Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2008 Model Variant: All Introduction Market Position Market Segment: The 2008 Polaris Sportsman 500 is positioned as a versatile and capable all-terrain vehicle (ATV) designed for utility, recreational riding, and light work, appealing to both casual riders and those who need a dependable workhorse. Competitive Analysis Competitors: Competes with models from Yamaha (Grizzly), Can-Am (Outlander), Honda (Foreman, Rubicon), and Kawasaki (Brute Force). Key Features Key Features: Known for its Polaris Independent Suspension (PIS), reliable engine performance, and robust chassis, offering comfort and capability in various terrains. Manual Details Coverage Areas Coverage: Complete factory service and repair for the 2008 Polaris Sportsman 500 All models. Page Count Page Count: Not specified, but described as '100% complete and intact'. Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF Manual Coverage Systems Covered Engine Service: Detailed procedures for engine disassembly, assembly, inspection, and repair. Drivetrain Service: Coverage of the transmission, final drive, AWD system (if applicable), and differentials. Suspension Steering: Service and repair for front and rear suspension components, shocks, springs, steering system, and linkages. Braking System: Maintenance, repair, and bleeding procedures for the hydraulic braking system, including calipers, master cylinder, and lines. Fuel System: Service and repair for the fuel pump, injectors, fuel lines, and fuel tank. Electrical System Electrical Diagnostics: Comprehensive wiring diagrams, troubleshooting guides, and component testing for the electrical system. Cooling System Cooling Service: Maintenance and repair of the radiator, coolant, hoses, and thermostat. Bodywork Chassis Body Repair: Procedures for body panel removal, installation, and basic chassis service. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, lubrication points, and general inspections. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common issues. Component Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components. Rebuild Procedures: Instructions for the complete overhaul or rebuild of the engine, transmission, and other major assemblies. Technical Depth Depth: Highly detailed, factory-level technical information suitable for professional technicians and advanced DIY mechanics. Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, clear text and illustrations suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC, 4-valve Engine Displacement: 499 cc Bore X Stroke: 92 mm x 77 mm Compression Ratio: 10.4:1 Fuel Delivery: Carbureted (likely Mikuni BS40 or similar, specific model not listed in product info but typical for this era/model). Ignition: CDI Performance Horsepower: Approx. 30-32 HP (typical for this engine configuration). Torque: Not specified, but robust low-end torque for utility. Fuel System Fuel Type: Unleaded gasoline Fuel Tank Capacity: 3.0 gal (11.4 L) (typical for this model). Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: On-Demand AWD / 2WD Final Drive: Shaft Drive Dimensions Exterior Length: 81 in. (206 cm) (typical) Width: 46 in. (117 cm) (typical) Height: 48 in. (122 cm) (typical) Weights Dry Weight: 669 lbs (303 kg) (typical) Ground Clearance: 11.25 in. (28.6 cm) (typical) Cargo Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) Towing Capacity: 1500 lbs (680 kg) Safety Features Ratings Safety Standards: ATVs are not typically rated by NHTSA or IIHS; however, Polaris adheres to industry safety standards. Active Features Braking System: Hydraulic disc brakes front and rear. Engine Braking: Standard feature on the PVT transmission for controlled descents. Passive Features Lighting: Dual headlights, taillight/brake light. Ergonomics: Designed for rider comfort and control with handlebar grip and control placement. Technology Features Infotainment Infotainment System: Basic instrumentation cluster (speedometer, odometer, fuel gauge, warning lights). No complex infotainment system. Driver Assistance Driver Assistance Features: None typical for this model. Focus is on mechanical functionality and rider input. Connectivity Connectivity Options: N/A Lighting Lighting Technology: Incandescent bulbs for headlights and taillight. Maintenance Service Intervals Oil Change Interval: Every 100 hours or 6 months, whichever comes first (typical for Polaris ATVs). Air Filter Service: Check every 25 hours, clean/replace as needed. Clean more frequently in dusty conditions. Spark Plug Replacement: Recommended every 100 hours or 1 year (typical). Drive Belt Inspection: Inspect every 50 hours, check for wear and damage. Replace as needed. Fluid Specifications Engine Oil Type: Polaris Synthetic 2W-50 (or equivalent API SG or higher). Engine Oil Capacity: Approx. 2.0 US quarts (1.9 L) with filter change (typical). Transmission Oil Type: Polaris Demand Drive Fluid (front differential) and Polaris PVT Fluid (transmission/clutch housing) - specific part numbers would be in manual. Coolant Type: Ethylene glycol-based antifreeze (50/50 mix with distilled water). Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: Drive belt, wheel bearings, tie rod ends, ball joints, and brake pads are common...