The Polaris Sportsman 500 Touring EFI, a 2008 model year all-terrain vehicle, is engineered for comfortable two-up riding and versatile off-road exploration. This ATV features a robust 499cc liquid-cooled engine with Electronic Fuel Injection (EFI) for responsive performance and efficiency. Its independent front and rear suspension, combined with an On-Demand All-Wheel Drive system, ensures a smooth and capable ride across varied terrains. Designed for recreational riders, hunters, and trail explorers, the Sportsman 500 Touring EFI prioritizes passenger comfort with a dedicated seat and backrest, alongside practical utility with front and rear cargo racks and a substantial towing capacity. This comprehensive English-language service and repair manual provides detailed guidance for maintaining and repairing the 2008 Polaris Sportsman 500 Touring EFI. It covers all essential systems, including the engine, automatic PVT transmission, drivetrain, suspension, brakes, electrical components, and fuel system. Within its pages, you will find step-by-step procedures for routine maintenance, troubleshooting common issues, component overhaul, and technical specifications. This manual is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Category: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Segment: Two-up touring ATV, emphasizing comfort and capability for extended rides. Target Audience: Recreational riders, hunters, trail explorers who value passenger comfort and utility. Competitive Analysis Competitors: Competed against other two-up ATVs from brands like Can-Am (Outlander Max), Arctic Cat (TRV), and Yamaha (Grizzly EPS 4x4). Key Features Seating: Designed for two riders with a dedicated passenger seat and backrest. Powertrain: Fuel-injected engine for improved throttle response, power, and fuel efficiency. Suspension: Independent front and rear suspension for a smoother ride over varied terrain. Drive System: On-Demand All-Wheel Drive (AWD) for enhanced traction. 📋 Manual Details Coverage Areas Manual Type: Full Service and Repair Manual Language: English Format: PDF Download Completeness: Comprehensive 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, overhaul, performance tuning, EFI system, ignition, cooling. Transmission: Automatic PVT (Polaris Variable Transmission) operation, belt inspection, clutch service, gearbox maintenance. Drivetrain: Shaft drive, AWD system operation, front and rear differential service, CV joint maintenance, driveshaft inspection. Suspension: Front and rear suspension geometry, shock absorber adjustment and replacement, bushing inspection and replacement, wheel alignment. Brakes: Hydraulic disc brake system, brake pad replacement, caliper service, brake fluid bleeding and replacement, parking brake adjustment. Electrical: Wiring diagrams, battery system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, ignition system troubleshooting, EFI sensor diagnosis. Fuel System: EFI system components, fuel pump, injectors, fuel filter replacement, fuel tank service. Bodywork: Plastic panel removal and installation, seat service, rack systems, body component repair. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, lubrication points, battery care, tire pressure checks. Troubleshooting: Diagnostic charts for common problems, error code interpretation (if applicable to EFI system), step-by-step fault finding. Repair: Component disassembly and reassembly, part replacement, internal engine and transmission repair procedures. Overhaul: Engine and transmission rebuilding procedures. Technical Depth Depth: Comprehensive for professional technicians and advanced DIY mechanics. Diagnostics: Includes EFI system diagnostics, sensor readings, and potential fault code interpretations. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval. Print Quality: Generally high, allowing for clear printing of diagrams and text. Binding Type: N/A (Digital Download) Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, Single Cylinder Displacement: 499cc Bore X Stroke: 92.0 mm x 76.0 mm Cooling System: Liquid-cooled Performance Horsepower: Approximately 39 HP (figures may vary slightly by source) Torque: Not readily specified in marketing materials, but designed for strong low-end and mid-range grunt. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with throttle body size typically around 44mm. Fuel Type: Unleaded gasoline, minimum 87 octane. Lubrication Oil Type: SAE 5W-50 Synthetic ATV Engine Oil (refer to manual for exact spec). Oil Capacity: Approximately 2.2 L (2.3 US qt) with filter change (verify in manual). 🔧 Transmission Standard Type: Automatic Polaris Variable Transmission (PVT) with Engine Braking. Gear Selection: High, Low, Neutral, Reverse, Park. Features Drive Belt: Heavy-duty, high-performance belt designed for ATV use. Clutch Service: Includes primary and secondary clutch inspection, cleaning, and belt replacement procedures. Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant (refer to manual for exact spec). Transmission Fluid Capacity: Approximately 0.57 L (0.6 US qt) (verify in manual). 📐 Dimensions Exterior Length: Approximately 211.8 cm (83.4 in) Width: Approximately 114.3 cm (45 in) Height: Approximately 129.5 cm (51 in) Wheelbase: Approximately 134.6 cm (53 in) Weights Dry Weight: Approximately 324 kg (715 lbs) Ground Clearance: Approximately 29.2 cm (11.5 in) Cargo Front Rack Capacity: Approximately 45 kg (100 lbs) Rear Rack Capacity: Approximately 90 kg (200 lbs) Towing Capacity: Approximately 680 kg (1500 lbs) Wheels Tires Front Tires: 25 x 8-12 Rear Tires: 25 x 11-10...