2007 Polaris Sportsman 450, 500 EFI & X2 500 EFI ATV Service Repair Manual (P/N 9920560)

This Polaris service manual (P/N 9920560) covers the 2007 Sportsman 450, Sportsman 500 EFI, and Sportsman X2 500 EFI. Model tables distinguish Standard, Deluxe, International, and Quadricycle configurations, with engine identification for the EH46PLE and EH50PLE families.

Text Search, Bookmarks and Wiring Detail

Finding procedures and circuit details: Main service text is searchable, and embedded PDF bookmarks organize the chapters and wiring appendix. Labels within the image-based wiring diagrams are not searchable. Small, light-gray wire codes and terminal markings require zooming on the diagrams checked.

The manual comes as one printable, English-language, 394-page PDF, including a 12-page wiring appendix. Four notes pages, a maintenance-record page, and two blank pages are already included in the total.

Engine, EFI and Drivetrain Service

The following selected coverage highlights outline major workshop sections rather than the complete contents. Other topics include winch operation and X2 cargo-box and passenger-seat configuration.

• Engine and cooling: Step-by-step procedures for engine removal, cylinder-head service, camshaft timing, crankcase assembly, and water-pump mechanical seal replacement.

• EFI diagnosis: Fuel-pressure testing, sensor checks, throttle position sensor initialization, diagnostic blink codes, and component-specific troubleshooting diagrams.

• Sportsman 450 carburetor: Mikuni BST 34 exploded views, jetting guidance, float inspection, carburetor disassembly, cleaning, and fuel-pump service.

• PVT and EBS clutches: Separate clutch assemblies, belt inspection, alignment, bushing replacement, drive and driven clutch service, and overheating troubleshooting.

• Final drive and transmission: CV boot replacement, Centralized Hilliard and ADC gearcase service, transmission disassembly, reassembly, and output-shaft backlash adjustment.

• Steering, suspension and brakes: MacPherson strut service, control-arm and hub work, caliper overhaul, hydraulic bleeding, and component inspection limits.

• Electrical troubleshooting: PDM specifications, charging and ignition tests, starter-circuit diagnosis, instrument-cluster checks, and model-specific wiring diagrams.

The internal overhaul and electrical diagnosis sections suit technicians familiar with mechanical inspection, test equipment, and workshop procedures.

Engine Inspection and Water-Pump Repair

Engine torque and internal service-data tables are labeled EH50PLE, with EH50PL engine exploded views and an oil-flow diagram. Cylinder-head and crankcase tightening patterns accompany piston-to-cylinder clearances, valve-guide tolerances, crankshaft runout limits, and camshaft timing procedures.

The water-pump section describes mechanical seal replacement on EH50PL engines with the engine installed, using puller P/N 2872105. It warns that careless puller use can bend the pump shaft; replacing that shaft requires engine removal and crankcase separation.

EFI Tests and Carburetor Service

Factory tolerance limits and electrical resistance values help technicians distinguish sensor faults from wiring or connection problems before selecting replacement components. EFI coverage includes the fuel injector, crankshaft position sensor, manifold pressure sensor, idle air control, and engine temperature sensor.

TPS testing and initialization use adapter harness 2201519. The manual warns that altering the factory-set throttle-body idle stop requires replacement of the throttle-body assembly; TPS initialization is a separate procedure.

For EFI models, fuel-pump diagnosis leads to replacement of the pump/tank assembly when faulty. The pressure regulator is also described as sealed and non-serviceable. Some dealer diagnostic checks reference Digital Wrench software and its separate manual.

The Sportsman 450 section instead explains the carburetor’s enrichment, pilot, and main circuits, with temperature- and altitude-related jetting guidance.

Clutches, Gearcases and Chassis

Standard and EBS clutch sections distinguish assembly layouts and service procedures. The manual specifically reserves PVT maintenance and repair for trained, certified Polaris Master Service Dealer technicians using the required special tools.

Centralized Hilliard and ADC gearcase sections include internal inspection and reassembly, with ADC hydraulic-circuit bleeding and piston replacement. Drive Axle Exploded Views support the CV shaft and propshaft procedures.

The Periodic Maintenance Chart identifies severe-use conditions, including mud, water, and sustained heavy-load operation. Steering, suspension, brake inspection, and long-term storage sections provide the related maintenance guidance.

Always ensure you have the proper training or consult a certified technician before tackling major mechanical or hydraulic repairs.

Electrical Diagrams and Reference Tables

The Starter Lockout Diagrams distinguish EFI and Sportsman 450 circuits. Charging System Testing Diagrams and the EFI Ignition System Testing Flow Chart support fault tracing, alongside PDM connector assignments and ADC/AWD coil tests.

Reference material includes alternator output, circuit-protection ratings, thermistor readings, transmission ratios, tire-pressure specifications, fluid capacities, general torque guidelines, conversion tables, and tap-drill charts.

A Preview of EFI Resistance Checks

The EFI fuel-injector test specifies 12.0 Ω ±0.4 Ω at 20°C (68°F). The crankshaft position sensor test uses 185 Ω ±20% at the same temperature.

For the EFI engine coolant temperature sensor, the resistance table gives 37.3–39.2 kΩ at 20°C (68°F), alongside an explanation of how its signal affects fuel, ignition, and fan control.