Official Polaris Sportsman 500 6x6 Diagnostics & Repair Manual - 2007-2008
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Sample pages from the Official Polaris Sportsman 500 6x6 Diagnostics & Repair Manual - 2007-2008 manual
Purchase Information
2007-2008 Polaris Sportsman 500 6x6 Service Manual - Technical Specifications
- Document Number / Seller:
- 32001 / Daniel Hicks
- File Size:
- 23.80 MB
- File Type:
- Language:
- English
- Pages:
- 277
- Printable:
- Yes
- Estimated Download Time:
- 0.49 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- 6x6
- Brand:
- Polaris
- Reviewed and Approved:
- Dec 24, 2025
Polaris Models and Parts Covered in this 6x6 Manual
- Sportsman 500 6x6 (2007)
- Sportsman 500 6x6 (2008)
Complete Manual Information
Polaris Sportsman 500 6x6 Service Manual (2007-2008)
Take full control of your maintenance and repair projects with this professional-grade service manual specifically designed for the Polaris Sportsman 500 6x6. This is not just a basic owner's guide; it is the complete technical authority used by master technicians to keep these six-wheeled workhorses in peak condition. Covering the 2007 and 2008 model years, this manual provides the deep-dive technical data you need to ensure your ATV remains reliable, whether you are deep in the woods or on a demanding job site.
Engineered for Precision and Performance
The Sportsman 500 6x6 is a unique machine with a specialized drivetrain and suspension system. This manual breaks down every complex component, including the Fuji 4-stroke single-cylinder engine (499cc) and the sophisticated Polaris Variable Transmission (PVT). You will find exact specifications for the Mikuni BST 34mm carburetor, including factory jetting charts for different altitudes and temperatures, ensuring your engine breathes perfectly in any environment.
Comprehensive Technical Coverage
- Engine Mastery: Full service data for the EH500PLE engine, including valve clearance specs (0.006" for both intake and exhaust), cylinder honing procedures, and detailed piston-to-cylinder clearance tolerances.
- Advanced Drivetrain: Step-by-step instructions for the 6x6-specific middle and rear axle drive chains, including precise slack adjustments (3/8" to 1/2" deflection) and eccentric locking procedures.
- Electric AWD System: Complete breakdown of the Hilliard-style front hub clutch and the electrical Power Distribution Module (PDM) that controls the All-Wheel Drive engagement.
- Liquid Cooling System: Critical bleeding procedures to prevent overheating, pressure testing for the 13-lb radiator cap, and thermistor resistance values for electrical troubleshooting.
- Electrical & Diagnostics: Detailed wiring schematics and a guide to the Instrument Cluster’s Diagnostic Mode, allowing you to check battery voltage, RPM, and gear circuit resistance (Park: 23 Ohms to High: 628 Ohms) directly on your display.
Vehicle Identification and Serial Numbers
For accurate parts ordering and service history, this manual guides you through every critical ID location on your machine:
- Machine Model & Serial Number: Stamped on the lower left side of the frame tube.
- Engine Serial Number: Located on the sticker on the recoil housing (right side) and stamped on the center top of the crankcase beneath the coolant elbow.
- Transmission I.D.: Found on top of the transmission on the right side of the machine.
- VIN Structure: Learn to decode your 17-digit VIN, from the World Mfg. ID to the individual serial number digits.
The Ultimate Resource for Owners and Pros
This manual provides more than just instructions; it offers peace of mind. With standard torque specifications, a complete glossary of terms, and a specialized tool list, you will have the "factory-fresh" knowledge to perform everything from a simple 25-hour break-in oil change to a complete crankshaft straightening or engine rebuild.
Keep your Sportsman 500 6x6 running stronger and longer with the most informative technical resource available!
Applicable Models
- Sportsman 500 6x6 (2007)
- Sportsman 500 6x6 (2008)
Download Instructions for Polaris 6x6 Manual
Frequently Asked Questions - Polaris 6x6 Manual
What does this Polaris manual cover?
This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for Official Polaris Sportsman 500 6x6 Diagnostics & Repair Manual - 2007-2008. It includes information for the following models: - Sportsman 500 6x6 (2007) - Sportsman 500 6x6 (2008).
Is this manual suitable for beginners?
Yes, this Polaris manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for 6x6 maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (23.80 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Polaris 6x6 manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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