Description
This Official 2007 Polaris Sportsman 450 & 500 EFI Factory Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2007 Polaris Sportsman 500 EFI and 2007 Polaris Sportsman 450 ATVs. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications. Wiring diagrams are included.
2007 Polaris Sportsman 450 500 X2 EFI Repair Manual ATVs Covered
2007 Polaris Sportsman 450
2007 Polaris Sportsman 500 EFI
2007 Polaris Sportsman 500 EFI X2
2007 Polaris Sportsman 450 500 X2 EFI ATV Repair Manual Table of Contents
General Information
Maintenance
Engine
Fuel System
Body / Suspension
Clutch
Final Drive
Transmission
Brakes
Electrical
International
2007 Polaris Sportsman 450 500 X2 EFI ATV Repair Manual Index of Topics
A
A-Arm Replacement
Active Descent Control (ADC) Coil
Active Descent Control Gearcase
ADC Gearcase Piston Service
ADC Gearcase, Disassembly / Inspection
ADC reservoir level inspection
Air Filter, Service
Alignment, Wheel
All Wheel Drive (AWD) Coil
All Wheel Drive and Speedometer Troubleshooting Tests
Alternator / Ignition Components
Alternator Output Test
ATV Cleaning and Storage
B
Ball Joint Replacement, Front
Battery Activation, Conventional
Battery Charging Procedure, Low Maintenance
Battery Load Test
Battery Load Test, Low Maintenance
Battery Off Season Storage
Battery Off Season Storage, Low Maintenance
Battery Open Circuit Voltage (OCV), Low Maintenance
Battery Removal / Inspection, Conventional
Battery Specific Gravity Tes, Conventional
Battery Terminals/Bolts
Battery, Installation
Battery, Maintenance
Body and Steering Torque Values
Body Assembly Exploded View
Body Rack Exploded View
Brake Bleeding
Brake Burnishing Procedure
Brake Caliper Exploded View
Brake Caliper Removal, Rear
Brake Caliper, Assembly
Brake Caliper, Front
Brake Disc, Front
Brake Disc, Inspection
Brake Light / Work Light Switch Replacement
Brake Light Switch
Brake Noise Troubleshooting
Brake Pad Install, Rear
Brake Pad Removal, Rear
Brake Pad, Rear
Brake Pad, Removal and Installation
Brake System Components, Std, Sportsman
Brake System Components, X2
Brake System Exploded View, International
Brake System Exploded Views
Brake System Overview, International
Brake, Master Cylinder Removal
Brake, Rear Auxiliary Brake
Brake, Rear Auxiliary Master Cylinder
Brake, Torque Specifications
Brakes, Inspection
Brakes, Operation Overview
Brakes, Troubleshooting
c
Cam Chain Removal
Cam Chain Tensioner, Inspection
Camshaft Removal
Camshaft Timing
Carburetor (BST34) Exploded View
Carburetor Jetting
Carburetor Operation
Carburetor Venting
Carburetor, Air/Fuel Ratio
Carburetor, Assembly
Carburetor, Choke System
Carburetor, Cleaning
Carburetor, Disassembly
Carburetor, Float Adjustment
Carburetor, Float System
Carburetor, Idle System
Carburetor, Inspection
Carburetor, Jet Needle
Carburetor, Main System
Carburetor, Needle Jet
Carburetor, Operation
Carburetor, Pilot Screw
Carburetor, Throttle Opening vs Fuel Flow
Cargo Box, Removal and Installation
Charging Procedure
Charging System – Break Even Test
Charging System Flow Chart
Choke System
Clutch Alignment
Clutch Offset
Clutch, Troubleshooting
Clutching Chart
Component Locations
Component Locations, Sportsman
Compression Test
Controls, Inspection
Conversion Table
Coolant Sensor Test
Coolant, Level Inspection
Coolant, Recommended Ratio
Cooling System Pressure Test
Cooling System Specifications
Cooling System, Maintenance
Counter Balancer Endplay Adjustment
Counter Balancer, Removal and Inspection
Crankcase Breather Filter, Service
Crankcase Separation
Crankshaft Endplay Adjustment
Crankshaft Position Sensor (CPS)
Crankshaft Position Sensor Gap
Crankshaft Straightening
Crankshaft, Removal and Inspection
Current Draw – Key Off Test
CV Boot, Inspection
CV Boot, Replacement
CV Carburetor System Function
Cylinder Head Removal
Cylinder Head Torque Procedure
Cylinder Honing
Cylinder Installation
Cylinder Removal
D
Decal Replacement
Diagnostic Codes
Diagnostic Mode, EFI System
Differential Solenoid
Drive Belt, Installation
Drive Belt, Removal/Inspection
Drive Clutch Springs
Drive Clutch Weights
Drive Clutch, Operation
Drive Clutch, Standard Service
Drive Shaft Boot Inspection
Driven Clutch, Operation
Driven Clutch, Standard Service
E
EBS Drive Clutch Service
EBS Driven Clutch Service
EBS Exploded View
EBS, Driven Clutch Operation
EFI Operation Overview
EFI Priming / Starting Procedure
Electrical Service Notes
Electrical, Service Notes
Electrical, Special Tools
Electronic Control Unit (ECU)
Elelctrical, Troubleshooting Diagrams
Engine Diagnostic Codes
Engine Disassembly
Engine Exploded Views
Engine Installation Notes
Engine Oil, Inspection
Engine Reassembly
Engine Removal
Engine Service Data
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Fastener Torque Patterns
Engine, Lubrication Requirements
Engine, Oil and Filter Change
Engine, Oil Pump Priming
Engine, Torque Specifications
Engine, Valve Clearance / Adjustment
ETC Operation Test
ETC Switch Operation
F
Fan Control Circuit Operation
Fan Control Circuit Operation / Testing
Fan Motor Current Draw
Final Drive Torque Specifications
Flywheel / Stator Removal
Foot Well Removal / Installation
Front Cab Removal / Installation
Front Cover Removal / Installation
Front Drive Axle Installation
Front Drive Axle Removal
Front Gearcase – Back Lash Pad Adjustment
Front Gearcase Coil Resistance
Front Gearcase Lubrication
Front Gearcase, Active Descent Control Exploded View
Front Gearcase, Diagnoses
Front Gearcase, Disassembly / Inspection
Front Gearcase, Exploded View
Front Gearcase, Installation
Front Gearcase, Operation
Front Gearcase, Reassembly
Front Gearcase, Reassembly / Inspection
Front Gearcase, Removal
Front Hub, Assembly
Front Hub, Disassembly
Front Storage Installation
Front Storage Removal
Fuel Filter
Fuel Filter, Replacement
Fuel Gauge Sender, Installation
Fuel Gauge Sender, Removal
Fuel Injection, Component Locations
Fuel Injection, Exploded View
Fuel Injection, Service Notes
Fuel Injection, Special Tools
Fuel Injector
Fuel Level Test
Fuel Pressure Regulator
Fuel Pump / Tank Assembly
Fuel Pump, Testing
Fuel Sender Test
Fuel System Special Tools
Fuel System, EFI Circuit Diagrams
Fuel System, Inspection
Fuel Tank Location
Fuel Tank/Fuel Delivery System
G
Gear Position Indicator Switch Test
Gearcase, ADC Hydraulic Fluid Change
Gearcase, Front Capacity and Fluid Type
Glossary of Terms
H
Handlebar Block Installation Procedure
Headlamp Switch Test
Headlight Housing Replacement
Headlight Pod Exploded View
High Beam Bulb Replacement
High Beam Headlight Adjustment
Hydraulic Brake System Operation Overview
I
Ignition System
Ignition System Troubleshooting
Instrument Cluster (Speedometer) Overview
Instrument Cluster Diagnostic Mode
Instrument Cluster Overview
Instrument Cluster, Setting New Service Interval
K
Keys, Replacement
L
Low Beam Headlight Adjustment
Low Maintenance Battery Charging
Low Maintenance Battery Info
Lower Headlamp Housing Removal
Lower Headlamp Removal
Lubricants/Fluids, Polaris Brand Part Numbers
Lubricants/Fluids, Polaris Brand Symbol Identification Chart
M
Maintenance Chart
Maintenance Schedule
Maintenance, General Information
MAP Sensor
Mikuni Jet Part Numbers
Misc Tables
Model
Model Number Information
N
Needle and Seat, Leakage Test
o
Oil Flow Chart
Oil Flow, Overview
Oil Pressure Test, Engine
Oil Pump Priming Procedure
Oil Pump Shaft Endplay Adjustment
Oil Pump, Removal and Inspection
P
Paint Codes
Passenger Seat, Operation
PDM, 450 and 500 EFI Overview
PDM, 450 Connector Pin Table
PDM, X2/EFI Connector Pin Table
Pilot System
Piston Identification
Piston Removal
Piston Ring Installation
Plastic Inserts
Power Distribution Module
Pre-ride Checklist
Propshaft, Removal
Publication Numbers
PVT Assembly
PVT Disassembly
PVT Drive Clutch Operation
PVT Drive Clutch Shift Weights
PVT Drive Clutch Specifications
PVT Driven Clutch Operation
PVT Drying
PVT Ducting
PVT Maintenance / Inspection
PVT Operation
PVT Overheating Chart
PVT Special Tools
PVT Torque Specs
PVT Troubleshooting Chart
PVT, Button to Tower Clearance
PVT, Clutch Alignment
PVT, Clutch Offset
PVT, Drive Belt Installation
PVT, Drive Belt Removal/Inspection
PVT, Drive Clutch Disassembly
PVT, Drive Clutch Exploded View
PVT, Drive Clutch Reassembly
PVT, Drive Clutch Spider Removal
PVT, Driven Clutch Bushing Service
PVT, Driven Clutch Disassembly
PVT, Driven Clutch Reassembly
PVT, EBS Clutch Operation
PVT, EBS Drive Clutch Bushing Service
PVT, EBS Drive Clutch Cover Bushing Remove/Install
PVT, Moveable Sheave Inspection
R
Radiator Cap Pressure Test
Radiator Screen Removal
Rear Cab Removal / Installation
Rear Master Cylinder, Exploded View
Rear Rack Removal / Installation
Rear Storage Removal / Installation
Rear Suspension Assembly
Recoil Housing, Draining / Inspection
Recoil, Reassembly
Recoil, Removal
s
Shift Linkage Inspection
Side Panel Removal
Solenoid, Differential
Spark Plug, Inspection / Replacement
Special Tools, Body & Steering
Special Tools, EFI
Special Tools, Engine
Special Tools, Final Drive
Special Tools, Speed Sensor
Specificaiton, Stator Plate Bolt Torque
Specification, Brake Disc Service Limit
Specification, Brake Disc Thickness
Specification, Brake Pad Thickness
Specification, Cam Chain Stretch
Specification, Cam Chain Tensioner Spring
Specification, Camshaft Lobe Height
Specification, Crankcase Bolt Torque
Specification, Crankshaft Slotted Nut Torque
Specification, Cylinder Compression
Specification, Cylinder Head Torque Procedure
Specification, Cylinder Head Warp
Specification, Cylinder Taper
Specification, Cylinder Warp
Specification, Differential Solenoid Resistance
Specification, Differential Solenoid Torque
Specification, Drill and Tap Sizes
Specification, Flywheel Nut Torque
Specification, Fuel Pump Pressure
Specification, Oil and Filter
Specification, Oil Pip Bolt Torque
Specification, Oil Pump Bolt Torque
Specification, Oil Pump Shaft Endplay
Specification, One Way Valve Spring Length
Specification, Piston to Cylinder Clearance
Specification, PVT Center-to-Center Distance
Specification, PVT Component Torque Table
Specification, PVT Drive Belt Width
Specification, Rocker Arm and Shaft
Specification, Rocker Shaft Bolt Torque
Specification, Spark Plug Gap
Specification, Speed Sensor Bolt Torque
Specification, Tensioner Blade Bolt Torque
Specification, Transmission Silent Chain Length
Specification, Valve Clearance
Specification, Valve Guide Height
Specification, Valve Stem and Guide
Specifications, Body and Steering Torque Values
Specifications, Brake Component Service Limits
Specifications, Brake Component Torque Values
Specifications, Engine Fastener Torque
Specifications, Engine Service Data
Specifications, Final Drive Torque Values
Specifications, Front Gearcase Lubrication Type/Capacity
Specifications, Piston
Specifications, Power Distribution Module
Specifications, Standard Torque Values
Specifications, Vehicle
Speed Sensor
Speedometer Installation
Speedometer Removal
Speedometer Troubleshooting Tests
Starter Armature Testing
Starter Assembly Exploded View
Starter Brush Inspection / Replacement
Starter Drive
Starter Drive Removal
Starter Lockout, Troubleshooting
Starter Motor Dissassembly / Replacement
Starter Reassembly / Installation
Starter System Flow Chart
Steering A-Arm Exploded View
Steering Lock, Exploded View
Steering Post Assembly
Steering Post Removal
Steering Torque Values
Steering, Inspection
Storage Compartment, Latch Operation
Strut Assembly
Strut Cartridge Replacement, Front
Suspension, Inspection
T
Thermostat Installation
Throttle Cable
Throttle Position Sensor
Throttle Position Sensor Initialization
Throttle Position Sensor Replacement
Throttle, Linkage Inspection
Tie Rod, Inspection
Trail Boss Emissions System
Transmission
Transmission ID Information
Transmission Mounts, Exploded View
Transmission, Disassembly
Transmission, Exploded View
Transmission, Fluid Check / Change
Transmission, Install
Transmission, Output Shaft Backlash Procedure
Transmission, Reassembly
Transmission, Removal
Transmission, Special Tools
Troubleshooting Diagrams, Elelctrical
Troubleshooting, EFI Circuit Diagrams
Troubleshooting, Engine
u
U-joint, Disassembly and Assembly
V ’
Valve Clearance Adjustment
Valve Seat Reconditioning
Vehicle Identification Number (VIN)
Voltage Drop Test
w
Warn Winch Operation
Water Pump Seal, Installation
Wheel Alignment
Wheels, Removal
Wheels, Tire Pressure
Wheels, Torque Table
Wire Diagram, Winch Basic
Wire Diagrams, Electrical
Work Light Switch
X
X2, Seat Disassembly
