Atv Segment:
Utility/Recreational Touring ATV
Target User:
Owners seeking to perform maintenance, repairs, and gain in-depth knowledge of their Polaris Sportsman 500 Touring EFI RSE.
Market Competitors:
Comparable models from brands like Can-Am (Outlander), Yamaha (Grizzly), Kawasaki (Brute Force), Arctic Cat (Wildcat).
Manual Benefit 1:
Empowers users to perform maintenance and repairs, potentially saving on labor costs.
Manual Benefit 2:
Enhances vehicle longevity through proper maintenance and timely issue resolution.
Manual Benefit 3:
Provides deep understanding of vehicle operation and preventative measures.
Model Years Covered:
1996-2000
Primary Region Of Sale:
North America (implied by product name and common Polaris markets)
Estimated Page Count:
Extensive (typical for a comprehensive service manual, likely 300-600+ pages)
Type:
Service and Repair Manual
Alternative Names:
Workshop Manual, Repair Manual, Maintenance Manual, Factory Manual, Shop Manual, Technical Manual
Digital Format:
PDF / WINRAR
Delivery Method:
Instant Download
Engine:
Complete overhaul, diagnostics, component testing, lubrication, cooling system, ignition system, fuel system, exhaust system.
Fuel System:
EFI (Electronic Fuel Injection) system components, fuel pump, injectors, pressure regulator, troubleshooting.
Body:
Bodywork, fenders, racks, seat, storage, plastics, trim, fasteners, graphics.
Suspension:
Front and rear suspension, shock absorbers, springs, control arms, bushings, alignment, adjustments.
Clutch:
Primary and secondary clutch service, belt inspection and replacement, clutch maintenance and adjustment.
Transmission:
Transmission overhaul, gear selection, lubrication, components, troubleshooting.
Final Drive:
Driveshaft, differential, axle shafts, bearings, seals, lubrication, maintenance.
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding, adjustments.
Electrical:
Wiring diagrams, battery, charging system (stator, voltage regulator), starter motor, ignition system, lighting, switches, sensors, EFI control unit.
International:
Potential for international model variations or specifications may be referenced, though typically less detailed than primary market.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication points, tire pressure checks, battery maintenance.
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all systems, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for component replacement, overhaul, and adjustment for all major systems.
Specifications:
Detailed torque specifications, clearance measurements, fluid capacities, electrical specifications, and diagnostic parameters.
Depth:
Comprehensive, covering basic user maintenance to advanced mechanical and electrical diagnostics and repairs, suitable for professional technicians and experienced DIY enthusiasts.
Engine Type:
4-Stroke, Liquid-Cooled, SOHC, 4-Valve
Displacement:
499cc (This is a common displacement for the 500cc class, specific to the Sportsman 500 EFI. The manual's coverage of 1996-2000 is important to note as engine specs could vary slightly across years within that range, but the 2008 listing in the product name is a point of contradiction to the manual's coverage years.)
Bore X Stroke:
Typical for class: ~90-93mm bore x ~73-76mm stroke (Specifics would be detailed in the manual)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Ignition System:
Electronic ignition with digital timing control
Cooling System:
Liquid-cooled with fan assist
Horsepower:
Estimated 30-35 HP (Actual HP figures for the 2008 model would be specific, but this is a general range for the 499cc engine of that era).
Torque:
Estimated 30-35 lb-ft (Specifics would be detailed in the manual)
Efi Components:
Throttle body, fuel pump, fuel filter, fuel injectors, crank position sensor, MAP sensor, O2 sensor (likely).
Recommended Fuel:
Unleaded gasoline, typically 87 octane or higher (refer to manual for exact specs).
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Drive Modes:
High, Low, Neutral, Reverse, Park
Gear Reduction:
N/A (PVT system handles gear reduction)
Clutch System:
Dual clutching system (Primary and Secondary)
Transmission Fluid:
Specific Polaris PVT fluid or compatible synthetic lubricant (refer to manual for exact specification and part number).
Length:
Approx. 83-85 inches (Specific to 2008 model, manual may detail variations)
Width:
Approx. 46-48 inches (Specific to 2008 model)
Height:
Approx. 48-50 inches (Specific to 2008 model)
Dry Weight:
Approx. 660-690 lbs (Specific to 2008 model, manual will confirm)
Gvw:
Not applicable for ATV (Gross Vehicle Weight is for trucks/cars)
Payload Capacity:
Combined rack capacity: Approx. 270 lbs (Front: 100 lbs, Rear: 170 lbs - typical for this model, confirm in manual).
Towing Capacity:
Up to 1,500 lbs (Typical for Sportsman 500 Touring, confirm in manual).
Atv Safety Standards:
Meets ANSI standards for recreational ATVs (common for Polaris).
Braking System:
Hydraulic disc brakes (front and rear), often with a dual-lever system and a foot brake.
Engine Braking:
Standard feature of the PVT transmission for controlled descents.
Lighting:
Dual headlights, taillight/brake light.
Operator Safety:
Training and safety warnings emphasized in manual; proper PPE (helmet, gloves, boots, eye protection) is critical.
Oil Change:
Every 100 hours or annually (typical for ATVs, refer to manual for exact interval and conditions).
Clutch Belt Inspect:
Every 50 hours or annually (critical for performance and preventing damage).
Air Filter Clean:
Every 25 hours or as needed in dusty conditions.
Spark Plug Inspect:
Every 100 hours or annually.
Engine Oil:
Polaris 5W-50 Synthetic 4-Cycle Engine Oil or equivalent SAE 5W-50 API SG or higher oil (confirm part number and specification in manual).
Coolant:
50/50 mixture of Polaris Premium All-Season Coolant and distilled water or equivalent ethylene glycol coolant (confirm part number and specification in manual).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid (refer to manual for exact specification).
Common Issue 1:
PVT belt wear or breakage if maintenance intervals are skipped or if subjected to excessive abuse.
Common Issue 2:
EFI system sensor issues (e.g., TPS, MAP) potentially causing running problems.
Common Issue 3:
Suspension component wear (bushings, ball joints) due to off-road use.
Polarishistory:
Polaris Industries Inc. is a long-standing American manufacturer known for pioneering ATVs and snowmobiles.
Sportsman Lineage:
The Sportsman line has been a flagship for Polaris, known for comfort, utility, and performance. The Touring models are specifically designed for extended riding comfort.
Efi Introduction:
EFI was a significant upgrade, improving throttle response, cold starting, and altitude compensation compared to carbureted models.
Manufacturing Location:
Polaris ATVs are typically manufactured in the USA.
