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Polaris

Polaris 500 EFI Touring Sportsman 2008 Service Manual

Polaris 500 EFI Touring Sportsman 2008 Service Manual

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Vehicle data plateRef 82670
Brand
Polaris
Vehicle
ATV
Models covered
500 EFI Touring Sportsman, Misc
Years
2008
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 500 EFI Touring
Year:
2008
Codes
Vin Prefix:
4XTRM0...
👋 Introduction
Market Position
Segment:
All-Terrain Vehicle (ATV) - Touring/Utility Crossover
Target Audience:
Recreational riders, hunters, and individuals seeking a versatile ATV for longer excursions and utility tasks.
Competitive Analysis
Competitors:
Can-Am Outlander, Yamaha Grizzly, Honda FourTrax Foreman/Rubicon.
Key Features
Touring Features:
Comfortable seating for two, extended wheelbase for stability and rider comfort, enhanced luggage capacity.
Engine Type:
Fuel-injected, liquid-cooled, single-cylinder engine for reliable performance.
Drivetrain:
Switchable AWD system for optimal traction in varied terrain.
📋 Manual Details
Coverage Areas
Languages:
English
Manual Type:
Workshop Service Manual
Page Count
Estimated Page Count:
600+
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnosis, and repair of the 499cc SOHC engine.
Fuel System:
EFI system components, fuel pump, injectors, throttle body, fuel filter replacement and diagnosis.
Cooling System:
Radiator, fan, thermostat, coolant flushing and replacement.
Transmission:
PVT (Polaris Variable Transmission) operation, clutch inspection, belt replacement, and gearbox maintenance.
Drivetrain:
All-Wheel Drive (AWD) system, front and rear differentials, CV joints, driveshafts, and axle boot replacement.
Suspension:
Front and rear suspension components, shock absorber adjustment and replacement, bushings, and ball joints.
Brakes:
Hydraulic brake system, brake pad replacement, caliper service, rotor inspection, and bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, and accessory wiring.
Steering:
Handlebar assembly, tie rods, steering column, and Power Steering (EPS) system diagnostics if applicable to the specific touring model.
Bodywork:
Panel removal and installation, seat adjustment, luggage rack, and accessory mounting.
Diagnostic Troubleshooting:
Comprehensive diagnostic flowcharts and fault code interpretation for EFI and other systems.
Procedures Included
Maintenance:
Regular scheduled maintenance, fluid changes, filter replacements, and general inspection.
Repair:
Detailed step-by-step repair instructions for all major vehicle components.
Rebuild:
Complete engine and transmission rebuild procedures with torque specifications and clearances.
Troubleshooting:
Systematic troubleshooting guides for common and uncommon issues.
Electrical Diagnostics:
Wiring diagrams, component testing, and troubleshooting of electrical faults.
Efi Tuning:
Information on EFI system adjustments and potential tuning aspects.
Technical Depth
Depth:
Covers basic owner maintenance to advanced engine and electrical diagnostics and repairs, suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Typically text-searchable for quick information retrieval.
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 2-valve, Single Cylinder
Displacement:
499 cc
Bore X Stroke:
92 mm x 75.9 mm
Cooling System:
Liquid-cooled
Ignition:
CDI with Electronic Advance
Performance
Horsepower:
Approx. 30-35 HP (estimated based on model configuration)
Torque:
N/A (specific figures often not publicly released by manufacturer for ATVs)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (minimum 87 octane)
Fuel Tank Capacity:
4.5 gallons (17 L)
🔧 Transmission
Standard
Type:
Polaris Variable Transmission (PVT) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional
Optional Features:
N/A for this specific model configuration
Features
Drive Modes:
2WD / 4WD with Active Descent Control (ADC) and Turret-Type Engine Braking
Final Drive:
Sealed Shaft Drive
📐 Dimensions
Exterior
Length:
85.7 inches (217.7 cm)
Width:
46 inches (116.8 cm)
Height:
48 inches (121.9 cm) to handlebars
Wheelbase:
56.5 inches (143.5 cm)
Ground Clearance:
11.25 inches (28.6 cm)
Cargo
Front Rack Capacity:
100 lbs (45.4 kg)
Rear Rack Capacity:
200 lbs (90.7 kg)
Weights
Dry Weight:
657 lbs (298 kg)
Towing Capacity:
1,500 lbs (680.4 kg)
Gcvwr:
2,025 lbs (918.5 kg)
🛡️ Safety Features
Ratings
Crash Test Ratings:
ATVs are not subject to the same passenger vehicle crash testing standards (NHTSA/IIHS). Safety is primarily dependent on rider skill and adherence to safe operating practices.
Active Features
Braking System:
Hydraulic Disc Brakes (Front & Rear), Engine Braking
Stability Control:
Active Descent Control (ADC) aids in controlled descents.
Passive Features
Lighting:
Dual Halogen Headlights, Tail/Brake Light
Seating:
Two-up seating with passenger footrests and grab handles.
💡 Technology Features
Infotainment
Display Features:
Digital instrumentation with speedometer, odometer, tripmeter, tachometer, fuel gauge, and gear indicator.
Driver Assistance
Efi Control:
Electronic Fuel Injection system provides optimized fuel delivery for throttle response and efficiency.
Connectivity
Accessory Power:
Pre-wired for accessories, including DC power outlets.
🔧 Maintenance
Service Intervals
Oil Change:
Every 100 hours or 12 months (whichever comes first).
Air Filter Cleaning:
Every 50 hours or as needed based on conditions.
Spark Plug Replacement:
Every 100 hours or 12 months.
Transmission Oil Change:
Every 200 hours or 24 months.
Fluid Specifications
Engine Oil Type:
SAE 0W-40 Synthetic (Polaris recommended) or equivalent API SG rated oil.
Engine Oil Capacity:
Approx. 2.5 quarts (2.4 L) with filter change.
Coolant Type:
Ethylene Glycol-based antifreeze (e.g., Polaris Premium All-Season Antifreeze).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Problems:
EFI system component failures (throttle position sensor, injectors), starter solenoid issues, front differential wear on heavily used units, radiator fan failures.
Common Issues
Belt Wear:
PVT belt wear and failure, requiring regular inspection and replacement.
Suspension Bushings:
Wear of control arm bushings and ball joints due to off-road use.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Polaris Industries, founded in 1954, Minnesota, USA. Known for snowmobiles, ATVs, UTVs, and motorcycles.
Model Evolution
Sportsman Lineage:
The Polaris Sportsman line is a long-standing and popular series of ATVs, known for its comfort, utility, and off-road capability. The 500cc engine has been a staple, with advancements like EFI and touring configurations evolving over the years.
Production
Manufacturing Location:
Primarily manufactured in Minnesota, USA.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Polaris Sportsman models consistently receive positive reviews for their performance, comfort, and versatility in the ATV market.
Ratings
Consumer Satisfaction:
Generally high consumer satisfaction, reflecting Polaris's long-standing reputation in the powersports industry.

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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