2007 Polaris Sportsman 450, 500 EFI & X2 500 EFI Service Repair Manual

Technical Scope and Documentation

• Covers 2007 Polaris Sportsman 450, 500 EFI, and X2 500 EFI ATVs in Standard, Deluxe, International, and Quadricycle configurations
• Original OEM publication 9920629, 9920364, and 9920632 internal cross-reference set
• Contains 57 detailed exploded-view component diagrams and 18 technical specification tables
• Accessible from your device as soon as the order is placed
• Permanent availability in your purchase account — no re-buy required
• Laid out for standard letter and A4 printing
• OCR text layer lets you jump to a torque spec by keyword
• This 2007 edition remains the primary reference for the EH46PLE and EH50PLE engine family maintenance and reassembly intervals

Engine and Chassis Walkthrough

The 2007 Polaris Sportsman service documentation provides comprehensive coverage for the 450 and 500 EFI engine platforms. Initial chapters establish foundational identification, covering VIN decoding, engine designation numbers, and model-specific component variations. The text details maintenance schedules based on riding conditions, categorizing severe use environments like mud or high-RPM racing. Chapters address fluid specifications for the front gearcase, transmission, and cooling systems, including specialized procedures for the ADC differential hydraulic circuit. Further documentation covers the mechanical inspection of steering components, suspension, and braking systems, alongside storage and transport guidelines for long-term maintenance.

Specification and Reference Data

Engine data includes detailed torque values for the EH50PLE and EH50PLE210 powerplants, with sequence patterns for cylinder head and crankcase assembly. Service limits are documented for piston-to-cylinder clearance, valve-to-guide tolerances, and crankshaft runout. Electrical specifications cover alternator output, fuse ratings, and thermistor resistance values at operating temperatures. The manual provides gear ratios for the transmission and front gearcase, tire pressure settings, and fuel system pressure standards. Reference charts for conversion, tap drill sizes, and general torque guidelines are integrated for shop-floor utility.

Reference only — always consult a certified technician before performing service on this equipment. This official 394-page Polaris OEM manual covers the 2007 Sportsman 450, 500 EFI, and X2 500 EFI, documenting engine, chassis, electrical, and fuel-injection specifications for the EH46PLE and EH50PLE engine series.