The 2008 Sportsman 500 is a versatile mid-size All-Terrain Vehicle (ATV) designed for a wide range of users, from recreational riders to those who require a capable machine for utility tasks on farms, ranches, or hunting expeditions. Renowned for its reliability, powerful 499cc liquid-cooled engine, and comfortable ride, the Sportsman 500 offers impressive off-road performance and a balanced blend of power and efficiency. Its robust engineering and thoughtful design, including independent suspension and on-demand all-wheel drive, make it a dependable choice for tackling challenging terrains, while its cargo capacity and towing capabilities enhance its utility for work and play. This comprehensive Factory Service Manual provides essential information for the maintenance, diagnosis, and repair of your 2008 Sportsman 500. It covers all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical components, offering detailed procedures, technical specifications, and troubleshooting guidance. Whether you are an owner performing routine maintenance or a technician undertaking complex repairs, this manual serves as an indispensable resource to ensure your Sportsman 500 operates at peak performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2008 Product Type: Shop Factory Service Manual 👋 Introduction Market Position Vehicle Segment: Mid-size All-Terrain Vehicle (ATV) Target Audience: Recreational riders, utility users, farmers, hunters, and those seeking a capable off-road vehicle. Competitive Analysis Key Competitors 2008: Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Kawasaki Prairie/Brute Force, Can-Am Outlander. Key Features Vehicle Strengths: Reliability, powerful engine for its class, comfortable ride, capable off-road performance, versatility for work and play. Manual Value Proposition Manual Benefit: Essential resource for maintaining and repairing the 2008 Polaris Sportsman 500, enabling owners to perform tasks efficiently and correctly, saving time and money. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service and repair information for the 2008 Polaris Sportsman 500. Specific Coverage Points: Engine, drivetrain, suspension, brakes, electrical system, body, chassis, maintenance, troubleshooting, and specifications. Page Count Estimated Pages: 500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine System: Detailed diagnosis, repair, and overhaul of the 499cc liquid-cooled, 4-stroke, SOHC engine. Fuel System: Carburetor (Mikuni BSR 40), fuel pump, fuel lines, and related components. Ignition System: CDI ignition, spark plug specifications, timing. Exhaust System: Exhaust pipe, muffler, heat shields. Cooling System: Radiator, fan, coolant, hoses, thermostat. Transmission System: PVT (Polaris Variable Transmission) automatic transmission, belt inspection and replacement, clutch service. Drivetrain System: Shafts, U-joints, differentials (front and rear), drive axles, and gear cases. Suspension System: Front and rear independent suspension, shock absorbers, bushings, control arms, ball joints. Brake System: Hydraulic disc brakes (front and rear), brake fluid specifications, caliper service, master cylinder, brake lines. Steering System: Handlebars, steering shaft, tie rods, steering rack (if applicable). Electrical System: Battery, starter, alternator/stator, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays, switches. Body And Chassis: Frame, fenders, racks, seats, body panels, decals. Wheels And Tires: Tire sizes, inflation pressures, wheel specifications. Procedures Included Maintenance Procedures: Regular servicing, lubrication, oil changes, filter replacements, valve adjustments, belt inspection/replacement, brake bleeding. Diagnostic Procedures: Troubleshooting guides for common issues, fault code interpretation (if applicable), systematic diagnostic steps for various systems. Repair Procedures: Detailed, step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components. Overhaul Procedures: Complete engine and transmission rebuild procedures. Wiring Diagrams: Detailed electrical schematics for all circuits. Technical Depth Depth Level: Factory-level technical information, suitable for professional mechanics and advanced DIY enthusiasts. Detail Level: Includes torque specifications, clearances, tolerances, and detailed assembly instructions. 📊 Manual Specifications File Format Format Details: Searchable PDF document for easy navigation and information retrieval. Print Quality Print Readability: High-resolution scans ensuring clarity of text and diagrams, suitable for printing. Binding Type Binding Style: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Single Cylinder, SOHC Displacement: 499cc Cooling System: Liquid-cooled Bore X Stroke: 92mm x 75mm Compression Ratio: 9.7:1 Performance Horsepower Est: ~30 HP @ 6000 RPM (estimate based on model year and displacement) Torque Est: ~28 lb-ft @ 4500 RPM (estimate based on model year and displacement) Fuel System Carburetor Model: Mikuni BSR 40 Fuel Type: Unleaded gasoline, 87 octane or higher recommended. Lubrication Oil Type Spec: SAE 5W-50 or 10W-40, Polaris 4-Stroke Oil or equivalent JASO MA certified oil. Oil Capacity: Approx. 2.1 L (2.2 US qt) with filter change. 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Automatic Optional Optional Transmission: N/A Features Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Final Drive Ratio: Refer to manual for specific gear ratios (typically around 3.00:1 for rear differential) Fluid Spec Transmission Fluid Type: Polaris Synthetic Gearcase Lubricant or equivalent GL-5 75W-90. Fluid Capacity Rear Gearcase Capacity: Approx. 0.23 L (0.25 US qt) Clutch...