2007 Polaris Ranger 500 Service & Repair Manual (P/N 9920634 / 9920635)

• Covers the 2007 Polaris Ranger 2x4, 4x4 Carb, and 4x4 EFI models equipped with the single-cylinder 499 cc SOHC liquid-cooled engine.
• Official Polaris factory reference material (P/N 9920634 for Carb and 9920635 for EFI) for the R07RB and R07RH variants.
• Provides the exact factory-specified clearances and torque settings for the EH50PLE power unit.
• Features 56 individual exploded-view diagrams, 16 maintenance task tables, 14 electrical reference specifications, and 4 fuel injection diagnostic flow charts.

Service and Maintenance Overview

This comprehensive 344-page official Polaris service manual delivers the exact technical data and maintenance procedures required for the 2007 Polaris Ranger 500 lineup. The material spans ten major sections detailing everything from engine internals to complex electrical system diagnostics. You will find complete reference data for carburetion, EFI tuning, chassis components, steering, and the drivetrain. Need to verify cooling system pressure or review braking system parameters? The exact factory specifications are documented here. Working with these heavy-duty utility vehicles involves high mechanical loads, so relying on this exact factory data is crucial to maintain equipment integrity and ensure personal safety during complex teardowns or rebuilds.

Technical Specifications and Data

Critical reference values for both engine assembly and chassis maintenance are strictly outlined for shop use. For instance, standard engine compression testing should yield 60-90 PSI. Intake and exhaust valve clearance is strictly specified at 0.006 inches (0.15 mm). The documentation also covers exact fluid capacities, listing 15.2 oz. (450 ml) for transmission oil and 18 oz. (532 ml) for the rear gearcase. When reassembling the top end, technicians can reference the precise multi-stage cylinder head bolt tightening sequence along with the final torque values. Standard spark plug gap is set at 0.035-0.036 inches (0.9 mm) across all variants, dependent directly on the specific fuel delivery configuration.