The 2008 Sportsman 500 Touring EFI is a versatile All-Terrain Vehicle (ATV) engineered for both utility and extended recreational riding. As part of the renowned Sportsman lineup, this model emphasizes comfort and capability, featuring a touring-focused design with an extended passenger seat and ergonomic controls for two-up excursions. Its 499cc, liquid-cooled, single-cylinder engine, equipped with Electronic Fuel Injection (EFI), ensures consistent power delivery and responsive performance across varying terrains and altitudes. The robust chassis, on-demand all-wheel-drive system, and independent suspension contribute to its reliable handling and adaptability for diverse outdoor activities. This comprehensive service manual provides essential information for the maintenance, repair, and servicing of the 2008 Sportsman 500 Touring EFI. It covers all major vehicle systems, including detailed procedures for engine mechanicals, fuel and ignition systems, cooling, transmission, suspension, steering, brakes, and the electrical system. The manual includes routine maintenance schedules, component rebuild instructions, troubleshooting guides, and technical specifications, such as torque values and fluid requirements. Designed for owners and professional technicians alike, this manual aims to facilitate proper upkeep, ensure optimal performance, and aid in the accurate diagnosis and resolution of any issues encountered with the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Vehicle Type: All-Terrain Vehicle (ATV) Codes Vin Code: Refer to VIN plate on vehicle frame for specific identification. 👋 Introduction Market Position Market Segment: Premium touring ATV, designed for comfort and utility over long distances and varied terrain. Competitive Analysis Key Competitors: Can-Am Outlander, Arctic Cat 500 TRV, Yamaha Grizzly. Key Features Touring Focus: Features like extended passenger seat, floorboards, and comfortable ergonomics for two-up riding. Engine Performance: EFI system for consistent power delivery and throttle response across changing altitudes and temperatures. 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, and Maintenance Vehicle Variants: Polaris Sportsman 500 Touring EFI 2008 Page Count Estimated Pages: Approx. 300-500 pages (typical for comprehensive service manuals of this era). Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, and repair of all internal components. Engine Fuel System: EFI system troubleshooting, injector cleaning, fuel pump, pressure regulator, and throttle body. Engine Ignition System: Ignition coil, CDI unit, spark plugs, and timing procedures. Cooling System: Radiator, fan, hoses, thermostat, and coolant specifications. Transmission Drivetrain: CVT (Continuously Variable Transmission) operation, belt inspection/replacement, clutch service, and final drive maintenance. Suspension Steering: Front and rear suspension components, shock absorber adjustment/replacement, steering linkage, and wheel alignment. Brakes: Hydraulic brake system, caliper service, pad replacement, fluid flush, and bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (stator, voltage regulator), starter motor, lighting, and accessory circuits. Chassis Frame: Frame inspection, body panel removal/installation, and seat service. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) if applicable for the EFI system, and common fault analysis. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, and general inspection checklists. Component Rebuilds: Detailed instructions for engine, transmission, and differential rebuilds. Troubleshooting Fault Finding: Systematic approaches to diagnose and resolve issues across all vehicle systems. Torque Specifications: Precise torque values for critical fasteners. Special Tools: Identification and usage of any specialized tools required for specific procedures. Technical Depth Depth: Comprehensive, from basic owner maintenance to advanced mechanical and electrical repair. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (typically text-searchable PDF) Printable: Yes (designed for printing individual pages or sections) Print Quality Quality Description: High-resolution digital scans ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve, Single Cylinder Displacement: 499cc Bore X Stroke: 92mm x 76mm (approx.) Cooling System: Liquid-cooled Performance Horsepower: Approx. 30-35 HP (estimated, actual figures may vary). Torque: Approx. 30-35 lb-ft (estimated, actual figures may vary). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch or similar system. Fuel Type: Unleaded Gasoline, 87 Octane (minimum) 🔧 Transmission Standard Transmission Type: Automatic Polaris Variable Transmission (PVT) with Hi/Lo range, Neutral, and Reverse. Optional Optional Gearbox: N/A (PVT is standard) Features Drive System: On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector. Differentials: Front: Polaris ADC (Active Descent Control) compatible with AWD engagement. Rear: Locked. Gear Reduction: Included within the PVT and final drive units. 📐 Dimensions Exterior Length: Approx. 85.5 inches (217.2 cm) Width: Approx. 45.2 inches (114.8 cm) Height: Approx. 48.5 inches (123.2 cm) to handlebars Wheelbase: Approx. 57 inches (144.8 cm) Ground Clearance: Approx. 11.25 inches (28.6 cm) Cargo Front Rack Capacity: Approx. 100 lbs (45 kg) Rear Rack Capacity: Approx. 200 lbs (91 kg) Weights Dry Weight: Approx. 660 lbs (299 kg) Towing Capacity: Approx. 1500 lbs (680.4 kg) Payload Capacity: Approx. 475 lbs (215.5 kg) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with...