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: 2008 Codes Platform Code: A08 👋 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: PDF 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,...