Polaris 2007 Sportsman 500 EF Service Manual

Polaris
Offroad Vehicle
📖  Manuals supported for 6 models of Polaris
  • 2007 Sportsman X2 500 EFI
  • 2007 Sportsman 450 EFI
  • 2008 sportsman 500 efi
  • 2008 sportsman 500 h.o.
  • 2008 sportsman x2
  • 2008 sportsman touring
Table of Contents
  • General information

    5
  • GENERAL

    6
  • Paint codes

    7
  • Sportsman 'deluxe' and 'standard' model component comparison

    8
  • SPORTSMAN X2 'DELUXE' AND 'STANDARD' MODEL COMPONENT

    9
  • SPORTSMAN 450

    10
  • FUEL SYSTEM

    11
  • SPORTSMAN 500 EFI

    12
  • Fuel system

    13
  • SPORTSMAN X-2 500 EFI

    14
  • MISC. NUMBERS/CHARTS

    16
  • SAE TAP DRILL SIZES

    17
  • CONVERSION TABLE

    18
  • GLOSSARY OF TERMS

    19
  • Maintenance chart key

    23
  • Periodic maintenance chart

    25
  • Lubrication / fluids

    27
  • Sportsman x2 component locations

    28
  • Polaris lubricants, maintenance and service products

    29
  • Polaris lubricant symbol identification

    30
  • Lubrication components

    31
  • Front gearcase lubrication

    32
  • Transmission lubrication

    33
  • Adc differential hydraulic circuit fluid change

    34
  • Throttle inspection

    35
  • Fuel lines

    36
  • Fuel filter

    37
  • Cooling system hoses

    39
  • Cooling system pressure test

    40
  • Air box sediment tube

    41
  • Recoil housing

    42
  • Engine oil level

    43
  • Valve clearance

    45
  • Intake valve clearance adjustment

    46
  • Wheel alignment

    47
  • BRAKES

    48
  • Brake system inspection

    49
  • Brake pad inspection

    50
  • Front suspension

    51
  • Wheel, hub, and spindle torque table

    52
  • Frame, nuts, bolts, fasteners

    53
  • Winch operation (if equipped)

    54
  • Atv cleaning & storage

    56
  • Specifications

    61
  • Engine service data

    62
  • General engine service

    64
  • Cooling system

    65
  • Engine removal (typical)

    66
  • Engine installation notes

    67
  • ELECTRICAL

    68
  • Oil flow - eh50pl

    69
  • Eh50pl oil flow diagram

    70
  • Engine disassembly

    72
  • Rocker arm/shaft inspection

    73
  • Camshaft removal

    74
  • Automatic compression release installation

    76
  • Cylinder head removal

    77
  • Cylinder head warp

    79
  • Valve inspection

    80
  • Combustion chamber

    81
  • Cylinder head assembly

    84
  • Piston removal

    86
  • Piston/rod inspection

    87
  • Piston ring installed gap

    88
  • Flywheel/stator removal/inspection

    89
  • One way valve removal

    90
  • Crankcase separation

    91
  • Oil pump assembly

    92
  • Crankshaft removal/inspection

    93
  • Crankcase bearing inspection

    94
  • End play inspection/adjustment

    95
  • Counter balancer shaft end play adjustment

    96
  • Oil pump shaft end play adjustment

    97
  • Engine reassembly

    98
  • Crankcase assembly

    99
  • One way valve installation

    100
  • Piston ring installation

    101
  • Piston installation

    102
  • Cylinder head installation

    103
  • Camshaft timing

    104
  • Cam chain tensioner installation

    107
  • Thermostat installation

    108
  • Recoil disassembly/inspection

    109
  • Recoil assembly

    110
  • Troubleshooting

    111
  • Special tools

    117
  • Efi service notes

    119
  • Efi system exploded view

    120
  • Efi system

    121
  • Fuel tank

    122
  • Initial priming / starting procedure

    123
  • Fuel pump assembly

    125
  • Fuel pump / tank assembly replacement

    126
  • Fuel pressure regulator

    127
  • Fuel filters

    128
  • Crankshaft position sensor test

    129
  • Map sensor test and replacement

    130
  • Idle air control (iac)

    131
  • Throttle position sensor (tps)

    132
  • Throttle position sensor (tps) initialization

    133
  • Engine temperature sensor

    134
  • Fuel system troubleshooting

    135
  • General information and specifications

    144
  • Bst 34 carburetor exploded view 1 of

    145
  • Bst 34 carburetor exploded view 2 of

    146
  • Cv carburetor system function

    147
  • Pilot (idle and slow) system

    148
  • Main system

    149
  • Pilot screw

    150
  • Jet needle

    151
  • Carburetor cleaning

    152
  • Carburetor inspection

    153
  • Needle and seat leakage test

    154
  • Fuel level test

    155
  • Fuel pump

    157
  • Fuel pump inspection and reassembly

    158
  • Sending unit installation

    159
  • Plastic insert removal / installation

    163
  • Side panel removal

    164
  • Foot well removal / installation

    165
  • Front storage installation

    168
  • Front cab/fender removal/installation

    169
  • Sportsman rear cab / fender removal / installation

    170
  • Radiator screen removal

    171
  • Headlight pod exploded view

    175
  • Handlebar block installation procedure

    176
  • Steering / a-arm exploded view

    177
  • A-arm replacement

    178
  • Ball joint replacement

    179
  • Steering post removal

    180
  • Strut assembly

    181
  • Removal / installation

    186
  • X2 seat operation - configuring cargo box for passenger riding

    189
  • Driver seat backrest removal / installation

    190
  • Pvt exploded views

    193
  • Clutch system

    194
  • Engine braking system (ebs) exploded view

    195
  • Pvt system

    196
  • Drive clutch spring

    198
  • Optional shift weights

    199
  • Pvt drying

    200
  • Pvt installation

    201
  • Drive belt installation

    203
  • Clutch alignment

    204
  • Ebs drive clutch service

    205
  • One-way clutch inspection (drive clutch)

    210
  • Ebs driven clutch service

    212
  • Ebs driven clutch reassembly

    215
  • Standard drive clutch

    218
  • Sheave / bushing inspection

    221
  • Drive clutch reassembly

    222
  • Standard driven clutch

    224
  • Pvt troubleshooting

    226
  • Problem, cause and remedy chart

    227
  • Final drive

    230
  • Front hub

    234
  • Prop shaft - front or rear

    235
  • Drive axle exploded views

    238
  • Front gearcase - centralized hilliard (standard models)

    239
  • Gearcase removal

    240
  • Setting ring gear backlash

    246
  • Front gearcase diagnosis

    247
  • Gearcase installation

    248
  • Front gearcase - active descent control (deluxe models)

    249
  • Adc coil testing

    251
  • Adc gearcase piston replacement procedure

    255
  • Rear hub

    260
  • Rear drive (cv) shaft

    263
  • Cv boot replacement

    265
  • Drive shaft and cv joint handling tips

    267
  • Torque specifications

    271
  • Transmission installation

    273
  • Troubleshooting checklist

    274
  • Transmission service

    275
  • Transmission disassembly

    277
  • Transmission assembly

    282
  • Component service limits

    290
  • Brake system exploded views

    291
  • Brake caliper exploded views

    293
  • Hydraulic brake system

    294
  • Brake noise troubleshooting

    295
  • Front master cylinder

    297
  • Front brakes

    298
  • Brake burnishing procedure

    300
  • Removal / replacement

    301
  • Front caliper

    302
  • Rear brake pad

    305
  • X2 pad installation

    306
  • Sportsman rear pad removal

    307
  • X2 rear caliper

    309
  • Sportsman rear caliper

    311
  • Rear brake disc

    313
  • Rear master cylinder

    314
  • X2 rear master cylinder removal and installation

    315
  • Pedal removal and installation

    317
  • Electrical service notes

    322
  • Power distribution modules (pdm)

    323
  • Sportsman 450 overview

    328
  • Instrument cluster diagnostic mode

    332
  • Setting a new service interval

    334
  • Efi diagnostic mode

    335
  • Active descent control (adc) coil

    342
  • Cooling system components

    343
  • Coolant temperature sensor

    344
  • Etc test

    345
  • Ignition system

    346
  • Crankshaft position sensor gap

    349
  • Charging system

    350
  • Charging system testing diagrams

    352
  • Headlight housing relacement

    355
  • High beam headlight adjustment

    356
  • Low beam headlight adjustment

    357
  • Brake light switch test

    359
  • Speed sensor

    360
  • Accessory power

    361
  • Starter system

    362
  • Starter motor removal / disassembly

    364
  • Armature testing

    365
  • Starter solenoid bench test

    366
  • Starter drive

    367
  • Starter system testing flow chart

    368
  • Battery activation

    375
  • Battery removal

    376
  • Low maintenance battery off-season storage

    377
  • Battery load test

    378
  • Low maintenance battery check

    379
  • Low maintenance battery load test

    380
  • INTERNATIONAL

    381