2007 Polaris Sportsman 450, 500 EFI & X2 500 EFI Service Repair Manual (P/N 9920629, 9920364, and 9920632)

• Details the 2007 Polaris Sportsman 450, 500 EFI, and X2 500 EFI ATVs in Standard, Deluxe, International, and Quadricycle configurations
• Includes the internal cross-reference set for OEM publications 9920629, 9920364, and 9920632
• Features 57 high-resolution exploded-view component diagrams and 18 technical specification tables
• Serves as the primary reference for maintenance and reassembly intervals on the EH46PLE and EH50PLE engine family

Engine and Chassis Overview

This service documentation breaks down the 450 and 500 EFI platforms. It starts with the basics: VIN decoding, engine designations, and model-specific variations. You will find maintenance schedules tailored to real-world riding conditions, including severe environments like deep mud or high-RPM use. The text maps out fluid specifications for the front gearcase, transmission, and cooling systems, alongside the specialized bleed procedures for the ADC differential hydraulic circuit. The guide also walks through mechanical inspections for steering, suspension, and braking systems, plus prep steps for long-term storage.

Specifications and Reference Data

Expect exact torque values for the EH50PLE and EH50PLE210 powerplants, complete with cylinder head and crankcase tightening sequences. It lists strict service limits for piston-to-cylinder clearance, valve-to-guide tolerances, and crankshaft runout. On the electrical side, the manual maps out alternator output, fuse ratings, and thermistor resistance values at operating temperatures. You also get transmission gear ratios, tire pressure settings, and fuel system pressure standards. Reference charts for conversion, tap drill sizes, and general torque guidelines are integrated for everyday shop utility. While this 394-page manual provides OEM-level technical depth for the 2007 Sportsman line, these specifications are provided for reference; always ensure you have the proper training or consult a certified technician before tackling major mechanical or hydraulic repairs.