The 2008 Sportsman 500 Touring EFI is a robust all-terrain vehicle engineered for both recreational touring and demanding utility tasks. Known for its comfortable, two-up seating and ample storage, this model offers a blend of performance and practicality, powered by a 499cc liquid-cooled, single-cylinder engine with Electronic Fuel Injection for optimized delivery. Its design prioritizes ride stability, with independent front and rear suspension, and enhanced off-road capability through its On-Demand All-Wheel Drive system. The Sportsman line has a strong reputation for durability and capability, making the 2008 model a reliable choice for navigating diverse terrains. This comprehensive English-language service repair manual provides detailed maintenance and repair procedures for the 2008 Sportsman 500 Touring EFI. It covers all essential vehicle systems, including engine, drivetrain, chassis, and electrical components, offering step-by-step instructions for everything from routine oil changes and filter replacements to complete engine rebuilds and complex electrical diagnostics. The manual includes crucial technical specifications, torque values, and detailed wiring diagrams, making it an invaluable resource for owners and technicians alike. Its thorough coverage ensures that users can effectively maintain, troubleshoot, and repair their vehicle, maximizing its performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Touring EFI Year: 2008 Product Name: Polaris Sportsman 500 Touring EFI 2008 Service Repair Manual 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) - Utility/Recreational Target User: Owners and technicians performing maintenance, repairs, and diagnostics on the 2008 Polaris Sportsman 500 Touring EFI. Competitive Analysis Competitors 2008: Can-Am Outlander, Yamaha Grizzly, Arctic Cat 500/550, Kawasaki Brute Force, Suzuki KingQuad. Key Features Vehicle Touring Capability: Designed for extended rides with comfortable seating for two and ample storage, suitable for recreational touring and utility tasks. Key Features Manual Completeness: Provides exhaustive technical information directly from the manufacturer, ensuring accuracy and completeness for all service procedures. 📋 Manual Details Coverage Areas Primary Coverage: Maintenance and Repair Procedures Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital (PDF) Page Count Pages: Estimated 500+ pages (based on typical comprehensive service manuals for this era and complexity). 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, troubleshooting, performance tuning, fuel injection system, ignition system, cooling system, lubrication system. Drivetrain Systems: Transmission, final drive, differential, axle shafts, drive shafts, CV joints. Chassis Systems: Frame, suspension (front and rear), steering system, brakes (hydraulic, calipers, master cylinder, lines), wheels, tires. Electrical Systems: Battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation, ignition switch, wiring diagrams, EFI sensors. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, coolant checks and flushes, brake fluid replacement, lubrication points, valve adjustments. Repair Procedures: Engine rebuilds, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and replacement, fuel system cleaning and repair. Troubleshooting Guidelines: Diagnostic charts for common problems, symptom-based troubleshooting, error code interpretation (if applicable for EFI system). Wiring Diagrams: Detailed electrical system wiring diagrams for troubleshooting and repair. Torque Specifications: Specific torque values for all critical fasteners and engine components. Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive, suitable for both amateur mechanics and professional technicians. Covers basic maintenance to complete overhauls and diagnostics. Manual Type Detail Document Type: Factory Service Manual / Repair Manual 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Quality: High-resolution scans of original manufacturer documentation, ensuring clear diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) Searchability Text Search: Searchable text allows for quick navigation and keyword-based information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled, SOHC, Single-Cylinder Displacement: 499 cc (30.45 cu. in.) Bore X Stroke: 92 mm x 76 mm (3.62 in. x 2.99 in.) Performance Horsepower: Approx. 30 HP (Actual figures vary slightly based on tuning and conditions, manual will provide precise figures) Torque: Approx. 28 lb-ft (Actual figures vary slightly, manual will provide precise figures) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin 40mm throttle body Fuel Type: Unleaded Gasoline, 87 Octane minimum Cooling System Type: Liquid-Cooled Coolant Type: Polaris Premium 2-Stroke Premix (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors - manual specifies exact type and mix ratio) Lubrication System Oil Type: SAE 5W-50 Synthetic or Polaris Premium 4 Synthetic (manual specifies exact viscosity and API rating) Oil Capacity: Approx. 2.1 US quarts (2.0 L) with filter change (manual specifies exact capacity) Ignition System Type: Electronic Ignition (CDI) Spark Plugs Type And Gap: NGK CR7E or equivalent, 0.028-0.031 in. (0.7-0.8 mm) gap (manual specifies exact part number and gap) 🔧 Transmission Standard Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive System: Shaft Drive, On-Demand AWD/2WD Features Gear Selection: High, Low, Neutral, Reverse, Park Fluid Type Transmission Fluid: Polaris AGL Premium Synthetic Gearcase Lubricant (manual specifies exact...