The 2008 Sportsman 500 EFI X2 EFI Touring is a versatile All-Terrain Vehicle (ATV) designed for a wide range of applications, from recreational trail riding and hunting to demanding utility tasks. Known for its robust 499cc liquid-cooled, single-cylinder engine with Electronic Fuel Injection (EFI), this model offers reliable power and efficient performance. Key features include its dual-seat capability, a practical tilting cargo bed with a substantial payload capacity, and an On-Demand All-Wheel Drive system for superior traction in challenging terrain. Built with a reputation for engineering quality and durability, the Sportsman 500 EFI X2 EFI Touring provides a comfortable ride and dependable operation, making it a strong contender in the utility ATV segment. This comprehensive factory service repair workshop manual provides detailed information essential for the maintenance, diagnosis, and repair of your 2008 Sportsman 500 EFI X2 EFI Touring. It covers all major systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical system, offering step-by-step instructions, troubleshooting guides, and factory specifications. The manual is designed to assist owners, mechanics, and technicians in performing everything from routine scheduled maintenance, such as oil changes and filter replacements, to complex overhauls and diagnostics. With factory-level technical depth and clear procedures, this manual is an invaluable resource for ensuring the longevity, performance, and safe operation of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 EFI X2 EFI Touring Model Variant: X2 EFI Touring Year: 2008 Codes Engine Code: Not specified in product info, but typically 500cc class EFI Chassis Code: Not specified in product info, standard Sportsman 500 X2 chassis 👋 Introduction Market Position Segment: Utility ATV (All-Terrain Vehicle) Target User: Hobbyists, farmers, hunters, recreational riders, and professional service technicians. Competitive Analysis Competitors: Competitors from brands like Yamaha (Grizzly), Can-Am (Outlander), Arctic Cat (TRV), and Honda (Rancher/Foreman). Key Features Vehicle Features: Dual-seat capability (X2), versatile cargo bed, robust 500cc EFI engine, capable AWD system. Manual Value Value Proposition: Provides essential technical data for maintaining and repairing the specific 2008 Polaris Sportsman 500 EFI X2 EFI Touring model, crucial for longevity and performance. 📋 Manual Details Coverage Areas Manual Type: Complete Factory Service Repair Workshop Manual Language: English Format: PDF Download Availability: Instant Download, No Expiry Dates, No Extra Fees Page Count Page Count: Estimated 300-500 pages (typical for full service manuals of this era and complexity) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, diagnostics, and component specifications. Fuel System: EFI system diagnosis, fuel pump, injectors, throttle body, sensors, and ECU operations. Transmission: CVT system (Primary and Secondary Clutch), gearcase maintenance, lubrication, and troubleshooting. Drivetrain: Front and rear differentials, driveshafts, U-joints, and AWD engagement system. Suspension: Front and rear suspension components, shock absorbers, springs, A-arms, bushings, and alignment procedures. Brakes: Hydraulic brake system, caliper servicing, master cylinder, brake lines, fluid replacement, and bleeding procedures. Electrical System: Wiring diagrams, lighting, ignition system, charging system (stator, regulator/rectifier), battery, starter, and ECU troubleshooting. Cooling System: Radiator, fan, thermostat, water pump, coolant flushing and replacement. Body And Frame: Body panel removal and installation, frame inspection, seating, cargo bed mechanisms (X2 specific). Controls: Handlebar controls, throttle, brake levers, shifter operation, and pedal systems. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, and spark plug servicing. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for common issues, error code interpretation. Repair: Step-by-step repair instructions for all major components and systems. Overhaul: Complete engine and transmission overhaul procedures with detailed torque specifications. Diagnostics: EFI system diagnostics, electrical system testing, and mechanical fault finding. Wiring Diagrams: Comprehensive electrical wiring schematics with component identification. Technical Depth Depth: Factory-level technical depth, suitable for professional mechanics and advanced DIY enthusiasts. Detail Level: Detailed disassembly, reassembly, measurement specifications, and tolerances. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Searchability: Likely text-searchable, allowing quick access to specific information. Printability: Printable, enabling users to create physical copies for workshop use. Print Quality Resolution: Assumed high-resolution for clear diagrams and text, typical of factory manuals. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve, single-cylinder Displacement: 499cc Bore X Stroke: Not specified in product info, typically around 92mm x 75mm for this engine family Cooling System: Liquid-cooled Compression Ratio: Not specified in product info, typically around 9.0:1 to 10.0:1 Performance Horsepower: Approx. 29-30 HP (at flywheel) Torque: Not specified in product info, but typically strong low-end torque Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline, Octane rating 87 or higher Lubrication Oil Type: Polaris recommends SAE 0W-40 Synthetic or SAE 10W-40 API SG or higher. Oil Capacity: Approx. 2.0 L (2.1 US qt) with filter change. Ignition Ignition System: Electronic Ignition (CDI) Spark Plug Type: NGK CR7HSA or equivalent Spark Plug Gap: 0.6 - 0.7 mm (0.024...