydraulic disc brakes, front and rear; single lever front brake, foot brake for rear.

Engine Braking:

PVT provides significant engine braking for downhill control.

Passive Features

Lighting:

Dual headlights, taillight, and brake light.

Rollover Protection:

No specific ROPS (Roll Over Protection System) as standard; rider training and protective gear are essential.

💡 Technology Features

Infotainment

Infotainment System:

None standard; basic instrument cluster (speedometer, odometer, trip meter, fuel gauge, indicator lights).

Driver Assistance

Traction Control:

AWD system provides enhanced traction.

Electronic Fuel Injection:

Provides optimal fuel delivery for performance and efficiency across varying conditions.

Connectivity

Connectivity Features:

None (basic ATV design).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 1000 miles (6 months). Check manual for specific interval.

Air Filter Cleaning:

Clean every 100 hours or 6 months; replace annually or as needed.

Spark Plug Service:

Inspect every 100 hours or 6 months.

Coolant Check:

Check level frequently, flush and replace coolant every 2 years or 24 months.

Fluid Specifications

Engine Oil Type:

Polaris 4-Stroke Synthetic 5W-50 PS-4 (or equivalent API SG/SH/SJ or higher, JASO MA certified oil).

Engine Oil Capacity:

Approx. 2.5 Quarts (2.4 Liters) with filter change.

Gearcase Oil Type:

Polaris 75W-140 Synthetic Gear Oil (or equivalent GL-5 rated).

Gearcase Oil Capacity:

Approx. 16 oz (0.47 Liters) for rear; check manual for front differential.

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid.

Coolant Type:

Ethylene Glycol based antifreeze, 50/50 mix with distilled water.

Known Issues

Clutch Wear:

PVT belts can wear prematurely if subjected to excessive slippage, mud, or improper engagement.

Efi System:

Fuel injectors can become clogged over time; regular fuel stabilizer use is recommended.

Electrical Connections:

Corrosion can affect electrical connections, especially in wet or muddy conditions. Regular inspection and dielectric grease application are beneficial.

Suspension Bushings:

A-arm bushings can wear, leading to steering looseness and premature tire wear.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc.

Specialty:

Pioneer in snowmobiles and ATVs, known for innovation.

Model Evolution

Sportsman Line:

The Sportsman line is Polaris's flagship utility ATV range, known for its IRS (Independent Rear Suspension) and AWD capabilities.

500 Engine:

The 499cc engine was a staple for Polaris for many years, offering a good balance of power and reliability.

X2 Touring:

The 'X2' designation typically refers to a convertible seat or cargo bed, allowing for single-rider configuration or 2-up riding. 'Touring' suggests features geared towards comfort on longer rides.

Production

Production Years:

The Sportsman 500 platform has been in production for many years, with continuous updates. The 2008 model represents a specific iteration.

🏆 Awards & Recognition

Recognitions

Atv Market Awards:

Polaris Sportsman series consistently receives positive reviews and awards for its utility, comfort, and off-road capability from various ATV publications and consumer surveys.

Ratings

Consumer Satisfaction:

Generally high consumer satisfaction for the Sportsman 500 platform due to its robust nature and versatility.

Certifications

Manufacturing Standards:

Manufactured to meet Polaris's internal quality standards and relevant industry safety certifications.