This service manual is designed prim arily for use by ce rtified Polaris Mas ter 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 procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain pro cedur es require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be d irected to: Service Publications Dept. @ Polaris Sales Inc. 2100
Hwy 55 Medina Minnesota 55340.
publication. Depictions and/or procedures in this publ ication are intended f or reference use only. No liability can be accepted for omission s or inaccuracies. Any r eprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
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.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
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
The machine model number must be used with any correspondence regarding warranty or service.
A07 MN 50 AU
Engine Designation Numbers
EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start
V ehicle Identification Number (VIN)
World
Mfg. ID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A M N 5 0 A * 7 P 0 0 0 0 0 0
Vehicle Descriptor
}
Vehicle Identifier
Body Style
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.
Engine
Powertrain
Emissions
The transmission I.D.number is located on top of
the transmission snorkel, right side of machine.
Model
Year
Check Digit
Plant No
Individual Serial Number
* This could be either
a number or a letter
The machine serial number is stamped on the lower left side of the frame tube (B).
1.2
Publications
GENERAL INFORMATION
Table 1-1: Publications
YearModelModel No.
A07MN50A
2007Sportsman 500 EFI
2007Sportsman X2 500 EFI
2007Sportsman 450 EFIA07MH46A99206299920557N/A
2007
Sportsman X2 500 EFI
Quadricycle
A07MH50A (Standard)
A07MH50F (Standard Intl’)
A07TN50A
A07TH50A (Standard)
A07MH46E99206509920899N/A
(Deluxe)
(Deluxe)
Owner's
Manual PN
99203649920365N/A
99206329920902N/A
Parts
Manual PN
Paint Codes
Table 1-2: Paint Codes
PAINTED PART
Sportsman FrameBlack9440P-067
COLOR
DESCRIPTION
DITZLER
NUMBER
Replacement Keys
1
Parts
Micro Fiche PN
POLARIS
NUMBER
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.
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’ MODELItem LocationSPORTSMAN ‘STANDARD’ MODEL
Winch1No Winch
PXT Tires2Titan Tires
PVT w/EBS3Non-EBS (X2 excluded)
Rear Work Lights4No Work Lights
Front Drive w/ Active Descent Control (ADC)5No Active Descent Control (ADC)
Speed Sensor Wiring for ADC6No Sensor Wiring Change
Rear Rack Extension7No Rack Extension
Cast Aluminum Wheels8Steel Wheels
Single Exhaust9Single Exhaust
Wire Harness w/ Active Descent Control (ADC)10Standard Wire Harness
PDM w/ Active Descent Control (ADC)10Standard PDM
3
7
10
9
4
1
5
6
Deluxe Model Pictured
8
1.4
2
GENERAL INFORMATION
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’ MODELItem LocationX2 ‘STANDARD’ MODEL
Winch1No Winch
Rear Work Lights2No Work Lights
Front Drive w/ Active Descent Control (ADC)3No Active Descent Control (ADC)
Cast Aluminum Wheels4Steel Wheels
1
2
1
3
Standard Model Pictured
4
1.5
GENERAL INFORMATION
2007 SPORTSMAN 450
Model Number: A07MH46AA, AZ
Engine Model: EH46PLE
Table 1-4: Sportsman 450 General
Specifications
CategoryDimension / Capacity
Length83 in./211 cm
Width48 in./122 cm
Height48 in./122 cm
Wheel Base50.5 in./128.3 cm
Ground Clearance11 in./27.94 cm
Dry Weight715 lbs./324 kg
Gross Vehicle Weight1210 lbs./549 kg
Front Rack Capacity90 lbs./40.8 kg
Rear Rack Capacity180 lbs./81.6 kg
Towing Capacity1225 lbs./555.6 kg
Body StyleSpirit
Hitch Tongue Capacity120 lbs./54.4 kg
1.6
GENERAL INFORMATION
Table 1-5: Sportsman 450
ENGINE
PlatformFuji Single Cylinder
Engine Model NumberEH46PL E010
Engine Displacement455cc
Number of Cylinders1
Bore & Stroke (mm)87.9 x 75 mm
Compression Ratio9.8:1
Compression Pressure50-90 psi
Engine Idle Speed
Engine Max Operating Rpm
Cooling System / CapacityLiquid - 2.25 qt / 2.1 ltr
Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC
(Standard Models)(Deluxe Models)(International)
Engine Model: EH50PLE
Table 1-9: Sportsman 500 EFI General
Specifications
CategoryDimension / Capacity
Length83 in./211 cm
Width48 in./122 cm
Height48 in./122 cm
Wheel Base50.5 in./128.3 cm
Ground Clearance11.25 in./28.6 cm
Dry Weight715 lbs./324 kg
Gross Vehicle Weight1200 lbs./544 kg
Front Rack Capacity90 lbs./40.8 kg
Rear Box Capacity180 lbs./81.6 kg
Towing Capacity1225 lbs./555.6 kg
Body StyleSpirit
Hitch Tongue Capacity120 lbs./54.4 kg
1.8
GENERAL INFORMATION
Table 1-10: Sportsman 500 EFI
ENGINE
PlatformFuji Single Cylinder
Engine Model NumberEH50PL E210
Engine Displacement499cc
Number of Cylinders1
Bore & Stroke (mm)92 x 75 mm
Compression Ratio
Transmission TypeDrumshift - H/L/N/R/P
Transmission Capacity32 oz. / 948 ml
Front Gearcase Capacity- CH8.97 / 265 ml
Front Gearcase Capacity- ADC9.3 / 275 ml
Gear Ratio : Low
Rev
High
Front Drive
Clutch TypePVT (Standard Models)
PVT w/EBS (Deluxe Models)
Belt3211113 EBS
23.91:1
21.74:1
10.57:1
3.82:1
3211077 Non-EBS
Steering / Suspension
Front Suspension / Shock A-arm / MacPherson Strut
Front Travel8.2 in. / 20.8 cm
Rear Suspension / Shock Progressive Rate Independent -
Coil - over shock
Rear Travel9.5 in. / 24.13 cm
Ground Clearance11 in. / 27.94 cm
Shock Preload Adjustment
Front / Rear
Turning Radius65 in./165.10 cm unloaded
Toe Out0-1/16 in / .0 - .159 mm
Front -Non Adjustable.
Rear - Ratchet Style- Std.
Wheels / Brakes
Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156
Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156
Recommended Air PressureFront & Rear - 5 psi
Brake - FrontDual Hydraulic Disc
Brake - RearSingle Hydraulic Disc
Brake FluidDOT - approved only
Table 1-12: Sportsman 500 EFI Clutching
AltitudeShift
M e t e r s
(Feet)
0-1800
(0-6000)
1800-3700
(6000-12000)
Weight
10 WH
(5630710)
10 RH
(5630709)
Drive
Clutch
Spring
Blu/Green
(7041157)
Blu/Green
(7041157)
Driven
Clutch
Spring
White/Yel
(7041635)
White/Yel
(7041635)
Helix*
*No
Adjustment
EBS
(5131674)
EBS
(5131674)
1
1.9
GENERAL INFORMATION
2007 SPORTSMAN X-2 500 EFI
Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA
CategoryDimension / Capacity
Length93 in./236 cm
Width48 in./122 cm
Height48 in./122 cm
Wheel Base57 in./145 cm
Ground Clearance11 in./28 cm
Dry Weight798 lbs./362 kg
Gross Vehicle Weight1500 lbs./680 kg
Front Rack Capacity90 lbs./40.8 kg
Rear Box Capacity400 lbs./81.6 kg
Towing Capacity1225 lbs./555.6 kg
Body StyleSpirit
Hitch Tongue Capacity120 lbs./54.4 kg
Rear box capacity and tongue weight
not to exceed 400 lbs./181kg
1.10
GENERAL INFORMATION
Table 1-14: Sportsman X2 500 EFI
ENGINE
PlatformFuji Single Cylinder
Engine Model NumberEH50PL E210
Engine Displacement499cc
Number of Cylinders1
Bore & Stroke (mm)92 x 75 mm
Compression Ratio10.2:1
Compression Pressure60-90 psi
Engine Idle Speed
Engine Max Operating Rpm
Cooling System / CapacityLiquid - 2.5 qt / 2.4 ltr
Transmission TypeDrumshift - H/L/N/Rev/Park
Transmission Capacity32 oz. / 948 ml
Front Gearcase Capacity- CH8.97 / 265 ml
Front Gearcase Capacity- ADC9.3 / 275 ml
Gear Ratio : Low
Rev
High
Front Drive
Clutch TypePVT w/EBS
Belt3211113
23.91:1
21.74:1
10.57:1
3.82:1
Steering / Suspension
Front Suspension / Shock A-arm / MacPherson Strut
Front Travel8.2 in. / 20.8 cm
Rear Suspension / Shock Progressive Rate Independent -
Coil - over shock
Rear Travel8.75 in. / 22.2 cm
Ground Clearance11 in. / 28 cm
Shock Preload Adjustment
Front / Rear
Turning Radius82 in./208 cm unlocked
Toe Out0-1/16 in / .0 - .159 mm
The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine
areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.
ft. lbs.x 12= in. lbs.
in. lbs.x .0833= ft. lbs.
ft. lbs.x 1.356= Nm
in. lbs.x .0115= kg-m
Nmx .7376= ft. lbs.
kg-mx 7.233= ft. lbs.
kg-mx 86.796= in. lbs.
kg-mx 10= Nm
in.x 25.4=mm
mmx .03937= in.
in.x 2.54= cm
mile (mi.)x 1.6= km
kmx .6214= mile (mi.)
Ounces (oz.)x 28.35= Grams (g)
Fluid Ounces (fl. oz.)x 29.57= Cubic Centimeters (cc)
Cubic Centimeters (cc)x .03381= Fluid Ounces (fl. oz.)
Grams (g)x 0.035= Ounces (oz.)
lb.x .454= kg
kgx 2.2046= lb.
Cubic inches (cu. in)x 16.387= Cubic centimeters (cc)
Cubic centimeters (cc)x 0.061= Cubic inches (cu. in)
Imperial pints (Imp pt.)x 0.568= Liters (l)
Liters (l)x 1.76= Imperial pints (Imp pt.)
Imperial quarts (Imp qt.)x 1.137= Liters (l)
Liters (l)x 0.88= Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.)x 1.201= US quarts (US qt.)
US quarts (US qt.)x 0.833= Imperial quarts (Imp qt.)
US quarts (US qt.)x 0.946= Liters (l)
Liters (l)x 1.057= US quarts (US qt.)
US gallons (US gal)x 3.785=Liters (l)
Liters (l)x 0.264= US gallons (US gal)
Pounds - force per square inch (psi)x 6.895= Kilopascals (kPa)
Kilopascals (kPa)x 0.145= Pounds - force per square inch (psi)
Kilopascals (kPa)x 0.01= Kilograms - force per square cm
Kilograms - force per square cmx 98.1= Kilopascals (kPa)
(3.14)xR
2
x H (height)= Cylinder Volume
°C to °F: 9 (°C + 40) 5 - 40 = °F
°F to °C: 5 (°F + 40)
9 - 40 = °C
1.14
Glossary Of Terms
GENERAL INFORMATION
ABDC: After bottom dead center.
ACV: Alternating current voltage.
ADC: Active Descent Control.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between
centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare
wire touching the chassis).
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Ft. lb. / Foot Pound: A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
Left Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a m agnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040,.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
PDM: Power Distribution Module.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
RPM:
Revolutions per minute.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat.
Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylin der wall.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication
of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operatio ns.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can ind icate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determin e th e cau se or se e you r dea ler.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance :
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or e xte nded idle. M ore preven tat ive maint ena nce is r equire d
under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For
engine oil, short trip cold weather riding also constitutes se vere use. Pay specia l attention to oil lev el. A rising
oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)
2
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked with
a
could result in component failure and lead to
serious injury or death. Have an authorized Polaris
dealer perform these services.
2.3
MAINTENANCE
Periodic Maintenance Chart
ItemMaintenance Interval
(whichever comes first)
HoursCalendarMiles
(KM)
Steering-Pre-Ride-
Front-suspension-Pre-Ride-
Rear-suspension-Pre-Ride-
Tires-Pre-RideBrake fluid level-Pre-Ride-
Brake lever travel-Pre-Ride-
Brake systems -Pre-RideWheels /fasteners-Pre-RideFrame fasteners-Pre-Ride-
Engine oil level-Pre-Ride-
E
Passenger Seat Lock Out-Pre-Ride-Verify Seat is secured
Dump Box Operation-Pre-Ride-Verify Box is latched
Air filter, pre-filter-Daily-Inspect; clean often
E
Air box sediment tube-Daily-Drain deposits when visible
E
Coolant-Daily-
Headlamp/tail lamp-DailyAir filter,
main element
E
Recoil housing-Weekly-
Brake pad wear10 H Monthly60 (100)Inspect periodically
Battery20 HMonthly125 (200)Check terminals; clean; test
Front gearcase oil (if