2008 Polaris Sportsman 500 / 500 EFI / 500 HO / Touring 500 EFI Service Manual
The 2008 Sportsman 500 service manual provides comprehensive repair information for multiple models, covering engine, drivetrain, and body systems.
Manual Preview
Sample pages from the 2008 Polaris Sportsman 500 / 500 EFI / 500 HO / Touring 500 EFI Service Manual manual
Purchase & Download
Polaris Models Covered & Key Technical Specifications
Models: Sportsman 500, Sportsman 500 EFI, Sportsman 500 HO, Sportsman Touring 500 EFI, Sportsman X-2 500 EFI
Sub-models / Variants: Touring Quadricycle, X2 Quadricycle, Deluxe, Standard, Intl’ Quadricycle
Build Years: 2008
Serial Numbers: SC14 FA000101–HA310085
Technical Data:
- Engine Displacement: 499 cc
- Engine Configuration: Single Cylinder, 4-stroke, Liquid Cooled
- Transmission: Drumshift (H/L/N/R/P)
- Drive System: 4WD/AWD
- Maximum Operating RPM: 6000 RPM ± 200 RPM
- Cylinder Compression: 60–90 psi
- Ignition Timing: 10°–30° ± 2° BTDC @ 1150–5000 RPM
- Dry Weight: 715–798 lbs. (324–362 kg)
- Fuel Capacity: 4.13–6 gallons (15.6–22.7 liters)
Polaris Manual Features & Content Preview
2008 Polaris Sportsman 500 and Touring 500 Technical Overview
- Covers 2008 Polaris Sportsman 500, 500 EFI, 500 HO, and Touring 500 EFI models, including X2 and standard configurations
- Official Polaris publication P/N 9921315, 2007 edition
- Contains 47 torque tables, 22 mechanical assembly diagrams, 2 electrical component pinout schematics, and 3 engine-specific flow charts
- Files are available immediately after the order is processed
- Your account maintains access to these files for re-downloading at any time
- Page layout optimized for standard letter and A4 printing
- This 2008 manual is the primary reference for the EH50PLE-series engine architecture used across the Sportsman 500 range
Contents Summary
This factory service publication provides detailed technical data for maintaining the 2008 Polaris Sportsman 500 and Touring 500 line. The documentation opens with general information and vehicle identification, followed by maintenance schedules for the engine, transmission, and cooling systems. Detailed chapters address engine disassembly and reassembly, fuel system tuning, and suspension adjustments.
Additional sections document the electrical system architecture, including stator output and power distribution modules. Parts and lubrication requirements are clearly defined, listing specific viscosity grades and sealant part numbers for the transmission and front gearcase. The manual also includes a comprehensive glossary of terms and understanding factory workshop documentation to assist owners and technicians.
Technical Preview
The 2008 Polaris Sportsman 500 engine oil capacity is specified at 2 quarts (1.9 L) using 2W-50 synthetic oil. Transmission fluid capacity is documented at 32 oz. (948 ml) in the drivetrain data section. Valve clearance for the intake and exhaust is set at 0.006" (0.15 mm) on a cold engine.
Torque specifications for the cylinder head assembly are detailed in a multi-stage sequence found in the engine data chapter. Crankshaft end play is documented between 0.008" and 0.016" (0.02–0.04 cm). The radiator cap relief pressure is listed as 13 PSI (89.6 kPa) in the cooling system technical table. Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions.
An official Polaris OEM service manual covering the 2008 Sportsman 500, 500 EFI, 500 HO, and Touring 500 EFI, documenting engine, chassis, transmission, and fuel-injection specifications for the EH50PLE-series build.
Manual FAQ, Purchase & Download Details
Customer Reviews
Read what our customers say about this Polaris ATV manual and share your own experience.