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

• Coverage and publication identity: A 277-page PDF whose model pages identify the 2007 Sportsman 500 6x6 (A07CL50AA, A07CL50MA) and 2008 Sportsman 500 6x6 (A08CL50AA, A08CL50MA). The engine is identified as EH500PLE, with EH50PLE/EH50PL used in engine-section headings. This is Polaris Service Manual P/N 9921312; Owner's Manual P/N 9921309 and Parts Manual P/N 9921310 are cross-referenced companion publications, not additional manuals in the file.
• Engine repair coverage: Covers removal and installation, cooling-system pressure testing and bleeding, oil-pressure testing and pump priming, top- and bottom-end disassembly, valve-seat service, cylinder honing, crankshaft runout inspection and straightening, crankcase and bearing assembly, and sealed recoil repair.
• Transmission and 6x6 final drive: Details the H-pattern shift selector and linkage, transmission removal and internal repair, PVT clutch and belt service, electric AWD hub and Hilliard clutch work, front axle and prop-shaft service, U-joints, front housing, middle axle and housing, and rear axle and chain-drive components.
• Chassis, suspension, and brakes: Addresses dump-box and body removal, A-arm and concentric swingarm work, rear strut stabilizer, front strut cartridge and ball joint replacement, steering service, dual hydraulic brake bleeding, master-cylinder repair, pad and caliper service, disc inspection, and brake troubleshooting.
• Fuel and electrical diagnosis: Provides Mikuni BST 34 carburetor and fuel-pump repair, jetting guidance, PDM and instrument-cluster diagnosis, speed-sensor and gear-position switch testing, ETC and DC/CDI checks, charging-system tests, battery service, lighting repair, and starter fault isolation.
• Factory reference material: Supplies assembly-specific torque data, approved lubricants and capacities, clearance and wear limits, electrical test specifications, troubleshooting charts, exploded views, system schematics, and the 2008 Sportsman 6x6 wiring diagrams.

This is shop-level documentation suited to experienced technicians and well-equipped owners who are comfortable with precision measurement, electrical testing, and factory specifications. The PVT chapter expressly limits clutch maintenance and repair to trained Polaris Master Service Dealer technicians using authorized tools, so that work should not be treated as a beginner procedure.

Engine and Fuel-System Work

The engine chapter is organized around inspection and repair decisions, not just scheduled maintenance. It covers cylinder-head warpage checks; rocker, camshaft, valve, guide, and seat inspection; piston, ring, cylinder, connecting-rod, and crankshaft measurements; counterbalancer and oil-pump end play; water-pump mechanical-seal work; cam timing; flywheel and stator service; and final engine assembly. Oil-flow charts support lubrication diagnosis, while the cooling section combines routing information with pressure-test, bleeding, and overheat troubleshooting coverage.

The BST 34 chapter explains CV carburetor and vent-system operation before moving into disassembly, cleaning, inspection, assembly, float adjustment, needle-and-seat leakage testing, fuel-level checking, and fuel-pump service. Maintenance pages also cover valve-clearance adjustment, compression testing, shift-linkage adjustment, drive-chain service, front-hub lubrication, steering alignment, and suspension inspection.

6x6 Drivetrain and Chassis Detail

This is genuine 6x6-specific material rather than a generic four-wheel ATV chapter. The final-drive section explains electric front-hub engagement through the magnetic coil, armature plate, roller cage, and Hilliard clutch, then carries the repair coverage through hub bearings and seals, CV boots, the front prop shaft, U-joints, front gearcase, middle axle and housing, and rear drive axle. The transmission troubleshooting checklist helps separate external linkage, idle, lubricant, belt, and adjustment problems from worn internal gear dogs or bearings.

Body and suspension drawings cover the dump box, body assembly, headlight pod, front storage box, steering assembly, rear strut stabilizer, and strut assembly. Brake material extends from hydraulic-system operation and bleeding to master-cylinder, caliper, pad, and disc repair, followed by burnishing and drag/noise diagnosis.

Diagnostics, Tools, and Repair Cautions

Useful diagnostic graphics include the EH50PL oil-flow chart, BST 34 fuel-flow diagram, PDM schematic, ignition and charging test flowcharts, starter-system test chart, and the two-page 2008 Sportsman 6x6 wiring-diagram set with harness and connector information. The electrical chapter also covers instrument-cluster diagnostic mode, warning indicators, service-interval reset, coolant-sensor testing, fan current draw, CDI output, alternator output, and starter-motor inspection.

Application-specific tools are identified by number, including clutch puller 2870506, drive-clutch spider tool 2870341, clutch-offset alignment tool 2870654, seal-sleeve installation kit 2871199, and Hilliard garter-spring tool 2870888.

The manual warns that shimming the drive-clutch spring can stack the coils and break the clutch cover. It also notes that pulling an installed front hub outward can disengage the armature-plate tabs and damage the roller clutch; applying heat during rear-axle straightening destroys the shaft temper and can leave it brittle. Securely support the 6x6 under the specified frame or footrest area before wheel, hub, axle, or brake repair that requires the vehicle to be raised.