The 2008 Sportsman 500 Touring EFI is a versatile All-Terrain Vehicle designed for recreational use, offering comfortable seating for two and robust off-road capability. Key features include a powerful 500cc engine with electronic fuel injection for improved performance and efficiency, independent front and rear suspension for a smooth ride over varied terrain, and substantial rack capacity for carrying gear. Its engineering emphasizes reliability and utility, making it a capable companion for exploration and work. This comprehensive Service Repair Manual provides detailed information for the maintenance, diagnosis, and repair of your 2008 Sportsman 500 Touring EFI. It covers all essential systems, including the engine, fuel system, transmission, drivetrain, brakes, electrical system, and suspension. The manual includes routine maintenance procedures, troubleshooting guides, step-by-step repair instructions, overhaul procedures, and detailed wiring diagrams, empowering owners and technicians to keep the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Codes Vin Decoder Notes: VIN typically starts with 4PF... 👋 Introduction Market Position Market Segment: Recreational ATV (All-Terrain Vehicle) Target Audience: Owners of the 2008 Polaris Sportsman 500 Touring EFI seeking to perform maintenance, repairs, and diagnostics. Competitive Analysis Competitors 2008: Can-Am Outlander, Arctic Cat 500, Yamaha Grizzly 550, Suzuki KingQuad 500. Key Features Vehicle Key Selling Points: Comfortable seating for two, powerful 500cc engine, independent rear suspension (IRS), electronic fuel injection (EFI), robust storage capacity. Key Features Manual Manual Value Proposition: Provides comprehensive technical information to maintain and repair the specific 2008 Sportsman 500 Touring EFI model, saving time and money on service. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: PDF Page Count Page Count: Approximately 600+ pages (typical for this model and era of service manual) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, lubrication system, cooling system, intake system, exhaust system. Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, fuel filter, fuel tank, fuel lines. Transmission: PVT (Polaris Variable Transmission) clutch inspection, adjustment, and replacement; gearbox overhaul, lubrication, and fluid specifications. Drivetrain: Front and rear drive systems, differentials, drive shafts, CV joints, bearings, seals. Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedures. Electrical System: Battery, charging system (stator, regulator/rectifier), ignition system, starter motor, lighting, switches, relays, fuses, wiring diagrams, EFI control module. Suspension: Front and rear suspension components, shocks, springs, A-arms, bushings, alignment specifications, steering system. Chassis Frame: Frame inspection, welds, components, body panels, seat, handlebars, racks. Cooling System: Radiator, fan, coolant, hoses, thermostat. Bodywork: Body panel removal, installation, care. Procedures Included Maintenance: Routine maintenance tasks, oil changes, filter replacements, spark plug service, air filter cleaning/replacement, valve clearance checks, lubrication points. Troubleshooting: Diagnostic charts and procedures for common and uncommon problems, error codes, performance issues. Repair: Step-by-step repair instructions for all major and minor mechanical and electrical components. Overhaul: Complete engine and transmission overhaul procedures. Disassembly Assembly: Detailed instructions for component disassembly and reassembly. Wiring Diagrams: Comprehensive electrical system wiring diagrams for easy troubleshooting. Technical Depth Depth Level: Comprehensive; covers basic maintenance to complete engine and component rebuilds, including advanced diagnostics and EFI system troubleshooting. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, designed for clear printing of diagrams, text, and specifications. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, 2-cylinder, SOHC, liquid-cooled, fuel-injected Engine Displacement: 499 cc (30.45 cubic inches) Bore X Stroke: 70 mm x 64 mm Compression Ratio: 9.5:1 Engine Oil Type: SAE 10W-40 Synthetic ATV Engine Oil (e.g., Polaris Synthetic 4T) Engine Oil Capacity: Approximately 2.3 quarts (2.2 liters) with filter change Spark Plug Type: NGK CR9EKB (or equivalent) Idle Speed: 1200-1400 RPM (refer to manual for precise specification) Performance Horsepower Estimated: Approximately 30-35 HP (actual figures can vary slightly) Torque Estimated: Approximately 30-35 lb-ft Fuel System Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: 4.0 gallons (15.1 liters) Fuel Pump Type: Electric Cooling System Coolant Type: Ethylene Glycol-based Antifreeze/Coolant (e.g., Polaris recommended mixture) Coolant Capacity: Approximately 1.7 quarts (1.6 liters) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking (EB) Drive Modes: 2WD / AWD (All-Wheel Drive) with VersaTrac Features Clutch System: Primary and secondary clutch system, belt drive. Gear Reduction: Standard reduction gear ratios for low-speed crawling and high-speed cruising (specific ratios detailed in manual). Fluid Specifications Gearbox Oil Type: SAE 75W-90 Synthetic Gear Oil (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: 85.5 inches (217.2 cm) Width: 48 inches (121.9 cm) Height: 50 inches (127 cm) 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: 661 lbs (299.8 kg) Towing...