2007-2008 Polaris Sportsman 500 6x6 Service Manual

Diagnostic procedures and component service for the transmission, final drive, and steering systems. Part number A07CL50AA.

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Document Details

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Document Number / Seller:
32001 / Daniel Hicks
File Size:
23.80 MB
File Type:
PDF
Language:
English
Pages:
277
Printable:
Yes
Category:
6x6
Last updated / verified
Dec 24, 2025

Models Covered & Key Technical Specifications

2007-2008 Polaris Sportsman 500 6x6 (A07CL50AA) Service Manual Diagnostic procedures and component service for the transmission, final drive, and steering systems. Part number A07CL50AA.

  • Nominal Weight Data: 1965 lbs. gross vehicle weight establishes the base operating capacity.
  • Prescribed Capacity Limits: 1500 lbs. towing capacity is designed for safe trailer hauling.
  • System Output Density: 250w alternator output defines the electrical power generation capability.
  • Technical Thresholds: 150 lbs. tongue weight is specified as the maximum allowable hitch load.
  • Standard Requirements: 4.25 gallons (16.09L) fuel capacity defines the operational range.
  • Defined Configuration: 6x6 drivetrain establishes the standard drive system architecture.

Manual Description & Preview

Polaris Sportsman 500 6x6 (2007-2008) Service Manual: Official Polaris Sportsman 500 6x6 Diagnostics & Repair Manual - 2007-2008 Transmission-Guide

Technical-Benchmarks: EH500PLE // Design-Core: Sportsman 500 6x6 / ATV Logic // Design-Core: 499cc, 4-stroke, single cylinder.

Documentation sections include:

  • Engine (3.1-3.54)
  • Fuel System/Carburetion (4.1-4.13)
  • Body/Steering/Suspension (5.1-5.16)
  • Clutch (6.1-6.26)
  • Final Drive (7.1-7.30)
  • Transmission (8.1-8.10)

This manual details engine service procedures including top-end and bottom-end disassembly, lubrication, and timing. It covers fuel system components like the Mikuni BST 34 carburetor, including jetting and troubleshooting. Additionally, it documents body, steering, suspension, clutch, final drive, and transmission services, offering exploded views and step-by-step instructions for repairs and maintenance to ensure optimal performance and longevity of your Polaris Sportsman 500 6x6.

FAQ

Calculate the **precise** pressure specifications for the brake system? keyboard_arrow_down

18 ft. lbs. (25 Nm) is the torque for the brake caliper mounting bolts, and 10-12 ft. lbs. (14-17 Nm) for the caliper mounting bracket.

What values for **proper** assembly sequence for the drive clutch? keyboard_arrow_down

200 ft. lbs. (276 Nm) is the torque for the spider, and 90 in. lbs. (10.4 Nm) for the cover screws.

Assess the **standard** service interval parameters for the engine oil? keyboard_arrow_down

Change engine oil every 1st month, 6 months, or 100 hours, with more frequent changes (25-50 hours) recommended for very dirty conditions or short trips in cold weather.

What components are **necessary** for the system architecture of the PVT system? keyboard_arrow_down

The PVT system consists of the drive clutch, driven clutch, and drive belt, with internal components controlling engagement, upshift, and backshift.

Confirm the **recommended** tool requirements for the front hub bearing adjustment? keyboard_arrow_down

13-14 Nm (108-144 in. lbs.) is the torque for the spindle nut after initial tightening and backing off.

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