The 2008 Sportsman 500 represents a robust and versatile all-terrain vehicle, available in several sub-models including the EFI, X2, Touring, and 500 H.O. Built by a manufacturer with a strong heritage in powersports, the Sportsman line is renowned for its comfort, utility, and advanced all-wheel-drive capabilities. This model features a 500cc class liquid-cooled, 4-stroke engine, typically producing around 33 horsepower, and utilizes Automatic PVT transmission with engine braking. Its engineering emphasizes reliability and performance, making it a popular choice for a wide range of activities from utility work to recreational trail riding. This comprehensive Service Repair Manual for the 2008 Sportsman 500 series provides in-depth information essential for maintenance and repair. Covering all applicable models, the manual details general information, maintenance schedules, engine specifics, fuel injection and carburetor systems, bodywork, steering, suspension, clutch system, final drive, transmission, brakes, and electrical systems, with specific sections for the 500 EFI X2/Touring Quadricycle. It includes complete tear-down and rebuild procedures, troubleshooting guides, diagnostic steps, and installation instructions, all supported by detailed illustrations, exploded diagrams, wiring schematics, and torque specifications. This resource is designed to empower both do-it-yourself enthusiasts and professional mechanics to keep their Sportsman 500 operating at peak performance. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Sub Models: EFI, X2, Touring, 500 H.O. Model Year: 2008 👋 Introduction Market Position Target Audience: Do-it-yourself enthusiasts and experienced mechanics Value Proposition Cost Savings: Inexpensive way to keep vehicle working properly, allows for DIY repairs to save money Manual Advantage Key Benefits: Complete information, detailed illustrations, diagrams, wiring schematics, specifications, step-by-step instructions for all diagnostic and repair procedures. 📋 Manual Details Coverage Applicable Models: 2008 Polaris Sportsman 500 EFI, Sportsman 500 X2, Sportsman 500 Touring, Sportsman 500 H.O. Pages Page Count: 406 Type Manual Type: Official Service Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Systems Covered: General Information, Maintenance, Engine, Fuel Injection/Carburetor, Body, Steering, Suspension, Clutch System, Final Drive, Transmission, Brakes, Electrical Systems, 500 EFI X2/Touring Quadricycle Specifics Procedures Procedures Included: Complete tear down and rebuild, maintenance, troubleshooting, diagnostic procedures, repair procedures, installation procedures Depth Technical Depth: Comprehensive (from basic maintenance to complete rebuilds, including detailed illustrations, exploded diagrams, wiring schematics, and torque specifications) 📊 Manual Specifications File Characteristics File Quality: High quality, searchable, bookmarked, printable Print Options Print Quality: Fully printable pages Delivery Delivery Method: Instant Download Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 500cc class, Liquid-cooled, 4-stroke, SOHC, 2-valve Performance Horsepower Approximate: Approximately 33 hp (specific to sub-model and tuning) Fuel System Fuel Delivery: Fuel Injection (EFI) for EFI models, Carburetor for H.O. models (manual covers both, refer to specific chapters) Bore Stroke Bore X Stroke: 92.0 mm x 75.0 mm (typical for 499cc displacement) Compression Ratio Compression Ratio: 10.0:1 (typical) Cooling System Cooling Method: Liquid-cooled Oil Capacity Engine Oil Capacity With Filter: Refer to manual for exact capacity (typically around 2.0-2.3 quarts/liters) Spark Plug Spark Plug Type: NGK CR9EB or equivalent (refer to manual for specific recommendation and gap) 🔧 Transmission Type Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive System Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Gear Reduction Gear Reduction Ratios: Manual provides detailed ratios for high/low range and reverse Clutch System Clutch Description: Primary and secondary clutch system for variable ratio drive 📐 Dimensions General Overall Length: Refer to manual for specific model (typically around 83 inches) Overall Width: Refer to manual for specific model (typically around 46 inches) Overall Height: Refer to manual for specific model (typically around 48 inches) Weights Dry Weight: Refer to manual for specific model (typically around 650-690 lbs) Capacity Towing Capacity: Refer to manual for specific model (typically around 1500 lbs) Rack Capacity Front: Refer to manual for specific model (typically around 90 lbs) Rack Capacity Rear: Refer to manual for specific model (typically around 170 lbs) 🛡️ Safety Features Features Braking System: Hydraulic disc brakes (front and rear), sealed hydraulic system Lighting: Dual headlights, taillight/brake light Rollover Protection: Not applicable to ATVs in standard configuration; emphasis on rider training and safe operation. 💡 Technology Features Engine Management Efi System: Electronic Fuel Injection system provides optimized fuel delivery for varying conditions. Powertrain AWD System: Polaris's On-Demand All-Wheel Drive automatically engages front-wheel drive when needed. Instrumentation Gauge Cluster: Digital/analog combination gauge cluster typically includes speedometer, odometer, trip meter, fuel gauge, and warning lights. Lighting Lighting Technology: Halogen headlights for primary illumination. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/hour intervals (typically every 100 hours or annually) Air Filter Maintenance: Recommended cleaning/replacement at regular intervals (refer to manual) Spark Plug Replacement: Refer to manual for recommended replacement interval Fluid Specifications Engine Oil Specification: SAE 5W-50 Synthetic (or as specified in manual, API CI-4 recommended) Coolant Type: Ethylene glycol-based...