2008 Polaris Sportsman 500 / 500 EFI / 500 HO / Touring 500 EFI Service Manual
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
Model 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
- 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).
- Serves as the primary reference for the EH50PLE-series engine architecture.
- Documents specific engine, chassis, transmission, and fuel-injection specifications.
- Contains 47 torque tables, 22 mechanical assembly diagrams, 2 electrical component pinout schematics, and 3 engine-specific flow charts.
Contents Summary
This factory service publication provides the exact technical data needed to maintain the 2008 Polaris Sportsman 500 and Touring 500 lineup. It opens with general vehicle identification details, followed immediately by strict maintenance schedules for the engine, transmission, and cooling systems. Chapters break down engine disassembly, fuel system tuning, and suspension adjustments.
Working on the electrical system? The documentation maps out stator output and power distribution modules. Finding the right fluid specs quickly keeps the shop moving. Because of this, the lubrication charts clearly define viscosity grades and OEM sealant part numbers for the transmission and front gearcase. Always wear appropriate personal protective equipment and follow standard shop safety practices when handling chemical fluids or servicing pressurized systems.
Technical Preview
Here is a quick look at some key specifications found inside. The 2008 Sportsman 500 engine requires 2 quarts (1.9 L) of 2W-50 synthetic oil. The transmission takes exactly 32 oz. (948 ml). When setting up the top end, cold engine valve clearance for both the intake and exhaust is 0.006" (0.15 mm).
You will also find multi-stage torque sequences for the cylinder head assembly directly in the engine data chapter. Crankshaft end play sits between 0.008" and 0.016" (0.02–0.04 cm). For routine cooling system checks, the radiator cap relief pressure is listed at 13 PSI (89.6 kPa). Please note that this page only outlines the specifications and sections covered in the manual. It does not provide the actual step-by-step diagnostic or repair procedures.
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