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2007 POLARIS SPORTSMAN 450 , 500 EFI , 500 X2 X-2 EFI SERVICE MANUAL DIY FACTORY SERVICE , REPAIR , MAINTENANCE MANUAL 07 - NOW !


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2007 POLARIS SPORTSMAN 450 / 500 EFI / 500 X2 X-2 EFI SERVICE MANUAL * DIY (DO-IT-YOURSELF) FACTORY SERVICE / REPAIR / MAINTENANCE MANUAL 07 - DOWNLOAD NOW !

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SERVICE DOCUMENT CONTAINS:
===

GENERAL 1
MAINTENENCE 2
ENGINE 3
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EFI X-2 EFI Repair Service Shop Manual Models Covered: 2007 Polaris Sportsman 450 2007 Polaris Sportsman 500 EFI
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FUEL SYSTEM 4
BODY / SUSPENSION 5
CLUTCH 6
TRANSMISSION 7
FINAL DRIVE 8
BRAKES 9
ELECTRICAL 10
INTERNATIONAL 11

DETAILED INDEX:
===

A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 10.24
Active Descent Control Gearcase . . . . . . . . . . . . . . . . . . 7.22
ADC Gearcase Piston Service . . . . . . . . . . . . . . . . . . . . 7.27
ADC Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.23
ADC reservoir level inspection . . . . . . . . . . . . . . . . . . . 2.18
Air Filter, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Alignment, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.24
All Wheel Drive and Speedometer Troubleshooting Tests . .
10.19
Alternator / Ignition Components . . . . . . . . . . . . . . . . . 10.29
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
ATV Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . 2.36
B
Ball Joint Replacement, Front . . . . . . . . . . . . . . . . . . . . 5.19
Battery Activation, Conventional . . . . . . . . . . . . . . . . . 10.57
Battery Charging Procedure, Low Maintenance . . . . . 10.62
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60
Battery Load Test, Low Maintenance . . . . . . . . . . . . . 10.62
Battery Off Season Storage . . . . . . . . . . . . . . . . . . . . . 10.59
Battery Off Season Storage, Low Maintenance . . . . . . 10.59
Battery Open Circuit Voltage (OCV), Low Maintenance . . .
10.62
Battery Removal / Inspection, Conventional . . . . . . . . 10.58
Battery Specific Gravity Tes, Conventional . . . . . . . . . 10.59
Battery Terminals/Bolts . . . . . . . . . . . . . . . . . . . . . . . . 10.58
Battery, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
Battery, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Body and Steering Torque Values . . . . . . . . . . . . . . . . . . 5.2
Body Assembly Exploded View . . . . . . . . . . . . . . 5.12, 5.13
Body Rack Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.14
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Burnishing Procedure . . . . . . . . . . . . . . . . . . . . . . 9.12
Brake Caliper Exploded View . . . . . . . . . . . . . . . . . . . . . 9.5
Brake Caliper Removal, Rear . . . . . . . . . . . . . . . . 9.21, 9.23
Brake Caliper, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9.24
Brake Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Brake Disc, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Brake Light / Work Light Switch Replacement . . . . . . 10.40
Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Pad Install, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Brake Pad Removal, Rear . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Brake Pad, Removal and Installation . . . . . . . . . . . . . . . 9.10
Brake System Components, Std, Sportsman . . . . . . . . . . 9.4
Brake System Components, X2 . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Exploded View, International . . . . . . . . . 11.3
Brake System Exploded Views . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Overview, International . . . . . . . . . . . . . . 11.2
Brake, Master Cylinder Removal . . . . . . . . . . . . . . . . . . . 9.9
Brake, Rear Auxiliary Brake . . . . . . . . . . . . . . . . . . . . . 9.28
Brake, Rear Auxiliary Master Cylinder . . . . . . . . . . . . .9.26
Brake, Torque Specifications . . . . . . . . . . . . . . . . . . . . . .9.2
Brakes, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
Brakes, Operation Overview . . . . . . . . . . . . . . . . . . . . . . .9.6
Brakes, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .9.29
C
Cam Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
Cam Chain Tensioner, Inspection . . . . . . . . . . . . . . . . . .3.14
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
Camshaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
Carburetor (BST34) Exploded View . . . . . . . . . . . . . . . .4.33
Carburetor Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
Carburetor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
Carburetor Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
Carburetor, Air/Fuel Ratio . . . . . . . . . . . . . . . . . . . . . . .4.38
Carburetor, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
Carburetor, Choke System . . . . . . . . . . . . . . . . . . . . . . .4.36
Carburetor, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.40
Carburetor, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .4.39
Carburetor, Float Adjustment . . . . . . . . . . . . . . . . . . . . .4.42
Carburetor, Float System . . . . . . . . . . . . . . . . . . . . . . . . .4.37
Carburetor, Idle System . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
Carburetor, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
Carburetor, Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
Carburetor, Main System . . . . . . . . . . . . . . . . . . . . . . . .4.37
Carburetor, Needle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
Carburetor, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
Carburetor, Pilot Screw . . . . . . . . . . . . . . . . . . . . . . . . . .4.38
Carburetor, Throttle Opening vs. Fuel Flow . . . . . . . . . .4.39
Cargo Box, Removal and Installation . . . . . . . . . . . . . . .5.26
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.60
Charging System - Break Even Test . . . . . . . . . . . . . . .10.32
Charging System Flow Chart . . . . . . . . . . . . . . 10.30, 10.34
Choke System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Clutch, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6.36
Clutching Chart . . . . . . . . . . . . . . . . . . . . . . . . 1.6, 1.8, 1.10
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
Component Locations, Sportsman . . . . . . . . . . . . . . . . . .2.7
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
Controls, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
Coolant Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . .10.26
Coolant, Level Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.20
Coolant, Recommended Ratio . . . . . . . . . . . . . . . . . . . . . .3.8
Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . .3.7
Cooling System Specifications . . . . . . . . . . . . . . . . . . . . .3.6
Cooling System, Maintenance . . . . . . . . . . . . . . . . . . . . .2.19
Counter Balancer Endplay Adjustment . . . . . . . . . . . . . .3.38
Counter Balancer, Removal and Inspection . . . . . . . . . .3.34
Crankcase Breather Filter, Service . . . . . . . . . . . . . . . . .2.22
Crankcase Separation . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
Crankshaft Endplay Adjustment . . . . . . . . . . . . . . . . . . .3.37
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . .4.17
IX.2
Crankshaft Position Sensor Gap . . . . . . . . . . . . . . . . . .10.31
Crankshaft Straightening . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Crankshaft, Removal and Inspection . . . . . . . . . . . . . . . .3.35
Current Draw - Key Off Test . . . . . . . . . . . . . . . . . . . .10.32
CV Boot, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
CV Boot, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
CV Carburetor System Function . . . . . . . . . . . . . . . . . . .4.35
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.19
Cylinder Head Torque Procedure . . . . . . . . . . . . . . . . . .3.45
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
D
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.17
Diagnostic Mode, EFI System . . . . . . . . . . . . . . . . . . .10.17
Differential Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .10.36
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
Drive Belt, Removal/Inspection . . . . . . . . . . . . . . . . . . .6.12
Drive Clutch Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Drive Clutch Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Drive Clutch, Standard Service . . . . . . . . . . . . . . . . . . . .6.28
Drive Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . .7.4
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Driven Clutch, Standard Service . . . . . . . . . . . . . . . . . . .6.34
E
EBS Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . .6.15
EBS Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . .6.22
EBS Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 6.4, 6.5
EBS, Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . .6.7
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . .4.10
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . .4.11
Electrical Service Notes . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Electrical, Service Notes . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Electrical, Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .10.3
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . .4.12
Elelctrical, Troubleshooting Diagrams . . . . . . . . . . . . .10.52
Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . .4.24
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . .3.13
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Engine Oil, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .4.22
Engine Temperature Sensor Replacement . . . . . . . . . . .4.22
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . .4.22
Engine, Fastener Torque Patterns . . . . . . . . . . . . . . . . . . .3.3
Engine, Lubrication Requirements . . . . . . . . . . . . . . . . .3.11
Engine, Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.23
Engine, Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . .2.25
Engine, Torque Specifications . . . . . . . . . . . . . . . . . . . . .3.3
Engine, Valve Clearance / Adjustment . . . . . . . . . . . . . .2.25
ETC Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
ETC Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
F
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.25
Fan Control Circuit Operation / Testing . . . . . . . . . . . 10.25
Fan Motor Current Draw . . . . . . . . . . . . . . . . . . . . . . . 10.25
Final Drive Torque Specifications . . . . . . . . . . . . . . . . . . 7.2
Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.31
Foot Well Removal / Installation . . . . . . . . . . . . . . . . . . . 5.5
Front Cab Removal / Installation . . . . . . . . . . . . . . . . . . . 5.9
Front Cover Removal / Installation . . . . . . . . . . . . . . . . . 5.4
Front Drive Axle Installation . . . . . . . . . . . . . . . . . . . . . . 7.4
Front Drive Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Front Gearcase - Back Lash Pad Adjustment . . . . . . . . 7.18
Front Gearcase Coil Resistance . . . . . . . . . . . . . . .7.14, 7.23
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.12
Front Gearcase, Active Descent Control Exploded View 7.21
Front Gearcase, Diagnoses . . . . . . . . . . . . . . . . . . . . . . . 7.19
Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.13
Front Gearcase, Exploded View . . . . . . . . . . . . . . . . . . 7.11
Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.20
Front Gearcase, Operation . . . . . . . . . . . . . . . . . . . . . . . 7.11
Front Gearcase, Reassembly . . . . . . . . . . . . . . . . . . . . . 7.29
Front Gearcase, Reassembly / Inspection . . . . . . . . . . . 7.17
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Front Hub, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Front Hub, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Front Storage Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Front Storage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Fuel Filter, Replacement . . . . . . . . . . . . . . . . . . . .2.17, 4.46
Fuel Gauge Sender, Installation . . . . . . . . . . . . . . . . . . . 4.47
Fuel Gauge Sender, Removal . . . . . . . . . . . . . . . . . . . . . 4.46
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.9
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.8
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.7
Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.5
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Fuel Level Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.13
Fuel Pump, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
Fuel System Special Tools . . . . . . . . . . . . . . . . . . . . . . . 4.32
Fuel System, EFI Circuit Diagrams . . . . . . . . . . . . . . . . 4.26
Fuel System, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Fuel Tank/Fuel Delivery System . . . . . . . . . . . . . . . . . . 4.44
G
Gear Position Indicator Switch Test . . . . . . . . . . . . . . 10.26
Gearcase, ADC Hydraulic Fluid Change . . . . . . . . . . . . 2.14
Gearcase, Front Capacity and Fluid Type . . . . . . . . . . . . 7.2
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
IX.3
IX H
Handlebar Block Installation Procedure . . . . . . . . . . . . . 5.16
Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Headlight Housing Replacement . . . . . . . . . . . . . . . . . 10.37
Headlight Pod Exploded View . . . . . . . . . . . . . . . . . . . . 5.15
High Beam Bulb Replacement . . . . . . . . . . . . . . . . . . . 10.36
High Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.38
Hydraulic Brake System Operation Overview . . . . . . . . . 9.6
I
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
Ignition System Troubleshooting . . . . . . . . . . . . . . . . . 10.31
Instrument Cluster (Speedometer) Overview . . . . . . . . 10.13
Instrument Cluster Diagnostic Mode . . . . . . . . . . . . . . 10.14
Instrument Cluster Overview . . . . . . . . . . . . . . . . . . . . 10.13
Instrument Cluster, Setting New Service Interval . . . . 10.16
K
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
L
Low Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.39
Low Maintenance Battery Charging . . . . . . . . . . . . . . . 10.61
Low Maintenance Battery Info . . . . . . . . . . . . . . . . . . . 10.61
Lower Headlamp Housing Removal . . . . . . . . . . . . . . 10.39
Lower Headlamp Removal . . . . . . . . . . . . . . . . . . . . . . 10.38
Lubricants/Fluids, Polaris Brand Part Numbers . . . . . . . . 2.9
Lubricants/Fluids, Polaris Brand Symbol Identification Chart
2.10
M
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
Maintenance, General Information . . . . . . . . . . . . . . . . . . 2.3
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Mikuni Jet Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . 4.32
Misc. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Model Number Information . . . . . . . . . . . . . . . . . . . . . . . 1.2
N
Needle and Seat, Leakage Test . . . . . . . . . . . . . . . . . . . . 4.42
O
Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Oil Flow, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pressure Test, Engine . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pump Priming Procedure . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pump Shaft Endplay Adjustment . . . . . . . . . . . . . . . 3.39
Oil Pump, Removal and Inspection . . . . . . . . . . . . . . . . 3.33
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Passenger Seat, Operation . . . . . . . . . . . . . . . . . . . . . . . 5.29
PDM, 450 and 500 EFI Overview . . . . . . . . . . . . . . . . . 10.5
PDM, 450 Connector Pin Table . . . . . . . . . . . . . . . . . . 10.11
PDM, X2/EFI Connector Pin Table . . . . . . . . . . . . . . . . 10.7
Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . 3.30, 3.43
Plastic Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
Power Distribution Module . . . . . . . . . . . . . . . . . . . . . . .10.5
Pre-ride Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
PVT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Drive Clutch Shift Weights . . . . . . . . . . . . . . . . . . .6.9
PVT Drive Clutch Specifications . . . . . . . . . . . . . . . . . . .6.8
PVT Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3
PVT Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . .6.7
PVT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Overheating Chart . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
PVT Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .6.37
PVT, Button to Tower Clearance . . . . . . . . . . . . . 6.17, 6.30
PVT, Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT, Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT, Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . .6.13
PVT, Drive Belt Removal/Inspection . . . . . . . . . . . . . . .6.12
PVT, Drive Clutch Disassembly . . . . . . . . . . . . . . 6.15, 6.28
PVT, Drive Clutch Exploded View . . . . . . . . . . . . . . . . . .6.3
PVT, Drive Clutch Reassembly . . . . . . . . . . . . . . 6.20, 6.32
PVT, Drive Clutch Spider Removal . . . . . . . . . . . 6.15, 6.29
PVT, Driven Clutch Bushing Service . . . . . . . . . . . . . . .6.24
PVT, Driven Clutch Disassembly . . . . . . . . . . . . . . . . . .6.22
PVT, Driven Clutch Reassembly . . . . . . . . . . . . . . . . . .6.25
PVT, EBS Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .6.7
PVT, EBS Drive Clutch Bushing Service . . . . . . . 6.18, 6.31
PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.19,
6.32
PVT, Moveable Sheave Inspection . . . . . . . . . . . . 6.18, 6.31
R
Radiator Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . .3.7
Radiator Screen Removal . . . . . . . . . . . . . . . . . . . . . . . .5.11
Rear Cab Removal / Installation . . . . . . . . . . . . . . . . . . .5.10
Rear Master Cylinder, Exploded View . . . . . . . . . . . . . .9.26
Rear Rack Removal / Installation . . . . . . . . . . . . . . . . . . .5.8
Rear Storage Removal / Installation . . . . . . . . . . . . . . . .5.11
Rear Suspension Assembly . . . . . . . . . . . . . . . . . . 5.22, 5.23
Recoil Housing, Draining / Inspection . . . . . . . . . . . . . .2.22
Recoil, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
Recoil, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
S
Shift Linkage Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
Solenoid, Differential . . . . . . . . . . . . . . . . . . . . . . . . . .10.36
Spark Plug, Inspection / Replacement . . . . . . . . . . . . . . .2.18
Special Tools, Body & Steering . . . . . . . . . . . . . . . . . . . .5.2
IX.4
Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Special Tools, Speed Sensor . . . . . . . . . . . . . . . . . . . . .10.42
Specificaiton, Stator Plate Bolt Torque . . . . . . . . . . . . . .3.49
Specification, Brake Disc Service Limit . . . . . . . . . . . . .9.25
Specification, Brake Disc Thickness . . . . . . . . . . . . . . . .9.25
Specification, Brake Pad Thickness . . . . . . . . . . . . . . . .9.19
Specification, Cam Chain Stretch . . . . . . . . . . . . . . . . . .3.32
Specification, Cam Chain Tensioner Spring . . . . . . . . . .3.15
Specification, Camshaft Lobe Height . . . . . . . . . . . . . . .3.18
Specification, Crankcase Bolt Torque . . . . . . . . . . . . . . .3.41
Specification, Crankshaft Slotted Nut Torque . . . . . . . .3.43
Specification, Cylinder Compression . . . . . . . . . . . . . . .2.17
Specification, Cylinder Head Torque Procedure . . . . . . .3.45
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.21
Specification, Cylinder Taper . . . . . . . . . . . . . . . . . . . . .3.29
Specification, Cylinder Warp . . . . . . . . . . . . . . . . . . . . .3.28
Specification, Differential Solenoid Resistance 10.36, 10.42
Specification, Differential Solenoid Torque . . . 10.36, 10.42
Specification, Drill and Tap Sizes . . . . . . . . . . . . . . . . . .1.13
Specification, Flywheel Nut Torque . . . . . . . . . . . . . . . .3.49
Specification, Fuel Pump Pressure . . . . . . . . . . . . . . . . .4.13
Specification, Oil and Filter . . . . . . . . . . . . . . . . . . . . . .2.23
Specification, Oil Pip Bolt Torque . . . . . . . . . . . . . . . . .3.50
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.34
Specification, Oil Pump Shaft Endplay . . . . . . . . . . . . . .3.39
Specification, One Way Valve Spring Length . . . . . . . .3.32
Specification, Piston to Cylinder Clearance . . . . . . . . . .3.29
Specification, PVT Center-to-Center Distance . . . . . . . .6.13
Specification, PVT Component Torque Table . . . . . . . . .6.2
Specification, PVT Drive Belt Width . . . . . . . . . . . . . . .6.13
Specification, Rocker Arm and Shaft . . . . . . . . . . . . . . .3.15
Specification, Rocker Shaft Bolt Torque . . . . . . . . . . . .3.50
Specification, Spark Plug Gap . . . . . . . . . . . . . . . . . . . .2.18
Specification, Speed Sensor Bolt Torque . . . . . . . . . . .10.42
Specification, Tensioner Blade Bolt Torque . . . . . . . . . .3.43
Specification, Transmission Silent Chain Length . . . . . .8.17
Specification, Valve Clearance . . . . . . . . . . . . . . . 2.26, 3.26
Specification, Valve Guide Height . . . . . . . . . . . . . . . . .3.23
Specification, Valve Stem and Guide . . . . . . . . . . . . . . .3.22
Specifications, Body and Steering Torque Values . . . . . .5.2
Specifications, Brake Component Service Limits . . . . . . .9.2
Specifications, Brake Component Torque Values . . . . . .9.2
Specifications, Engine Fastener Torque . . . . . . . . . . . . . .3.3
Specifications, Engine Service Data . . . . . . . . . . . . . . . . .3.4
Specifications, Final Drive Torque Values . . . . . . . . . . . .7.2
Specifications, Front Gearcase Lubrication Type/Capacity 7.2
Specifications, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
Specifications, Power Distribution Module . . . . . . . . .10.10
Specifications, Standard Torque Values . . . . . . . . . . . . .1.12
Specifications, Vehicle . . . . . . . . . . . . . . . . . . 1.6, 1.8, 1.10
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.42
Speedometer Installation . . . . . . . . . . . . . . . . . . . . . . . .10.18
Speedometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . .10.18
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . 10.19
Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . 10.47
Starter Assembly Exploded View . . . . . . . . . . . . . . . . 10.48
Starter Brush Inspection / Replacement . . . . . . . . . . . . 10.46
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Starter Lockout, Troubleshooting . . . . . . . . . . . . . . . . 10.44
Starter Motor Dissassembly / Replacement . . . . . . . . . 10.46
Starter Reassembly / Installation . . . . . . . . . . . . . . . . . 10.48
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . . 10.50
Steering A-Arm Exploded View . . . . . . . . . . . . . . . . . . 5.17
Steering Lock, Exploded View . . . . . . . . . . . . . . . . . . . 11.4
Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Steering Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Steering Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Steering, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Storage Compartment, Latch Operation . . . . . . . . . . . . 2.33
Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
Strut Cartridge Replacement, Front . . . . . . . . . . . . . . . . 5.20
Suspension, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
T
Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.21
Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.21
Throttle, Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 2.15
Tie Rod, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Trail Boss Emissions System . . . . . . . . . . . . . . . . . . . . . 11.5
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Transmission I.D. Information . . . . . . . . . . . . . . . . . . . . . 1.2
Transmission Mounts, Exploded View . . . . . . . . . . . . . . 8.2
Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 8.9
Transmission, Exploded View . . . . . . . . . . . . . . . . . . . . . 8.7
Transmission, Fluid Check / Change . . . . . . . . . . . . . . . 2.13
Transmission, Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Transmission, Output Shaft Backlash Procedure . . . . . . 8.15
Transmission, Reassembly . . . . . . . . . . . . . . . . . . . . . . . 8.14
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Transmission, Special Tools . . . . . . . . . . . . . . . . . . . . . . 8.3
Troubleshooting Diagrams, Elelctrical . . . . . . . . . . . . 10.52
Troubleshooting, EFI Circuit Diagrams . . . . . . . . . . . . . 4.26
Troubleshooting, Engine . . . . . . . . . . . . . . . . . . . . . . . . 3.53
U
U-joint, Disassembly and Assembly . . . . . . . . . . . . . . . . 7.7
V
Valve Clearance Adjustment . . . . . . . . . . . . . . . . .2.26, 3.26
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.23
Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . 1.2
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
W
Warn Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Water Pump Seal, Installation . . . . . . . . . . . . . . . . . . . . 3.41
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
IX.5
IX Wheels, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wheels, Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wheels, Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wire Diagram, Winch Basic . . . . . . . . . . . . . . . . . . . . . 10.51
Wire Diagrams, Electrical . . . . . . . . . . . . . . . . . . . . . . 10.52
Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
X
X2, Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .

---

DESCRIPTION:
===

COVERS ALL MODELS & ALL REPAIRS A-Z

THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. Here you will find the EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.

COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!

YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE PDF Document. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN.

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ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!

---

Parts and searches covered in this document:
===
2007 SPORTSMAN 450,
2007 SPORTSMAN 500 EFI,
2007 SPORTSMAN 500 X2 EFI,
07 POLARIS SPORTSMAN 450,
07 POLARIS SPORTSMAN 500 EFI,
07 POLARIS SPORTSMAN 500 X2 EFI,
2007 POLARIS SPORTSMAN 450, 500 EFI, 500 X2 EFI, 07, 2007, POLARIS, SPORTSMAN, 450, 500, X2, EFI, X-2, fix it, replace, troubleshooting, buy, REPLACE, SPARE PARTS, PARTS

---

PLEASE NOTE:
===

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Tags: 2007 polaris sportsman 450 500 efi 500 x2 x-2 efi service manual, 07, 2007, polaris, sportsman, 450, 500, x2, efi, 2007 sportsman 450, 2007 sportsman 500 efi, 2007 sportsman 500 x2 efi, 07 polaris sportsman 450, 07 polaris sportsman 500 efi, 07 polaris sportsman 500 x2 efi, x-2, 450 500, instant download, service manual, fix it, replace, troubleshooting, buy, download, troubleshoot, spare parts, parts

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