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

This manual covers 2007 Polaris Sportsman 450, 500 EFI, and X2 500 EFI models with comprehensive repair procedures for engine, fuel system, and drivetrain. Includes diagnostic codes and troubleshooting.

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Document Details

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Document Number / Seller:
31962 / Ronald Hernandez
File Size:
22.86 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
Dec 9, 2025

Models Covered & Key Technical Specifications

Expert Operations Hydraulic Manual: Polaris Sportsman 450, 500 EFI, and X2 500 EFI Comprehensive Service Manual (2007) Calibration-Manual Model & Serial Data: A07MH46AA, AZ // Engine Specs: EH46PLE Logic // System Capacity: 2.1 L Engine Designation: EH46PLE, EH50PLE Vehicle Identification: VIN Tire Size: 25x8-12 Front / 25x11-12 Rear Fuel Capacity: 4.25 US gal / 19.9 liters Engine Oil Capacity: 2 qt. / 1.9 ltr Ignition Timing: 30°± 2° BTDC @ 5000 RPM

Professional Workshop Service Manual & Technical Specifications

Expert Operations Hydraulic Manual: Polaris Sportsman 450, 500 EFI, and X2 500 EFI Comprehensive Service Manual (2007) Calibration-Manual

Assembly-Group: A07MH46AA, AZ // Diagnostic-Area: EH46PLE // Assembly-Group: 2.1 L

Identifier Value Calibration-Standards
Engine Designation EH46PLE, EH50PLE N/A
Vehicle Identification VIN N/A
Tire Size 25x8-12 Front / 25x11-12 Rear N/A
Fuel Capacity 4.25 US gal / 19.9 liters N/A
Engine Oil Capacity 2 qt. / 1.9 ltr N/A
Ignition Timing 30°± 2° BTDC @ 5000 RPM N/A

Factory procedures are documented for:

Fuel System

Ignition System

Engine Components

Clutch System

Suspension Components

This manual provides thorough coverage for engine, fuel, and ignition systems, including detailed procedures for component removal, inspection, and installation. It covers engine disassembly, assembly, and calibration for optimal performance and longevity, ensuring your vehicle operates efficiently and reliably.

FAQ

Check the **standard** torque for the drive clutch retaining bolt. keyboard_arrow_down

40 ft.lbs. (54 Nm) is the standard torque specification for the drive clutch retaining bolt, ensuring proper clutch assembly.

What are the **necessary** adjustment procedures for the throttle position sensor? keyboard_arrow_down

To adjust the TPS, set the throttle body idle stop, verify the 9-volt battery is new, and check the voltage output of the TPS reads 1.10 - 1.14 vdc. If it does not read correctly, loosen the screws and rotate the TPS until the correct voltage is achieved, then re-tighten the screws.

Reference the **recommended** air filter replacement interval. keyboard_arrow_down

It is recommended that the air filter and pre-filter be replaced annually, or more frequently if riding in extremely dusty conditions. Proper placement of the air filter is important to prevent rattles and air leaks.

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Reviews (5)

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The information is well-organized and the illustrations are clear. Customer support was quick to respond to my questions.
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This manual has been a lifesaver for my ATV maintenance. The troubleshooting section is particularly helpful!
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Rated 4 out of 5 stars
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Whether you're a pro or just getting started, this manual covers everything you need. Excellent service, I had no issues downloading it!
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I had a smooth download process and received the link almost instantly. The manual is very detailed and easy to follow!