The Polaris Sportsman 500 Touring EFI is a 2008 All-Terrain Vehicle (ATV) designed for premium utility and recreational use, catering to off-road enthusiasts, hunters, farmers, and riders seeking a capable two-up experience. This model features a fuel-injected, liquid-cooled 499cc engine, independent front and rear suspension for enhanced comfort and handling, and a switchable on-demand All-Wheel Drive (AWD) system for optimal traction. Its robust engineering, evident in its substantial towing capacity of 1500 lbs and cargo rack capacities of 100 lbs front and 200 lbs rear, reflects a long-standing heritage of producing innovative and reliable powersports vehicles. This comprehensive Workshop Service Repair Manual provides detailed guidance for the maintenance, diagnosis, and repair of the 2008 Polaris Sportsman 500 Touring EFI. It covers all major vehicle systems, including the engine, fuel system, drivetrain, transmission, brakes, suspension, steering, and electrical components. The manual includes step-by-step repair instructions, assembly and disassembly procedures, troubleshooting guides, and essential technical specifications such as torque values and fluid requirements. Its purpose is to empower owners, mechanics, and technicians with the knowledge necessary to keep this ATV in optimal working condition, ensuring its longevity and performance. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Category: Premium Utility/Recreational ATV Target Audience: Off-road enthusiasts, hunters, farmers, and recreational riders seeking a capable and comfortable two-up ATV. Competitive Analysis Key Competitors 2008: Can-Am Outlander 800, Yamaha Grizzly 700, Arctic Cat Thundercat 1000, Kawasaki Brute Force 750. Key Features Touring Capability: Designed for two-up riding with a comfortable seat and passenger footrests. Engine Type: Fuel-injected, liquid-cooled, single-cylinder engine for reliable performance. Suspension Type: Independent front and rear suspension for superior ride comfort and handling. Drivetrain Features: Switchable on-demand AWD system for optimal traction in various conditions. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, and repair, including top-end and bottom-end components, lubrication system, cooling system, and timing. Fuel System: EFI system diagnosis and repair, fuel pump, injectors, pressure regulator, throttle body, and sensors. Drivetrain: All-wheel drive (AWD) system, viscous differential, rear differential, drive shafts, CV joints, and clutches (primary and secondary). Transmission: Automatic transmission (PVT - Polaris Variable Transmission) inspection, maintenance, and repair, belt replacement, sheave inspection. Brakes: Hydraulic braking system, calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures. Suspension: Front and rear suspension components, shock absorbers, A-arms, ball joints, tie rods, and wheel bearings. Steering: Steering system diagnosis and repair, steering shaft, tie rods, steering column, and any associated components. Electrical: Complete electrical system, battery, charging system (stator, voltage regulator), ignition system, lighting, starter motor, and wiring diagrams. Body Frame: Body panel removal and installation, chassis inspection and repair, seat, handlebars, and rack components. Procedures Included Maintenance: Regular maintenance procedures, including oil changes, filter replacements, spark plug service, lubrication points, and valve adjustments. Troubleshooting: Diagnostic charts and troubleshooting guides for common issues and symptoms, aiding in problem identification. Repair: Step-by-step repair instructions for all major vehicle components and systems. Assembly Disassembly: Detailed instructions for the disassembly and reassembly of all major mechanical and electrical parts. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including understanding EFI codes and sensor outputs. Rebuild Procedures: Comprehensive rebuild procedures for major components such as the engine and transmission. Specifications: Detailed torque specifications, clearances, and tolerances for all adjustable and replaceable parts. Wiring Diagrams: Complete, easy-to-read electrical wiring diagrams for all vehicle systems. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable pages for physical reference. Digital Quality: High-resolution scans ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve Displacement: 499cc Bore X Stroke: 92mm x 75mm Cooling System: Liquid-cooled Performance Horsepower Est: Approx. 39 HP @ 6500 RPM (Note: Official Polaris figures may vary slightly) Torque Est: Approx. 35 lb-ft @ 5000 RPM (Note: Official Polaris figures may vary slightly) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane or higher Ignition Ignition Type: Electronic ignition Lubrication Oil Type: SAE 5W-50 Synthetic Oil (Refer to manual for specific Polaris recommendations) Oil Capacity: Approx. 2.1 L (2.2 U.S. qt) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) - Automatic Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: Shaft drive, On-Demand AWD Clutch Type: Dual clutch (Primary and Secondary) Transmission Fluid: Polaris Synthetic AWD/Transmission Fluid (Refer to manual for specific part number and type) 📐 Dimensions Exterior Length: Approx. 85 in (2159 mm) Width: Approx. 46 in (1168 mm) Height: Approx. 48 in (1219 mm) (to handlebars) Wheelbase: Approx. 50.5 in (1283 mm) Ground Clearance: Approx. 11.25 in (286...