2007 POLARIS SPORTSMAN 450 / 500 EFI / 500 X2 X-2 EFI Service Manual * DIY FACTORY Service / Repair / Maintenance Manual 07 - DO

2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFI SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some p rocedures o utlined in this man ual re quire a so und kn owledge o f m echanical th eory, too l us e, and sh op procedures in order to perform the work safely and c orrectly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. 2007 Sportsman 450 / 500 EFI / 500 X2 EFI Service Manual PN 9920560

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION

1 GENERAL 2 MAINTENENCE 3 ENGINE 4 FUEL SYSTEM 5 BODY / SUSPENSION 6 CLUTCH 7 TRANSMISSION 8 FINAL DRIVE 9 BRAKES 10 ELECTRICAL 11 INTERNATIONAL

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPORTSMAN ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON . . 1.4 SPORTSMAN X2 ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON1.5 2007 SPORTSMAN 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL NUMBER: A07MH46AA, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2007 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL NUMBER: A07MH50AX, AY, AZ / A07MN50AQ, AF / A07MH50FC. . . . . . . . . 1.8 2007 SPORTSMAN X-2 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 MODEL NUMBER: A07TH50AU, AZ / A07TN50AF, AQ / A07TH50EA . . . . . . . . . . . . 1.10 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

1.2 GENERAL INFORMATION MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Vehicle Identification Number (VIN) Transmission I.d. Location Engine And Machine Serial Numbers The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. The machine serial number is stamped on the lower left side of the frame tube (B). A 07 MN 50 AU } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier } Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 4 X A M N 5 0 A * 7 P 0 0 0 0 0 0 The transmission I.D.number is located on top of the transmission snorkel, right side of machine.

1.3 GENERAL INFORMATION 1 Publications Paint Codes Replacement Keys Replacement keys can be made from the original key (Phoenix excluded). To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required. Table 1-1: Publications Year Model Model No. Owner's Manual PN Parts Manual PN Parts Micro Fiche PN 2007 Sportsman 500 EFI A07MN50A (Deluxe) A07MH50A (Standard) A07MH50F (Standard Intl’) 9920364 9920365 N/A 2007 Sportsman X2 500 EFI A07TN50A (Deluxe) A07TH50A (Standard) 9920632 9920902 N/A 2007 Sportsman 450 EFI A07MH46A 9920629 9920557 N/A 2007 Sportsman X2 500 EFI Quadricycle A07MH46E 9920650 9920899 N/A Table 1-2: Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman Frame Black 9440 P-067 Table 1-3: Key Numbers Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Cover PN 5433534

1.4 GENERAL INFORMATION Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘STANDARD’ MODEL Winch 1 No Winch PXT Tires 2 Titan Tires PVT w/EBS 3 Non-EBS (X2 excluded) Rear Work Lights 4 No Work Lights Front Drive w/ Active Descent Control (ADC) 5 No Active Descent Control (ADC) Speed Sensor Wiring for ADC 6 No Sensor Wiring Change Rear Rack Extension 7 No Rack Extension Cast Aluminum Wheels 8 Steel Wheels Single Exhaust 9 Single Exhaust Wire Harness w/ Active Descent Control (ADC) 10 Standard Wire Harness PDM w/ Active Descent Control (ADC) 10 Standard PDM 1 2 3 4 5 6 7 8 9 10 Deluxe Model Pictured

1.5 GENERAL INFORMATION 1 Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL Winch 1 No Winch Rear Work Lights 2 No Work Lights Front Drive w/ Active Descent Control (ADC) 3 No Active Descent Control (ADC) Cast Aluminum Wheels 4 Steel Wheels 1 2 3 4 Standard Model Pictured

1.6 GENERAL INFORMATION 2007 SPORTSMAN 450 Model Number: A07MH46AA, AZ Engine Model: EH46PLE Table 1-4: Sportsman 450 General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11 in./27.94 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1210 lbs./549 kg Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

2007 POLARIS SPORTSMAN 450 / 500 EFI / 500 X2 X-2 EFI Service Manual * DIY FACTORY Service / Repair / Maintenance Manual 07 - DO

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