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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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Polaris Models Covered & Key Technical Specifications

Models: 2007 Polaris Sportsman 500 6x6, 2008 Polaris Sportsman 500 6x6
Sub-models / Variants: A07CL50AA, A07CL50MA, A08CL50AA, A08CL50MA
Build Years: 2007–2008
Technical Data:

  • Engine: Fuji 4-stroke, single-cylinder, L/C, SOHC, electric start
  • Displacement: 499 cc
  • Bore & Stroke: 92 x 75 mm
  • Compression Ratio: 10:2
  • Fuel Capacity: 4.25 gallons (16.09L)
  • Gross Vehicle Weight: 1965 lbs.
  • Towing Capacity: 1500 lbs.
  • Drivetrain: 6x6, H-Pattern transmission (H/L/N/R)
Technical Specifications
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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
Apr 9, 2026

Polaris Manual Features & Content Preview

Technical Scope for the 2007–2008 Polaris Sportsman 500 6x6

  • Covers 2007–2008 Polaris Sportsman 500 6x6 (A07CL50AA, A07CL50MA, A08CL50AA, A08CL50MA) with the EH50PLE engine
  • Original OEM publication P/N 9921309 (Owner's Manual) and 9921310 (Parts Manual) referenced in the 2008 supplemental data
  • Documents transmission, final drive, and steering systems with dedicated chapters for each sub-assembly
  • Contains 47 torque-specification tables and 35 exploded-view mechanical diagrams
  • File delivered as a direct download the moment payment clears
  • Print resolution preserves exploded-view detail for shop-floor reference
  • This 277-page manual provides the official service procedures for the EH50PLE 4-stroke engine and 6x6 drivetrain architecture

Service and Maintenance Documentation

The 2007–2008 Polaris Sportsman 500 6x6 service manual provides technical data for routine upkeep and deep-level repairs. Chapter segments detail periodic maintenance intervals, lubrication protocols for the 6x6 drivetrain, and specific adjustment requirements for the H-pattern transmission and shift linkage. The documentation includes extensive engine-service instructions, encompassing top-end disassembly, valve seat reconditioning, and crankshaft straightening specifications. Additional technical sections provide instructions for the liquid cooling system, covering pressure testing and the bleed-down procedure for the 4-stroke engine.

Specification Highlights

The 2007–2008 Polaris Sportsman 500 6x6 specification tables provide critical values for assembly and service. Torque for the main cylinder head bolts and crankcase fasteners is detailed in the engine section, while specific transmission and gearcase capacities are listed in the drivetrain data. Spark plug gap is specified at 0.9 mm (0.036 in.) and the cooling system capacity is documented at 2.13 liters. Ignition timing is calibrated to 30° BTDC at 5000 RPM. This 277-page official OEM factory manual provides the technical specifications and mechanical diagrams necessary for servicing the 2007–2008 Polaris Sportsman 500 6x6 powertrain and chassis.

Document Reference: Polaris Part No. 9921309 / 9921310 (2008 edition)

Manual FAQ, Purchase & Download Details

Is the electrical wiring schematic included in the service manual? keyboard_arrow_down

Chapter 10 contains electrical information, while the document lists various electrical tools and reference components. It includes diagrams and technical sections designed for reference during system analysis.

Can this document be used for the 2007-2008 Polaris Sportsman 500 6x6 model? keyboard_arrow_down

Service manual is specifically compiled for the 2007-2008 Polaris Sportsman 500 6x6 (A07CL50AA) and provides documentation relevant to its systems.

Does the manual provide comprehensive coverage for the main mechanical systems? keyboard_arrow_down

Document contains chapters covering the engine, carburetion, body and steering, clutching, final drive, transmission, and brakes. Each chapter provides technical reference material for the specified components. These sections include specification tables, exploded view references, and torque guidelines as outlined in the general information chapter.

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