POLARIS SPORTSMAN 450 500 EFI ATV Service Repair Manual PDF 2007 Download

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 450 EFI / 500 EFI Year: 2007 Vehicle Type: All-Terrain Vehicle (ATV) Platform: Polaris Sportsman Engine Code Prefix: N/A Chassis Code: A07CH45AA (450), A07CH50AA (500) 👋 Introduction Market Position Segment: Mid-size utility ATV segment, known for versatility and comfort. Target Audience: Recreational riders, farm use, light trail riding, hunting. Competitive Analysis Competitors: Honda Foreman/Rubicon, Yamaha Kodiak/Grizzly, Can-Am Outlander/Commander, Suzuki King Quad. Key Features Feature 1: Polaris's signature independent rear suspension (IRS) for a smoother ride. Feature 2: On-Demand All-Wheel Drive (AWD) system. Feature 3: Electronic Fuel Injection (EFI) for improved throttle response and cold starts. Feature 4: Comfortable seating and ergonomic design. 📋 Manual Details Coverage Areas Primary Coverage: 2007 Polaris Sportsman 450 EFI and 500 EFI ATVs Secondary Coverage: General ATV maintenance, troubleshooting, and repair procedures applicable to closely related models and years. Page Count Estimated Pages: Hundreds (as stated in description) Manual Type Type: Service Repair Manual Purpose: Repair, Maintenance, Rebuild, Refurbish, Restoration Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, overhaul, ignition system, fuel system (EFI), cooling system, lubrication system. Transmission: PVT (Polaris Variable Transmission) operation, belt maintenance, clutch inspection and adjustment, gearcase servicing. Drivetrain: Front and rear drive systems, AWD (All-Wheel Drive) engagement, driveshaft and U-joint servicing, differential maintenance. Suspension: Front and rear suspension components, shock absorber adjustments and replacement, A-arm servicing, wheel bearing maintenance. Brakes: Hydraulic brake system, caliper servicing, pad replacement, fluid bleeding, master cylinder inspection. Electrical: Ignition system, starting system, charging system (stator, regulator/rectifier), battery maintenance, lighting, EFI control module (ECU) diagnostics. Fuel System: EFI components (throttle body, injectors, fuel pump, pressure regulator), fuel filter replacement, diagnostic procedures. Cooling System: Radiator, fan, thermostat, coolant flush and refill, leak detection. Chassis Frame: Frame inspection, steering system overhaul, handlebar and control mounting. Bodywork Plastics: Body panel removal and installation, fender and rack components. Procedures Included Maintenance: Routine inspections, lubrication, filter changes, fluid flushes, belt inspection and adjustment. Troubleshooting: Diagnostic flowcharts, common problem identification, specific symptom resolution for EFI and mechanical issues. Repair: Step-by-step instructions for component replacement and repair across all covered systems. Rebuild: Detailed procedures for engine, transmission, and differential rebuilds. Diagnostics: EFI system diagnostics, error code interpretation, sensor testing, wiring diagrams. Technical Depth Depth: Comprehensive, covering basic to advanced repair and diagnostic procedures. Suitable for professional technicians and experienced DIYers. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text (standard for professional PDFs) Print Quality Quality: High-resolution digital scans, suitable for printing specific sections or the entire manual. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type 450: 4-stroke, SOHC, 2-valve, Single Cylinder Engine Displacement 450: 455cc Engine Type 500: 4-stroke, SOHC, 2-valve, Single Cylinder Engine Displacement 500: 499cc Performance Horsepower 450 Approx: Approx. 28 HP Horsepower 500 Approx: Approx. 34 HP Torque 450 Approx: Approx. 29 lb-ft Torque 500 Approx: Approx. 32 lb-ft Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Fuel Pump Type: In-tank electric pump Cooling System Cooling Method: Liquid-Cooled Coolant Capacity Qt: Approx. 2.0 qt (1.9 L) Thermostat Opening Temp F: Approx. 170-180°F (77-82°C) Lubrication System Oil Type Viscosity: SAE 5W-50 or 10W-40 (refer to manual for specific ambient temperature recommendations) Oil Capacity Qt W Filter: Approx. 2.2 qt (2.1 L) Oil Filter Part Number: e.g., 2540086 (confirm with manual) 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with EBS (Engine Braking System) Drive System: Shaft Drive Gear Reduction: High, Low, Neutral, Reverse, Park Belt Type: CVT Belt Clutch Engagement Rpm: Approx. 2500-2800 RPM (confirm with manual) Features Feature Ebs: Engine Braking System for downhill control. Feature AWD: On-Demand All-Wheel Drive engagement. Fluid Specifications Gearcase Oil Type: SAE 80W-90 Hypoid Gear Lubricant (API GL-4 or GL-5) Gearcase Oil Capacity Qt: Approx. 10.5 oz (0.31 L) 📐 Dimensions Exterior Length In: Approx. 83 in (210.8 cm) Width In: Approx. 46 in (116.8 cm) Height In: Approx. 49 in (124.5 cm) Wheelbase In: Approx. 50.5 in (128.3 cm) Ground Clearance In: Approx. 11 in (27.9 cm) Towing Capacity Lbs: 1500 lbs (680 kg) Rack Capacity Front Lbs: 100 lbs (45 kg) Rack Capacity Rear Lbs: 200 lbs (90 kg) Weights Dry Weight Lbs: Approx. 650 lbs (295 kg) Fuel Capacity Gal: 3.3 gal (12.5 L) Wheels Tires Front Tire Size: AT25 x 8-12 Rear Tire Size: AT25 x 10-12 Wheel Bolt Pattern: 4 x 110 mm 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI B71.1-2003 (standard for ATVs at the time of manufacture). Active Features Feature AWD: On-demand AWD enhances traction and control. Feature Ebs: Engine Braking System for controlled descents. Passive Features Feature Irs: Independent Rear Suspension improves stability and ride comfort. Braking System: Hydraulic disc brakes front and rear. Warnings Operator Training Importance: Manual will...

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Type: Atv

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Sku: 32833

Collections: ALL ATV Powersports

Availability: In stock

Tags: 2007 ATV Polaris Powersports SPORTSMAN 450 SPORTSMAN 500 SPORTSMAN EFI Sportsman Series

Product variants

Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 450 EFI / 500 EFI

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Platform:

Polaris Sportsman

Engine Code Prefix:

Chassis Code:

A07CH45AA (450), A07CH50AA (500)

👋 Introduction

Market Position

Segment:

Mid-size utility ATV segment, known for versatility and comfort.

Target Audience:

Recreational riders, farm use, light trail riding, hunting.

Competitive Analysis

Competitors:

Honda Foreman/Rubicon, Yamaha Kodiak/Grizzly, Can-Am Outlander/Commander, Suzuki King Quad.

Key Features

Feature 1:

Polaris's signature independent rear suspension (IRS) for a smoother ride.

Feature 2:

On-Demand All-Wheel Drive (AWD) system.

Feature 3:

Electronic Fuel Injection (EFI) for improved throttle response and cold starts.

Feature 4:

Comfortable seating and ergonomic design.

📋 Manual Details

Coverage Areas

Primary Coverage:

2007 Polaris Sportsman 450 EFI and 500 EFI ATVs

Secondary Coverage:

General ATV maintenance, troubleshooting, and repair procedures applicable to closely related models and years.

Page Count

Estimated Pages:

Hundreds (as stated in description)

Manual Type

Type:

Service Repair Manual

Purpose:

Repair, Maintenance, Rebuild, Refurbish, Restoration

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine assembly, disassembly, overhaul, ignition system, fuel system (EFI), cooling system, lubrication system.

Transmission:

PVT (Polaris Variable Transmission) operation, belt maintenance, clutch inspection and adjustment, gearcase servicing.

Drivetrain:

Front and rear drive systems, AWD (All-Wheel Drive) engagement, driveshaft and U-joint servicing, differential maintenance.

Suspension:

Front and rear suspension components, shock absorber adjustments and replacement, A-arm servicing, wheel bearing maintenance.

Brakes:

Hydraulic brake system, caliper servicing, pad replacement, fluid bleeding, master cylinder inspection.

Electrical:

Ignition system, starting system, charging system (stator, regulator/rectifier), battery maintenance, lighting, EFI control module (ECU) diagnostics.

Fuel System:

EFI components (throttle body, injectors, fuel pump, pressure regulator), fuel filter replacement, diagnostic procedures.

Cooling System:

Radiator, fan, thermostat, coolant flush and refill, leak detection.

Chassis Frame:

Frame inspection, steering system overhaul, handlebar and control mounting.

Bodywork Plastics:

Body panel removal and installation, fender and rack components.

Procedures Included

Maintenance:

Routine inspections, lubrication, filter changes, fluid flushes, belt inspection and adjustment.

Troubleshooting:

Diagnostic flowcharts, common problem identification, specific symptom resolution for EFI and mechanical issues.

Repair:

Step-by-step instructions for component replacement and repair across all covered systems.

Rebuild:

Detailed procedures for engine, transmission, and differential rebuilds.

Diagnostics:

EFI system diagnostics, error code interpretation, sensor testing, wiring diagrams.

Technical Depth

Depth:

Comprehensive, covering basic to advanced repair and diagnostic procedures. Suitable for professional technicians and experienced DIYers.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text (standard for professional PDFs)

Print Quality

Quality:

High-resolution digital scans, suitable for printing specific sections or the entire manual.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type 450:

4-stroke, SOHC, 2-valve, Single Cylinder

Engine Displacement 450:

455cc

Engine Type 500:

4-stroke, SOHC, 2-valve, Single Cylinder

Engine Displacement 500:

499cc

Performance

Horsepower 450 Approx:

Approx. 28 HP

Horsepower 500 Approx:

Approx. 34 HP

Torque 450 Approx:

Approx. 29 lb-ft

Torque 500 Approx:

Approx. 32 lb-ft

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Fuel Pump Type:

In-tank electric pump

Cooling System

Cooling Method:

Liquid-Cooled

Coolant Capacity Qt:

Approx. 2.0 qt (1.9 L)

Thermostat Opening Temp F:

Approx. 170-180°F (77-82°C)

Lubrication System

Oil Type Viscosity:

SAE 5W-50 or 10W-40 (refer to manual for specific ambient temperature recommendations)

Oil Capacity Qt W Filter:

Approx. 2.2 qt (2.1 L)

Oil Filter Part Number:

e.g., 2540086 (confirm with manual)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) with EBS (Engine Braking System)

Drive System:

Shaft Drive

Gear Reduction:

High, Low, Neutral, Reverse, Park

Belt Type:

CVT Belt

Clutch Engagement Rpm:

Approx. 2500-2800 RPM (confirm with manual)

Features

Feature Ebs:

Engine Braking System for downhill control.

Feature AWD:

On-Demand All-Wheel Drive engagement.

Fluid Specifications

Gearcase Oil Type:

SAE 80W-90 Hypoid Gear Lubricant (API GL-4 or GL-5)

Gearcase Oil Capacity Qt:

Approx. 10.5 oz (0.31 L)

📐 Dimensions

Exterior

Length In:

Approx. 83 in (210.8 cm)

Width In:

Approx. 46 in (116.8 cm)

Height In:

Approx. 49 in (124.5 cm)

Wheelbase In:

Approx. 50.5 in (128.3 cm)

Ground Clearance In:

Approx. 11 in (27.9 cm)

Towing Capacity Lbs:

1500 lbs (680 kg)

Rack Capacity Front Lbs:

100 lbs (45 kg)

Rack Capacity Rear Lbs:

200 lbs (90 kg)

Weights

Dry Weight Lbs:

Approx. 650 lbs (295 kg)

Fuel Capacity Gal:

3.3 gal (12.5 L)

Wheels Tires

Front Tire Size:

AT25 x 8-12

Rear Tire Size:

AT25 x 10-12

Wheel Bolt Pattern:

4 x 110 mm

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI B71.1-2003 (standard for ATVs at the time of manufacture).

Active Features

Feature AWD:

On-demand AWD enhances traction and control.

Feature Ebs:

Engine Braking System for controlled descents.

Passive Features

Feature Irs:

Independent Rear Suspension improves stability and ride comfort.

Braking System:

Hydraulic disc brakes front and rear.

Warnings

Operator Training Importance:

Manual will detail operator training, safety gear recommendations (helmet, eye protection, etc.).

💡 Technology Features

Infotainment

Infotainment System:

Not applicable for this model. Basic instrumentation includes speedometer, odometer, fuel gauge, and warning lights.

Driver Assistance

Traction Control:

On-Demand AWD system provides enhanced traction.

Engine Management:

Electronic Fuel Injection (EFI) with an Engine Control Unit (ECU) for optimized performance and emissions.

Connectivity

Connectivity Features:

No advanced connectivity features; basic electrical systems for lighting and ignition.

🔧 Maintenance

Service Intervals

Initial Service Hrs:

20-hour or 1-month service (oil change, filter check, belt inspection, etc.)

Regular Oil Change Interval Hrs:

Every 100 hours or 6 months (whichever comes first)

Air Filter Cleaning Hrs:

Every 50 hours, or more frequently in dusty conditions

Spark Plug Replacement Hrs:

Every 100 hours (confirm with manual for specific plug type and gap)

Cv Belt Inspection Hrs:

Every 50 hours, or annually

Brake Fluid Flush Years:

Every 2 years

Fluid Specifications

Engine Oil Spec:

SAE 5W-50 or 10W-40 Synthetic Motorcycle/ATV Oil (JASO MA/MA2 rated recommended)

Gearcase Oil Spec:

SAE 80W-90 Hypoid Gear Lubricant (API GL-4 or GL-5)

Coolant Spec:

Ethylene Glycol based antifreeze with corrosion inhibitors (e.g., Polaris Premium Long Life Coolant or equivalent)

Brake Fluid Spec:

DOT 4 Hydraulic Brake Fluid

Known Issues

Issue Cv Belt:

Premature wear or breakage of the CVT belt, especially with aggressive riding or improper adjustment.

Issue Efi Cold Start:

Occasional rough idling or stalling when cold, often related to sensor readings or fuel system cleanliness.

Issue Ebr Clutch:

EBS clutch wear or malfunction, affecting engine braking performance.

Issue Wheel Bearings:

Wear on wheel bearings, particularly in wet or muddy conditions, leading to play or noise.

Common Repairs

Repair Cv Belt Replacement:

Regular replacement and proper tensioning are key.

Repair Suspension Bushings:

Replacement of worn suspension bushings for optimal handling.

Repair Throttle Body Cleaning:

Periodic cleaning of the throttle body for optimal EFI performance.

📚 Vehicle History

Brand Heritage

Brand Origins:

Polaris Industries, founded in 1954, a significant player in the powersports industry.

Powersports Focus:

Known for snowmobiles, ATVs, UTVs, and motorcycles.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving with features like IRS and EFI.

Efi Introduction:

The 2007 model year marked the widespread adoption of EFI across Polaris's ATV lineup, including the Sportsman 450 and 500.

Production

Manufacturing Location:

Primarily manufactured in the USA.

Market Segment Development:

Polaris consistently innovated to meet the demands of the growing utility ATV market.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2007 Sportsman 450/500 are not widely documented as individual awards, the Polaris Sportsman line has consistently been recognized for its utility, comfort, and innovation in the ATV market by powersports publications and consumer reviews.