The Polaris Sportsman 500 Touring EFI, produced around 2008, is a robust all-terrain vehicle designed for both recreational trail riding and practical utility tasks. It features a capable 499cc liquid-cooled engine with Electronic Fuel Injection (EFI) for consistent performance and improved throttle response. Key innovations include Independent Rear Suspension (IRS) for enhanced comfort and handling, and a True On-Demand All-Wheel Drive system for superior traction. This model is engineered for comfort, offering a spacious two-up seating arrangement with passenger amenities, and is built with a reputation for durability and reliability in mind. This comprehensive full service repair manual provides detailed instructions for maintaining, troubleshooting, and repairing the 2008 Polaris Sportsman 500 Touring EFI. It covers all essential systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical components. The manual offers step-by-step procedures for routine maintenance, diagnostics, and complex repairs, along with valuable information on technical specifications, wiring diagrams, and common issues. This resource is designed to assist owners and technicians in keeping the vehicle in optimal condition and ensuring its longevity and performance. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Product Name: Polaris Sportsman 500 Touring EFI 2008 Full Service Repair Manual Codes Engine Code: Likely a variant of the ProStar 500, specific engine code not provided in product info but common for this model/year. 👋 Introduction Market Position Positioning: The Polaris Sportsman 500 Touring EFI was positioned as a versatile, comfortable, and capable two-up ATV for recreational riding, trail exploration, and light utility work. It aimed to blend the performance of the Sportsman line with the comfort for a passenger. Competitive Analysis Competitors: Competed with other 500cc-class two-up ATVs from brands like Can-Am (Outlander Max), Arctic Cat (Prowler), and Yamaha (Grizzly). Key selling points were its established Polaris reputation, comfort features for a passenger, and the EFI system for consistent performance. Key Features Features: Electronic Fuel Injection (EFI) for improved throttle response and cold starts, Independent Rear Suspension (IRS) for superior ride comfort and handling, True On-Demand All-Wheel Drive (AWD), powerful 500cc engine, comfortable two-up seating with passenger backrest and floorboards, front and rear racks for cargo. 📋 Manual Details Coverage Areas Coverage: Comprehensive repair, maintenance, troubleshooting, and diagnostics for the Polaris Sportsman 500 Touring EFI 2008 model. Page Count Page Count: Detailed page count not specified in product information, but described as 'very detailed'. Manual Type Type: Full Service Repair Manual Language Language: English (presumed, standard for this type of manual) Format Format: Digital (likely PDF, common for online sales of service manuals). 📖 Manual Coverage Systems Covered Engine: Engine overhaul, disassembly, assembly, tuning, fuel system (EFI), ignition system, cooling system, lubrication. Transmission: Automatic transmission (CVT) maintenance, repair, belt replacement, clutch inspection. Drivetrain: All-Wheel Drive (AWD) system, front differential, rear differential, drive shafts, U-joints, CV joints. Suspension: Front and rear suspension components, shocks, springs, control arms, bushings, wheel bearings. Brakes: Hydraulic brake system, brake caliper service, pad replacement, rotor inspection, bleeding procedures, parking brake. Electrical: Wiring diagrams, starter system, charging system (alternator/stator), battery maintenance, lighting, instrumentation, EFI control module (ECU). Bodywork: Body panel removal and installation, fairings, seat, handlebars, rack systems, cosmetic repairs. Chassis: Frame inspection, steering system, wheel alignment. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, tire pressure checks, lubrication points. Troubleshooting: Diagnostic flowcharts for common problems, electrical troubleshooting, engine performance issues, starting difficulties. Repair: Step-by-step instructions for all major component repairs and replacements, including engine rebuilds, suspension overhaul, and brake system service. Diagnostics: EFI system diagnostics, sensor testing, actuator testing, fault code interpretation (if applicable). Installation: Instructions for installing genuine Polaris accessories or common aftermarket upgrades. Technical Depth Depth: Comprehensive, covering from basic scheduled maintenance to full engine and transmission rebuilds, including electrical diagnostics and component-level repair. 📊 Manual Specifications File Format Format Details: Likely a searchable PDF document, allowing for easy navigation and keyword searching. Print Quality Quality: High-resolution scans of original factory service manuals, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital format) Paper Type Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve, Single Cylinder, Liquid-Cooled Displacement: 499cc (Actual displacement may vary slightly based on specific engine revisions, but commonly listed as 499cc or 498cc) Bore X Stroke: Typical for this engine family: 93.0 mm x 73.0 mm Compression Ratio: Typically around 10.0:1 Engine Cooling: Liquid-Cooled Performance Horsepower: Approximately 30-33 HP (figures vary slightly by source and specific tune) Torque: Around 28-30 lb-ft (figures vary slightly by source and specific tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with a throttle body size typically around 40mm. Fuel Type: Unleaded gasoline, minimum 87 octane. Ignition Ignition System: Digital CDI (Capacitor Discharge Ignition) with electronic advance. Lubrication Oil Type: Typically SAE 5W-50 or 10W-50 API SG or higher, JASO MA certified synthetic...