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2007 Sportsman 500 EF
Polaris 2007 Sportsman 500 EF Manuals
Manuals and User Guides for Polaris 2007 Sportsman 500 EF. We have
1
Polaris 2007 Sportsman 500 EF manual available for free PDF download: Service Manual
Polaris 2007 Sportsman 500 EF Service Manual (406 pages)
Atv Polaris 2007 Sportsman 450 / 500 EFI / 500 X2 EFI
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 56.73 MB
Table of Contents
General Information Chapter 1 1
5
Table of Contents
5
Chapter 1
6
Engine and Machine Serial Numbers
6
Engine Designation Numbers
6
General
6
Model Number
6
Model Number Information
6
Transmission I.D. Location
6
Vehicle Identification Number (Vin)
6
Paint Codes
7
Publications
7
Replacement Keys
7
Sportsman 'Deluxe' and 'Standard' Model Component Comparison
8
Sportsman X2 'Deluxe' and 'Standard' Model Component Comparison1.5
9
2007 Sportsman 450
10
Model Number: A07Mh46Aa, Az
10
Fuel System
11
2007 Sportsman 500 Efi
12
Model Number: A07Mh50Ax, Ay, Az / A07Mn50Aq, Af / A07Mh50Fc
12
Fuel System
13
2007 Sportsman X-2 500 Efi
14
Model Number: A07Th50Au, Az / A07Tn50Af, Aq / A07Th50Ea
14
Misc. Numbers/Charts
16
Standard Torque Specifications
16
Sae Tap Drill Sizes
17
Metric Tap Drill Sizes
17
Conversion Table
18
Glossary of Terms
19
Maintenance Chapter 2 Maintenance 2
21
Chapter 2
23
Maintenance
23
Maintenance Chart Key
23
Periodic Maintenance Chart
23
Lubrication / Fluids
27
Sportsman Component Locations
27
Sportsman X2 Component Locations
28
Polaris Lubricants, Maintenance and Service Products
29
Polaris Lubricant Symbol Identification
30
Pre-Ride / Daily Inspection
30
Lubrication Components
31
Front Gearcase Lubrication
32
Transmission Lubrication
33
Adc Differential Hydraulic Circuit Fluid Change
34
Vehicle Inspection
34
Shift Link Rod Inspection
34
Throttle Inspection
35
Fuel System
36
Fuel Lines
36
Vent Lines
36
Fuel Filter
37
Compression Test
37
Engine Mounts
37
Spark Plug
38
Active Descent Control (Adc) Reservoir Level
38
Battery Maintenance
38
Liquid Cooling System Overview
39
Coolant Strength / Type
39
Cooling System Hoses
39
Radiator/Grill Screen
39
Cooling System Pressure Test
40
Coolant Level Inspection
40
Radiator Coolant Level Inspection
40
Air Filter/Pre-Filter Service
40
Air Box Sediment Tube
41
Breather Filter Inspection
42
Breather Hose
42
Recoil Housing
42
Engine Oil Level
43
Oil and Filter Change
43
Oil Pump Priming Procedure
45
Valve Clearance
45
Intake Valve Clearance Adjustment
46
Exhaust Valve Clearance Adjustment
46
Steering
46
Tie Rod End/Steering Inspection
47
Camber and Caster
47
Wheel Alignment
47
Brakes
48
Toe Alignment Adjustment
48
Exhaust Pipe
48
Brake System Inspection
49
Brake Pad Inspection
50
Hose/Fitting Inspection
50
Auxiliary Brake Adjustment (Hydraulic)
50
Auxiliary Brake Testing
50
Controls
51
CV Shaft Boot Inspection
51
Front Suspension
51
Suspension Spring Preload Adjustment
51
Wheels
51
Tire Pressure
52
Wheel Installation
52
Wheel Removal Front or Rear
52
Wheel, Hub, and Spindle Torque Table
52
Frame, Nuts, Bolts, Fasteners
53
Storage Compartments
53
Tire Inspection
53
Winch Operation (if Equipped)
54
Atv Cleaning & Storage
56
Maintenance Schedule
58
Chapter 3 Engine
59
Engine Fastener Torque Patterns
61
Special Tools
61
Specifications
61
Torque Specifications
61
Engine Service Data
62
General Engine Service
64
Piston Identification
64
Cooling System Specifications
64
Cooling System
65
Accessible Components
66
Engine Removal (Typical)
66
Engine Installation Notes
67
Cylinder Hone Selection/ Honing Procedure
67
Honing to Oversize
67
Electrical
68
Cleaning the Cylinder after Honing
68
Crankshaft Straightening
68
Engine Lubrication-EH 50PL
69
Oil Pressure Test - Eh 50Pl
69
Oil Pump Priming Procedure
69
Oil Flow - Eh50Pl
69
Eh50Pl Oil Flow Diagram
70
Eh50Pl Engine Exploded Views
71
Engine Disassembly
72
Cam Chain Tensioner/Rocker Arm/ Camshaft Removal
72
Cam Chain Tensioner Inspection
72
Rocker Arm/Shaft Inspection
73
Camshaft Removal
74
Automatic Compression Release Removal/Inspection
75
Automatic Compression Release Installation
76
Camshaft Inspection
76
Cylinder Head Removal
77
Cylinder Head Exploded View, Eh50Pl
78
Cylinder Head Inspection
79
Cylinder Head Warp
79
Cylinder Head Disassembly
79
Valve Inspection
80
Combustion Chamber
81
Valve Seat Reconditioning
81
Cylinder Head Assembly
84
Valve Sealing Test
84
Valve Clearance Adjustment
84
Cylinder/Piston Removal and Inspection
85
Piston Removal
86
Cylinder Inspection
86
Piston-To-Cylinder Clearance
87
Piston/Rod Inspection
87
Piston Ring Installed Gap
88
Crankcase Disassembly
88
Starter Drive Removal/Inspection
89
Flywheel/Stator Removal/Inspection
89
Cam Chain/Tensioner Blade
90
One Way Valve Removal
90
Crankcase Separation
91
Oil Pump Removal/Inspection
91
Oil Pump Assembly
92
Counter Balancer Shaft Removal/Inspection
92
Crankshaft Removal/Inspection
93
Crankcase Bearing Inspection
94
Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal
94
Crankcase Inspection
94
Bearing Installation
95
End Play Inspection/Adjustment
95
Crankshaft End Play Adjustment
95
Counter Balancer Shaft End Play Adjustment
96
Oil Pump Shaft End Play Adjustment
97
Engine Reassembly
98
Pump Shaft Oil Seal Installation
98
Crankshaft/Counter Balance/Oil Pump Installation
98
Crankcase Assembly
99
Water Pump Mechanical Seal Installation
99
Water Pump Mechanical Seal Removal - Engine Installed
99
One Way Valve Installation
100
Cam Chain Drive Sprocket Installation
101
Tensioner Blade Installation
101
Piston Ring Installation
101
Piston Installation
102
Cylinder Installation
102
Cylinder Head Installation
103
Cam Chain/Camshaft Installation
103
Camshaft Timing
106
Cam Chain Tensioner Installation
107
Stator, Flywheel and Starter Drive Installation
107
Rocker Shaft/Rocker Arm Assembly Installation
108
Thermostat Installation
108
Oil Pipes
108
Recoil
109
Recoil Disassembly/Inspection
109
Recoil Assembly
110
Troubleshooting
111
Spark Plug Fouling
111
Engine
111
Cooling System
112
Fuel Injection Chapter 4 Fuel Injection
115
Chapter 4 Part Numbers / Descriptions
117
Special Tools
117
Efi Service Notes
119
General Service Information
119
Efi System Exploded View
120
Efi System
121
Component Locations/Identification
121
Electronic Fuel Injection
122
General Information
122
Efi Operation Overview
122
Initial Priming / Starting Procedure
123
Fuel Tank
122
Exploded View
122
Fuel Lines
123
Quick Connect Removal/Installation
123
Electronic Control Module (Ecm)
124
Operation Overview
124
Ecm Replacement
124
Ecm Service
124
Fuel Pump Assembly
125
Operation / Testing
125
Fuel Pump Test
125
Fuel Pump / Tank Assembly Replacement
126
Fuel Pressure Regulator
127
General Information
127
Fuel Filters
128
General Information
128
Fuel Injector
128
Crankshaft Position Sensor (Cps)
129
General Information
129
Fuel Injector Replacement
129
Manifold Air Pressure Sensor (Map)
130
Operation Overview
130
Map Sensor Test
130
Crankshaft Position Sensor Replacement
130
Map Sensor Replacement
130
Idle Air Control (Iac)
131
General Information
131
Intake Air Temperature Sensor (Iat)
131
Operation Overview
131
Intake Air Temperature Sensor Test
131
Intake Air Temperature Sensor Replacement
131
Throttle Position Sensor (Tps)
132
Operation Overview
132
Throttle Position Sensor Test
132
Throttle Position Sensor Replacement
133
Throttle Position Sensor (Tps) Initialization
133
Engine Temperature Sensor
134
General Information
134
Engine Temperature Sensor Test
134
Engine Temperature Sensor Replacement
134
Fuel System Troubleshooting
135
Fuel Starvation / Lean Mixture
135
Efi Diagnostics Using 'Blink Codes
136
Blink Codes - Operation
136
Troubleshooting Diagrams
138
Efi Circuit - Power on
138
Efi Circuit - Crank Position Sensor
138
Efi Circuit - Fuel Pump
139
Efi Circuit - Ignition Coil
139
Efi Circuit - Idle Air Control
140
Efi Circuit - Throttle Position Sensor
140
Efi Circuit - Manifold Absolute Pressure Sensor
141
Efi Circuit - Engine Coolant Temperature
141
Efi Circuit - Air Temperature Sensor
142
Efi Circuit - Malfunction Indicator Light
142
Carburetor - Sportsman 450 Chapter 4 Carburetor - Sportsman 450
143
Carburetor - Sportsman 450
144
General Information and Specifications
144
Special Tools
144
Carburetor Jetting
144
Mikuni Jet Part Numbers
144
Carburetor Specifications
144
Carburetion
145
Bst 34 Carburetor Exploded View 1 of 2
145
Bst 34 Carburetor Exploded View 2 of 2
146
CV Carburetor System Function
147
Carburetor Venting
147
Mikuni CV Carb Operation
147
Starter System (Choke or Enrichment)
148
Pilot (Idle and Slow) System
148
Main System
149
Float System
149
Pilot Screw
150
Air/Fuel Mixture Ratio
150
Jet Needle
151
Needle Jet
151
Throttle Opening Vs. Fuel Flow
151
Carburetor Disassembly - Mikuni CV
151
Carburetor Cleaning
152
Carburetor Inspection
153
Carburetor Assembly
153
Float Height Adjustment
154
Needle and Seat Leakage Test
154
Fuel Level Test
155
Fuel Tank/Fuel Delivery System
156
Fuel System Exploded View
156
Fuel Pump
157
Fuel Pump Testing
157
Fuel Pump Disassembly
157
Fuel Pump Inspection and Reassembly
158
Fuel Filter Replacement
158
Fuel Gauge Sending Unit
158
Sending Unit Removal
158
Testing
159
Sending Unit Installation
159
Troubleshooting
159
Fuel Starvation/Lean Mixture
159
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
161
Chapter 5
162
Decal Replacement
162
General Information
162
Special Tools
162
Torque Specifications
162
Plastic Insert Removal / Installation
163
Body
164
Side Panel Removal
164
Front Cover Removal / Installation
164
Foot Well Removal / Installation
165
X2 Foot Well Removal / Installation
165
Front Storage Removal
166
Front Storage Installation
168
Sportsman Rear Rack Removal / Installation
168
Front Cab/Fender Removal/Installation
169
Sportsman Rear Cab / Fender Removal / Installation
170
X2 Rear Quarter Panel Removal / Installation
170
Sportsman Rear Storage Removal / Installation
171
Radiator Screen Removal
171
Sportsman Body Assembly Exploded View
172
X2 Body Assembly Exploded View
173
Body Rack Exploded Views
174
Headlight Pod Exploded View
175
Steering
176
Handlebar Block Installation Procedure
176
Steering / A-Arm Exploded View
177
A-Arm Replacement
178
Ball Joint Replacement
179
Steering Post Removal
180
Steering Post Assembly
180
Suspension
180
Front Strut Cartridge Replacement
180
Strut Assembly
181
Sportsman Rear Suspension Assembly
182
X2 Rear Suspension Exploded View
183
X2 Torsion Bar Exploded View
184
X2 Cargo Box
185
Exploded View
185
Removal / Installation
186
X2 Seat Assembly
188
Exploded Views
188
X2 Seat Operation - Configuring Cargo Box for Passenger Riding
189
Driver Seat Backrest Removal / Installation
190
Passenger Seat Backrest Removal / Installation
190
Clutch System Chapter 6 Clutch System
191
Chapter 6
192
Component Fastener Torques
192
Special Tools
192
Special Tools and Specifications
192
Pvt Exploded Views
193
Pvt Sealing and Ducting Components
193
Drive Clutch Exploded View
193
Engine Braking System (Ebs) Exploded View
195
Pvt System
196
Pvt Operation Overview
196
Drive Clutch Operation
196
Driven Clutch Operation
196
Ebs Clutch Operation
197
Pvt Maintenance / Inspection
197
Drive Clutch Spring
198
Optional Shift Weights
199
Pvt Drying
200
Pvt Disassembly
200
Pvt Installation
201
Drive Belt Removal / Inspection
202
Drive Belt Installation
203
Clutch Alignment
204
Clutch Offset
204
Ebs Drive Clutch Service
205
Drive Clutch Disassembly
205
Spider Removal
205
Button to Tower Clearance Inspection
207
Shift Weight Inspection
207
Drive Clutch Inspection
207
Moveable Sheave Bushing Inspection
208
Drive Clutch Bushing Service
208
One-Way Clutch Inspection (Drive Clutch)
210
Drive Clutch Reassembly
210
Ebs Driven Clutch Service
212
Driven Clutch Disassembly
212
Driven Clutch Bushing Removal/Installation
214
Ebs Driven Clutch Reassembly
215
Standard Drive Clutch
218
Drive Clutch Disassembly
218
Spider Removal
219
Button to Tower Clearance Inspection
220
Shift Weight Inspection
220
Drive Clutch Reassembly
222
Standard Driven Clutch
224
Disassembly
224
Inspection
224
Assembly
225
Pvt Troubleshooting
226
Overheating
226
Problem, Cause and Remedy Chart
227
Final Drive Chapter 7 Final Drive
229
Chapter 7
230
Final Drive
230
Front Drive Axle
230
Removal
230
Installation
232
Gearcase Fluid / Capacity
230
Special Tools
230
Specifications
230
Torque Table
230
Front Drive Shaft (CV) Boot
232
Inspection
232
Replacement
232
Front Hub
234
Disassembly
234
Assembly
234
Prop Shaft - Front or Rear
235
Removal and Installation
235
U-Joint
235
Disassembly
235
Assembly
236
Drive Axle Exploded Views
238
Drive Shafts and Propshafts
238
Front Gearcase - Centralized Hilliard (Standard Models)
239
Exploded View (Standard Models)
239
Operation
240
Gearcase Removal
240
Disassembly / Inspection
241
Reassembly / Inspection
245
Setting Ring Gear Backlash
246
Front Gearcase Diagnosis
247
Gearcase Installation
248
Front Gearcase - Active Descent Control (Deluxe Models)
249
Adc Gearcase Exploded View (Deluxe Models)
249
Operation
250
Adc Coil Testing
251
Adc Differential Hydraulic Circuit Bleeding
251
Disassembly / Inspection
251
Adc Gearcase Piston Replacement Procedure
255
Assembly
257
Rear Hub
260
Removal
260
Disassembly
261
Assembly
262
Installation
262
Rear Drive (CV) Shaft
263
Removal
263
Service
264
CV Boot Replacement
265
Installation
266
Drive Shaft and CV Joint Handling Tips
267
General Information Chapter 8 General Information
269
Chapter 8
270
General Information
270
Mounting Exploded View
270
Transmission - General
270
Gear Selector Removal
271
Lubrication
271
Special Tools
271
Torque Specifications
271
Transmission Removal
271
Transmission Installation
273
Troubleshooting Checklist
274
Transmission Service
275
Exploded View
275
Transmission Disassembly
277
Transmission Assembly
282
Brakes Chapter 9 Brakes
289
Chapter 9
290
Component Service Limits
290
Specifications
290
Torque Table
290
Brake System Exploded Views
291
X2 System Component Exploded View
291
Sportsman System Component Exploded View
292
Brake Caliper Exploded Views
293
Sportsman and X2 Front Caliper Assembly
293
X2 Rear Caliper Assembly
293
Sportsman Rear Caliper Assembly
294
Hydraulic Brake System
294
Operation Overview
294
Brake Noise Troubleshooting
295
Brake Bleeding / Fluid Change
295
Front Master Cylinder
297
Removal
297
Installation
297
Front Brakes
298
Pad Removal
298
Assembly
299
Brake Burnishing Procedure
300
Front Brake Disc
300
Inspection
300
Removal / Replacement
301
Front Caliper
302
Removal
302
Inspection
303
Reassembly
303
Installation
304
Rear Brake Pad
305
X2 Pad Removal
305
X2 Pad Installation
306
Sportsman Rear Pad Removal
307
Sportsman Rear Pad Installation
308
Brake Burnishing Procedure
308
X2 Rear Caliper
309
Removal
309
Inspection
310
Reassembly
310
Sportsman Rear Caliper
311
Removal and Inspection
311
Assembly
312
Rear Brake Disc
313
Inspection
313
Rear Master Cylinder
314
X2 Exploded View
314
Overview
315
X2 Rear Master Cylinder Removal and Installation
315
Sportsman Rear Master Cylinder Removal / Installation
316
Pedal Removal and Installation
317
Troubleshooting
317
Brakes Squeal
317
Poor Brake Performance
317
Lever Vibration
317
Caliper Overheats (Brakes Drag)
317
Brakes Lock
317
Chapter 10 Electrical
319
General Information
321
Ignition System / Basic Electrical Components
321
Special Tools
321
Electrical Service Notes
322
Troubleshooting
322
Power Distribution Modules (Pdm)
323
Sportsman Efi Overview
323
Sportsman 450 Overview
328
Instrument Cluster
331
Overview
331
Instrument Cluster Diagnostic Mode
332
Setting a New Service Interval
334
Efi Diagnostic Mode
335
Speedometer Removal
336
Speedometer Installation
336
All Wheel Drive and Speedometer Troubleshooting
337
Test 1 - no All Wheel Drive
337
Test 2 - no Speedometer Display
338
Test 3 - no Reverse Speed Limit
338
Test 4 - no Awd Hub Safety Limit
339
Test 5 - Reverse Speed Limiter Activated in Forward Gear
340
Test 6 - Wheel Speed Sensor
340
Test 7 - Fuel Gauge Display Not Working
341
Test 8 - Shift Indicator Not Working
341
Active Descent Control (Adc) Coil
342
Operation Overview
342
Diagnosing System Failures
342
All Wheel Drive (Awd) Coil
342
Cooling System Components
343
Fan Control Circuit Operation
343
Fan Control Bypass Test
343
Fan Motor Current Draw Test
343
Coolant Temperature Sensor
344
Gear Position Indicator Switch
344
Test Diagram
344
Electronic Throttle Control (Etc) Switch
345
Operation Overview
345
Etc Test
345
Ignition System
346
Overview
346
Components of Efi Alternator and DC / CDI Ignition System
347
Efi Ignition System Testing Flow Chart
348
Crankshaft Position Sensor Gap
349
Ignition Troubleshooting
349
Ignition Output Test Using Gap Tester
349
Charging System
350
Current Draw - Key off
350
Break Even Test
350
Alternator Output Test
350
Charging System Testing Diagrams
352
Differential Solenoid
354
Testing
354
Replacement
354
Lighting
354
High Beam Headlight Bulb Replacement
354
Headlight Housing Relacement
355
High Beam Headlight Adjustment
356
Lower Headlamp Removal / Installation
356
Low Beam Headlight Adjustment
357
Headlamp Switch Test
357
Work Light Switch
358
Brake Light / Work Light Replacement
358
Brake Light Switch Test
359
Fuel Sender
360
Speed Sensor
360
Testing
360
Replacement
360
Accessory Power
361
Wire Connections
361
Starter System
362
Troubleshooting
362
Voltage Drop Test
362
Starter Lockout Troubleshooting- Sportsman
362
Starter Lockout Troubleshooting- Efi Models
362
Starter Lockout Diagram- Efi
363
Starter Motor Removal / Disassembly
364
Brush Inspection / Replacement
364
Armature Testing
365
Starter Solenoid Bench Test
366
Starter Exploded View
366
Starter Drive
367
Pinion Gear - Anti-Kick out Shoe, Garter Spring Replacement
367
Starter System Testing Flow Chart
368
Basic Winch Wiring
369
Pre-Wired Models
369
Troubleshooting Diagrams
370
Power on - Efi
370
Start Circuit - Efi
370
Ignition Coil - Efi
371
Fuel Pump - Efi
371
Fan - Efi
372
Charging System - Efi
372
All Wheel Drive - Efi
373
Transmission Switch - Efi
373
Reverse Override - Efi
374
Differential Solenoid - X2
374
Battery
375
Battery Identification
375
Battery Activation
375
Terminal Preparation
376
Battery Removal
376
Battery Installation
376
Off Season Storage
377
Low Maintenance Battery Off-Season Storage
377
Battery Testing
377
Conventional Battery Ocv - Open Circuit Voltage Test
377
Conventional Battery Specific Gravity Test
377
Battery Load Test
378
Charging Procedure
378
Low Maintenance Battery Check
379
Low Maintenance Battery Charging
379
Low Maintenance Battery - Ocv- Open Circuit Voltage Test
380
Low Maintenance Battery Load Test
380
Low Maintenance Battery Charging Procedure
380
International
381
500 Efi International / Quadricycle Brake System
382
Exploded View
383
500 Efi International / Quadricycle Steering Post and Lock
384
Steering Assembly Exploded View
384
500 Efi Quadricycle Emissions System
385
Overview
385
Quadricycle Electrical
386
Turn / Hazard Signal Diagram
386
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