2007-2008 Polaris Sportsman 500 6x6 Service Manual (P/N 9921309, 9921310)

• Covers 2007–2008 Polaris Sportsman 500 6x6 models (A07CL50AA, A07CL50MA, A08CL50AA, A08CL50MA) equipped with the EH50PLE engine.
• Cross-references OEM publication part numbers 9921309 (Owner's Manual) and 9921310 (Parts Manual) within the 2008 supplemental data.
• 277 pages of official factory procedures, featuring 47 torque-specification tables and 35 high-resolution exploded-view diagrams.
• Instant digital download: print the exact pages needed for the shop floor to preserve exploded-view details without ruining the original book with greasy hands.

Drivetrain and Engine Coverage

This documentation breaks down routine maintenance, deep-level engine teardowns, and the specific demands of the 6x6 architecture. It details the H-pattern transmission, shift linkage adjustments, and lubrication protocols for the extended final drive. Engine coverage is comprehensive, outlining top-end disassembly, valve seat reconditioning, and crankshaft straightening limits. Due to the extreme weight and complexities of multi-axle power delivery, always ensure the chassis is safely supported on heavy-duty jack stands before initiating any drivetrain service.

Critical Specifications

Precise tolerances are non-negotiable for the EH50PLE 4-stroke engine. The manual provides dedicated torque values for main cylinder head bolts and crankcase fasteners, alongside exact fluid capacities for the transmission and gearcase. It also outlines essential tuning data, including the 0.9 mm (0.036 in.) spark plug gap, 30° BTDC ignition timing at 5000 RPM, and bleed-down procedures for the 2.13-liter liquid cooling system.