The 2008 Sportsman 500 Touring EFI is a robust, liquid-cooled, 499cc ATV designed for heavy-duty utility and recreational riding. Engineered for comfort during longer excursions, it features a comfortable two-up seating arrangement, an extended wheelbase, and an On-Demand All-Wheel Drive system for superior traction in varied terrain. Its Electronic Fuel Injection (EFI) ensures reliable performance, improved throttle response, and efficient cold-weather starting, making it a capable choice for off-road enthusiasts, hunters, farmers, and recreational riders alike. This model builds on the well-established Sportsman lineage, known for its ruggedness and utility. This comprehensive Service and Repair Manual provides detailed guidance for the maintenance, diagnosis, and repair of the 2008 Sportsman 500 Touring EFI. Covering all major systems, including the engine, fuel injection, transmission, brakes, electrical, and suspension, this manual offers step-by-step procedures, critical technical specifications, and troubleshooting charts. Its purpose is to empower owners and technicians to perform routine maintenance, complex repairs, and complete overhauls, ensuring the longevity and optimal performance of the vehicle. The manual includes detailed illustrations, exploded views, and schematics to facilitate understanding and accurate execution of all procedures. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Product Name: Polaris Sportsman 500 Touring EFI 2008 All Service Repair Manual Download Product Type: Service and Repair Manual Format Availability: Downloadable 👋 Introduction Market Position Vehicle Segment: Heavy-duty utility and recreational ATV Target Audience: Off-road enthusiasts, hunters, farmers, and recreational riders seeking a capable and comfortable touring ATV. Competitive Analysis Key Competitors 2008: Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rancher, Suzuki KingQuad Key Features Touring Focus: Designed for longer rides and passenger comfort with a comfortable seat and extended wheelbase. Efi Technology: Electronic Fuel Injection for improved throttle response, fuel efficiency, and cold-weather starting. Aawd System: On-Demand All-Wheel Drive for enhanced traction in challenging terrain. Manual Value Proposition Diy Repair Benefit: Empowers owners to perform maintenance and repairs themselves, saving on labor costs and ensuring quality. 📋 Manual Details Coverage Areas Vehicle Model Coverage: Polaris Sportsman 500 Touring EFI 2008 Page Count Estimated Page Count: Likely 300+ pages (typical for comprehensive ATV service manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, specifications, troubleshooting for the 500cc EFI engine. Fuel System: EFI system components, fuel pump, injectors, pressure regulator, troubleshooting, and maintenance. Ignition System: Ignition coil, CDI unit, spark plug, timing, and troubleshooting. Cooling System: Radiator, fan, thermostat, coolant, and related components. Transmission Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission), clutch system, drive belts, gearcase, differentials, AWD system, drivelines, and CV joints. Braking System: Hydraulic brake system (front and rear calipers, master cylinders), brake lines, pads, discs, bleeding procedures, and parking brake. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, switches, fuses, and relays. Suspension Steering: Front and rear suspension (struts, shocks, control arms), wheel bearings, steering system components, tie rods, and alignment. Body Chassis: Frame, body panels, plastics, seats, racks, and mounting hardware. Lubrication Maintenance: Scheduled maintenance, fluid capacities, lubrication points, and filter replacement. Troubleshooting: Diagnostic procedures for common problems, fault codes (if applicable to EFI), and systematic problem-solving. Procedures Included Routine Maintenance: Oil changes, filter replacements (air, oil, fuel), spark plug service, battery checks, chain/belt adjustments (if applicable), and general inspections. Engine Repairs: Top-end rebuild (cylinder head, piston), valve adjustment, camshaft replacement, crankshaft service, and seal replacement. Fuel System Service: Injector cleaning, fuel pump testing, pressure checks, fuel filter replacement. Transmission Service: Drive belt inspection and replacement, clutch inspection and adjustment, gearcase oil changes, differential service. Brake System Service: Brake pad replacement, caliper service, master cylinder rebuild, brake line bleeding. Electrical Diagnostics: Charging system testing, starter motor diagnosis, lighting circuit troubleshooting, use of wiring diagrams. Suspension And Steering Repair: Shock absorber replacement, ball joint inspection, tie rod end replacement, wheel bearing replacement. Overhaul Rebuilds: Detailed instructions for complete disassembly, inspection, repair, and reassembly of major components. Technical Depth Depth Of Coverage: Comprehensive (covers routine maintenance, diagnostics, repair, and complete overhauls) Diagnostic Capabilities: Detailed troubleshooting charts and procedures for identifying and resolving mechanical and electrical issues. Specification Detail: Includes critical torque specifications, clearances, fluid types, capacities, and electrical values. 📊 Manual Specifications File Format File Format: PDF Print Quality Resolution And Clarity: High-resolution scans with clear text and diagrams for easy reading and printing. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Searchability Text Searchability: Searchable PDF allowing quick access to specific information. Illustration Quality Illustrations And Diagrams: Includes detailed illustrations, exploded views, schematics, and diagrams. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, single cylinder Displacement: 499cc (30.45 cu. in.) Bore X Stroke: 92 mm x 74 mm (3.62 in. x 2.91 in.) Cooling System: Liquid-cooled Performance Horsepower Estimated: Approx. 35-40 HP...