Download 2007 Polaris Sportsman 450/500 EFI Repair Manual PDF
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🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman
Year:
2007
Trim Levels Covered:
450 EFI, 500 EFI, X2 500 EFI
Vehicle Type:
All-Terrain Vehicle (ATV)
👋 Introduction
Market Position
Positioning:
High-performance utility ATV aimed at recreational and working use.
Competitive Analysis
Competitors:
Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Can-Am Outlander, Kawasaki Brute Force
Key Features
Engine Type:
Liquid-cooled, SOHC, Electronic Fuel Injection (EFI)
Suspension Type:
Independent Front Suspension (IFS) and Independent Rear Suspension (IRS) on most models
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD option
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and Maintenance
Target Audience:
Professional Technicians, DIY Mechanics
Page Count
Estimated Page Count:
Varies (typically 500+ pages for comprehensive ATV repair manuals)
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, fuel system (EFI), ignition, cooling, lubrication, starting, charging
Drivetrain:
Transmission, final drive, differential, drive shafts, CV joints, AWD system
Suspension:
Front and rear suspension, shocks, springs, control arms, bushings
Brakes:
Hydraulic brake system, master cylinder, calipers, pads, lines, parking brake
Electrical:
Wiring diagrams, lighting, battery, starter, alternator, sensors, EFI control unit, diagnostics
Chassis And Body:
Frame, plastics, body panels, seating, handlebars, storage
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, inspections
Repair:
Component removal, disassembly, cleaning, assembly, installation, adjustment
Troubleshooting:
Diagnostic procedures, fault codes, common issues and solutions
Diagnostics:
EFI system diagnostics, electrical system troubleshooting, engine performance analysis
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine overhaul and advanced diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (typical for high-quality PDFs)
Printable:
Yes
Print Quality
Quality:
High-resolution scans/digital creation, designed for clarity of text and diagrams
Binding Type
Binding:
Not applicable (digital download)
Paper Type
Paper Type:
Not applicable (digital download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 4-valve
Displacement 450:
450cc
Displacement 500:
499cc
Performance
Horsepower 500 Approx:
Approximately 30-35 HP (subject to tuning and specific model variant)
Torque 500 Approx:
Approximately 28-32 lb-ft (subject to tuning and specific model variant)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Cooling System
Cooling Method:
Liquid-cooled
Ignition System
Ignition Type:
Electronic Ignition (CDI)
🔧 Transmission
Standard
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with engine braking
Optional
Gear Selection:
High, Low, Neutral, Reverse, Park
Features
Drive Modes:
2WD / AWD On-Demand
📐 Dimensions
Exterior
Length Approx:
83.5 inches
Width Approx:
48 inches
Height Approx:
47 inches
Weights
Dry Weight Approx:
650-700 lbs (depending on model variant)
Towing Capacity Approx:
1500 lbs
Rack Capacity Front Approx:
200 lbs
Rack Capacity Rear Approx:
400 lbs
Tires
Front Tire Size Std:
AT 25 x 8-12
Rear Tire Size Std:
AT 25 x 10-12
Wheels
Wheel Bolt Pattern:
4x110mm
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable (ATVs are not subject to standard automotive crash testing ratings)
Active Features
Braking System:
Hydraulic disc brakes front and rear, parking brake
Drive System Safety:
On-Demand AWD for enhanced traction
Passive Features
Lighting:
Dual headlights, brake light/taillight
Operator Controls:
Handlebar controls, throttle lever, brake levers, gear selector
💡 Technology Features
Infotainment
Infotainment System:
Not applicable (utility ATV focus, minimal infotainment)
Driver Assistance
Traction Control:
On-Demand AWD system provides enhanced traction
Connectivity
Connectivity Features:
Not applicable
Efi System
Efi Benefits:
Improved throttle response, better fuel efficiency, easier starting in various conditions, altitude compensation.
🔧 Maintenance
Service Intervals
Oil Change Interval Engine:
Every 100 hours or 12 months, whichever comes first (refer to manual for exact specifications).
Air Filter Cleaning:
Inspect every 25 hours, clean as needed. Replace if damaged.
Spark Plug Replacement:
Refer to manual, typically every 12 months or as per wear.
Fluid Specifications
Engine Oil Type:
SAE 5W-50 Synthetic (Polaris recommends specific proprietary oil, but compatible synthetics are common)
Engine Oil Capacity:
Approximately 2.0 quarts (refer to manual)
Coolant Type:
Ethylene Glycol-based antifreeze (50/50 mix with distilled water)
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 GL-5 gear oil)
Known Issues
Common Issues:
CV joint wear, drive belt wear, potential electrical connector issues, battery drainage (with age/use).
📚 Vehicle History
Brand Heritage
Heritage:
Polaris is a long-standing manufacturer of powersports vehicles, known for innovation in ATVs and snowmobiles.
Model Evolution
Evolution Sportsman:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving with independent suspension, EFI, and advanced AWD systems over the years.
Production
Manufacturing Location:
USA (Primarily Spirit Lake, Iowa, and Roseau, Minnesota)
🏆 Awards & Recognition
Recognitions
Atv Awards:
Polaris Sportsman models have historically received positive reviews for their utility and performance, though specific awards for the 2007 450/500 EFI may not be widely documented as distinct entities.
Polaris is a long-standing manufacturer of powersports vehicles, known for innovation in ATVs and snowmobiles.
Model Evolution
Evolution Sportsman:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving with independent suspension, EFI, and advanced AWD systems over the years.
Production
Manufacturing Location:
USA (Primarily Spirit Lake, Iowa, and Roseau, Minnesota)
🏆 Awards & Recognition
Recognitions
Atv Awards:
Polaris Sportsman models have historically received positive reviews for their utility and performance, though specific awards for the 2007 450/500 EFI may not be widely documented as distinct entities.
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