Polaris Sportsman 450-500 (2007) - Repair, Service Manual and Electrical Wiring Diagrams

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POLARIS SPORTSMAN 450-500 (2007) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 450-500 (2007).

 
CONTENTS:

MODEL NUMBER INFORMATION
- Model Number
- Engine Designation Numbers
- Vehicle Identification Number (VIN)
- Transmission I.d. Location
- Engine And Machine Serial Numbers
- Publications
- Paint Codes
- Replacement Keys
- Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison
- Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison
2007 SPORTSMAN 450
- Model Number: A07MH46AA, AZ
2007 SPORTSMAN 500 EFI
- Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC
2007 SPORTSMAN X-2 500 EFI
- Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA
MISC. NUMBERS/CHARTS
- Standard Torque Specifications
- SAE Tap Drill Sizes
- Metric Tap Drill Sizes
- Decimal Equivalents
- Conversion Table
- Glossary Of Terms
MAINTENANCE
- Periodic Maintenance Chart
- Maintenance Chart Key
- Periodic Maintenance Chart
LUBRICATION / FLUIDS
- SPORTSMAN Component Locations
- SPORTSMAN X2 Component locations
- Polaris Lubricants, Maintenance and Service Products
- Polaris Lubricant Symbol Identification
- Pre-ride / Daily Inspection
- Lubrication Components
- Front Gearcase Lubrication
- Transmission Lubrication
- ADC Differential Hydraulic Circuit Fluid Change
VEHICLE INSPECTION
- Shift Link Rod Inspection
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
- Fuel System
- Fuel Lines
- Vent Lines
- Fuel Filter
- Compression Test
- Engine Mounts
- Spark Plug
- Active Descent Control (ADC) Reservoir Level
- Battery Maintenance
- Liquid Cooling System Overview
- Coolant Strength / Type
- Cooling System Hoses
- Radiator/Grill Screen
- Cooling System Pressure Test
- Coolant Level Inspection
- Radiator Coolant Level Inspection
- Air Filter/Pre-Filter Service
- Air Box Sediment Tube
- Breather Filter Inspection
- Breather Hose
- Recoil Housing
- Engine Oil Level
- Oil and Filter Change
- Oil Pump Priming Procedure
- Valve Clearance
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Steering
- Tie Rod End/Steering Inspection
- Camber and Caster
- Wheel Alignment
- Toe Alignment Adjustment
- Exhaust Pipe
- Brake System Inspection
- Brake Pad Inspection
- Hose/Fitting Inspection
- Auxiliary Brake Testing
- Auxiliary Brake Adjustment (Hydraulic)
- Suspension Spring Preload Adjustment
- Front Suspension
- CV Shaft Boot Inspection
- Controls
- Wheels
- Wheel, Hub, And Spindle Torque Table
- Wheel Removal Front or Rear
- Wheel Installation
- Tire Pressure
- Tire Inspection
- Frame, Nuts, Bolts, Fasteners
- Storage Compartments
- Winch Operation (If Equipped)
- ATV Cleaning & Storage
- Maintenance Schedule
SPECIFICATIONS
- Torque Specifications
- Special Tools
- Engine Fastener Torque Patterns
- Engine Service Data
- Engine Service Data
GENERAL ENGINE SERVICE
- Piston Identification
- Cooling System Specifications
- Cooling System
- Accessible Components
- Engine Removal (TYPICAL)
- Engine Installation Notes
- Cylinder Hone Selection/ Honing Procedure
- Honing To Oversize
- Cleaning the Cylinder After Honing
- Crankshaft Straightening
- Engine Lubrication- EH 50PL
- Oil Pressure Test - EH 50PL
- Oil Pump Priming Procedure
- Oil Flow - EH50PL
- EH50PL Oil Flow Diagram
- EH50PL Engine Exploded Views
ENGINE DISASSEMBLY
- Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal
- Cam Chain Tensioner Inspection
- Rocker Arm/Shaft Inspection
- Camshaft Removal
- Automatic Compression Release Removal/ Inspection
- Automatic Compression Release Installation
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Exploded View, EH50PL
- Cylinder Head Inspection
- Cylinder Head Warp
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Valve Clearance Adjustment
- Cylinder/Piston Removal and Inspection
- Piston Removal
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Piston/Rod Inspection
- Piston Ring Installed Gap
- Crankcase Disassembly
- Starter Drive Removal/Inspection
- Flywheel/Stator Removal/Inspection
- Cam Chain/Tensioner Blade
- One Way Valve Removal
- Crankcase Separation
- Oil Pump Removal/Inspection
- Oil Pump Assembly
- Counter Balancer Shaft Removal/Inspection
- Crankshaft Removal/Inspection
- Crankcase Bearing Inspection
- Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)
- Crankcase Inspection
- Bearing Installation
- End Play Inspection/Adjustment
- Crankshaft End Play Adjustment
- Counter Balancer Shaft End Play Adjustment.
- Oil Pump Shaft End Play Adjustment
ENGINE REASSEMBLY
- Pump Shaft Oil Seal Installation
- Crankshaft/Counter Balance/Oil Pump Installation
- Crankcase Assembly
- Water Pump Mechanical Seal Installation
- Water Pump Mechanical Seal Removal - Engine Installed
- One Way Valve Installation
- Cam Chain Drive Sprocket Installation
- Tensioner Blade Installation
- Piston Ring Installation
- Piston Installation
- Cylinder Installation
- Cylinder Head Installation
- Cam Chain/Camshaft Installation
- Camshaft Timing
- CAMSHAFT TIMING
- Cam Chain Tensioner Installation
- Stator, Flywheel and Starter Drive Installation
- Rocker Shaft/Rocker Arm Assembly Installation
- Thermostat Installation
- Oil Pipes
RECOIL
- Recoil Disassembly/Inspection
- Recoil Assembly
TROUBLESHOOTING
- Spark Plug Fouling
- Engine
- Cooling System
SPECIAL TOOLS
- Part Numbers / Descriptions
EFI SERVICE NOTES
- General Service Information
EFI SYSTEM EXPLODED VIEW
EFI SYSTEM
- Component Locations/Identification
FUEL TANK
- Exploded View
ELECTRONIC FUEL INJECTION
- General Information
- EFI Operation Overview
- Initial Priming / Starting Procedure
FUEL LINES
- Quick Connect Removal/Installation
ELECTRONIC CONTROL MODULE (ECM)
- Operation Overview
- ECM Replacement
- ECM Service
FUEL PUMP ASSEMBLY
- Operation / Testing
- FUEL PUMP TEST
- Fuel Pump / Tank Assembly Replacement
FUEL PRESSURE REGULATOR
- General Information
FUEL FILTERS
- General Information
FUEL INJECTOR
- General Information
CRANKSHAFT POSITION SENSOR (CPS)
- General Information
MANIFOLD AIR PRESSURE SENSOR (MAP)
- Operation Overview
- Map Sensor Test
- Map Sensor Replacement
INTAKE AIR TEMPERATURE SENSOR (IAT)
- Operation Overview
- Intake Air Temperature Sensor Test
- Intake Air Temperature Sensor Replacement
I DLE AIR CONTROL (IAC)
- General Information
THROTTLE POSITION SENSOR (TPS)
- Operation Overview
- Throttle Position Sensor Test
- Throttle Position Sensor Replacement
- Throttle Position Sensor (Tps) Initialization
ENGINE TEMPERATURE SENSOR
- General Information
- Engine Temperature Sensor Test
- Engine Temperature Sensor Replacement
FUEL SYSTEM TROUBLESHOOTING
- FUEL STARVATION / LEAN MIXTURE
EFI DIAGNOSTICS USING ‘BLINK CODES’
- Blink Codes - Operation
TROUBLESHOOTING DIAGRAMS
- EFI CIRCUIT - Power On
- EFI CIRCUIT - Crank Position Sensor
- EFI CIRCUIT - Fuel Pump
- EFI CIRCUIT - Ignition Coil
- EFI CIRCUIT - Idle Air Control
- EFI CIRCUIT - Throttle Position Sensor
- EFI CIRCUIT - Manifold Absolute Pressure Sensor
- EFI CIRCUIT - Engine Coolant Temperature
- EFI CIRCUIT - Air Temperature Sensor
- EFI CIRCUIT - Malfunction Indicator Light
GENERAL INFORMATION AND SPECIFICATIONS
- Special Tools
- Carburetor Jetting
- Mikuni Jet Part Numbers
- Carburetor Specifications
CARBURETION
- BST 34 Carburetor Exploded View 1 of 2
- BST 34 Carburetor Exploded View 2 of 2
- CV Carburetor System Function
- Carburetor Venting
- Mikuni CV Carb Operation
- Starter System (Choke or Enrichment)
- Pilot (Idle and Slow) System
- Main System
- Float System
- Pilot Screw
- Air/Fuel Mixture Ratio
- Jet Needle
- Needle Jet
- Throttle Opening vs. Fuel Flow
- Carburetor Disassembly - Mikuni CV
- Carburetor Cleaning
- Carburetor Inspection
- Carburetor Assembly
- Float Height Adjustment
- Needle and Seat Leakage Test
- Fuel Level Test
FUEL TANK/FUEL DELIVERY SYSTEM
- Fuel System Exploded View
FUEL PUMP
- Fuel Pump Testing
- Fuel Pump Disassembly
- Fuel Pump Inspection and Reassembly
- Fuel Filter Replacement
FUEL GAUGE SENDING UNIT
- Sending Unit Removal
- Testing
- Sending Unit Installation
TROUBLESHOOTING
- Fuel Starvation/Lean Mixture
GENERAL INFORMATION
- Torque Specifications
- Special Tools
- Decal Replacement
- Plastic Insert Removal / Installation
BODY
- Side Panel Removal
- Front Cover Removal / Installation
- Foot Well Removal / Installation
- X2 Foot Well Removal / Installation
- Front Storage Removal
- Front Storage Installation
- Sportsman Rear Rack Removal / Installation
- Front Cab/Fender Removal/Installation
- Sportsman Rear Cab / Fender Removal / Installation
- X2 Rear Quarter Panel Removal / Installation
- Sportsman Rear Storage Removal / Installation
- Radiator Screen Removal
- Sportsman Body Assembly Exploded View
- X2 Body Assembly Exploded View
- Body / Rack Exploded Views
- Headlight Pod Exploded View
STEERING
- Handlebar Block Installation Procedure
- Steering / A-arm Exploded View
- A-Arm Replacement
- Ball Joint Replacement
- Steering Post Removal
- Steering Post Assembly
SUSPENSION
- Front Strut Cartridge Replacement
- Strut Assembly
- Sportsman Rear Suspension Assembly
- X2 Rear Suspension Exploded View
- X2 Torsion Bar Exploded View
X2 CARGO BOX
- Exploded View
- Removal / Installation
X2 SEAT ASSEMBLY
- Exploded Views
- X2 Seat Operation - Configuring Cargo Box For Passenger Riding
- Driver Seat Backrest Removal / Installation
- Passenger Seat Backrest Removal / Installation
SPECIAL TOOLS AND SPECIFICATIONS
- Special Tools
- Component Fastener Torques
PVT EXPLODED VIEWS
- PVT Sealing And Ducting Components
- Drive Clutch Exploded Views (Standard and Deluxe)
- Driven Clutch Exploded Views (Standard and Deluxe)
- Engine Braking System (EBS) Exploded View
PVT SYSTEM
- PVT Operation Overview
- Drive Clutch Operation
- Driven Clutch Operation
- EBS Clutch Operation
- PVT Maintenance / Inspection
- Drive Clutch Spring
- Optional Shift Weights
- PVT Drying
- PVT Disassembly
- PVT Installation
- Drive Belt Removal / Inspection
- DRIVE BELT INSTALLATION
- Clutch Alignment
- Clutch Offset
EBS DRIVE CLUTCH SERVICE
- Drive Clutch Disassembly
- Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- Drive Clutch Inspection
- Moveable Sheave Bushing Inspection
- Drive Clutch Bushing Service
- One-Way Clutch Inspection (Drive Clutch)
- Drive Clutch Reassembly
EBS DRIVEN CLUTCH SERVICE
- Driven Clutch Disassembly
- DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION
- EBS DRIVEN CLUTCH REASSEMBLY
STANDARD DRIVE CLUTCH
- Drive Clutch Disassembly
- Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- Sheave / Bushing Inspection
- Drive Clutch Bushing Service
- Drive Clutch Reassembly
STANDARD DRIVEN CLUTCH - 500 X2, 700, 800 EFI MODELS
- Disassembly
- Inspection
- Assembly
STANDARD DRIVEN CLUTCH - 500 EFI AND 450
- Exploded View
- Clutch Disassembly / Inspection
- Bushing Service
- Moveable Sheave - Bushing Installation
- Clutch Assembly
PVT TROUBLESHOOTING
- Overheating
- Problem, Cause and Remedy Chart
SPECIFICATIONS
- Torque Table
- Special Tools
- Gearcase Fluid / Capacity
FRONT DRIVE AXLE
- Removal
- Installation
FRONT DRIVE SHAFT (CV) BOOT
- Inspection
- Replacement
FRONT HUB
- Disassembly
- Assembly
PROP SHAFT - FRONT OR REAR
- Removal and Installation
U-JOINT
- Disassembly
- Assembly
DRIVE AXLE EXPLODED VIEWS
- Drive Shafts and Propshafts
FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS)
- Exploded View (Standard Models)
- Operation
- Gearcase Removal
- Disassembly / Inspection
- Reassembly / Inspection
- Setting Ring Gear Backlash
- Front Gearcase Diagnosis
- Gearcase Installation
FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS)
- ADC Gearcase Exploded View (Deluxe Models)
- Operation
- ADC Coil Testing
- ADC Differential Hydraulic Circuit Bleeding
- Disassembly / Inspection
- ADC Gearcase Piston Replacement Procedure
- Assembly
REAR HUB
- Removal
- Disassembly
- Assembly
- Installation
REAR DRIVE (CV) SHAFT
- Removal
- Service
- CV Boot Replacement
- INSTALLATION
- Drive Shaft and CV Joint Handling Tips
TRANSMISSION - GENERAL
- Mounting Exploded View
- Torque Specifications
- Special Tools
- Lubrication
- Gear Selector Removal
- Transmission Removal
- Transmission Installation
- Troubleshooting Checklist
TRANSMISSION SERVICE
- Exploded View
- Transmission Disassembly
- Transmission Assembly
- Transmission Front Output Shaft Backlash Procedure and Reassembly
SPECIFICATIONS
- Torque Table
- Component Service Limits
BRAKE SYSTEM EXPLODED VIEWS
- X2 System Component Exploded View
- Sportsman System Component Exploded View
BRAKE CALIPER EXPLODED VIEWS
- Sportsman and X2 Front Caliper Assembly
- X2 Rear Caliper Assembly
- Sportsman Rear Caliper Assembly
HYDRAULIC BRAKE SYSTEM
- Operation Overview
- Brake Noise Troubleshooting
- Brake Bleeding / Fluid Change
FRONT MASTER CYLINDER
- Removal
- Installation
FRONT BRAKES
- Pad Removal
- Assembly
- Brake Burnishing Procedure
FRONT BRAKE DISC
- Inspection
- Removal / Replacement
FRONT CALIPER
- Removal
- Inspection
- Reassembly
- Installation
REAR BRAKE PAD
- X2 Pad Removal
- X2 Pad Installation
- Sportsman Rear Pad Removal
- Sportsman Rear Pad Installation
- Brake Burnishing Procedure
X2 REAR CALIPER
- Removal
- Inspection
- Reassembly
SPORTSMAN REAR CALIPER
- Removal and Inspection
- Assembly
REAR BRAKE DISC
- Inspection
REAR MASTER CYLINDER
- X2 Exploded View
- Overview
- X2 Rear Master Cylinder Removal and Installation
- Sportsman Rear Master Cylinder Removal / Installation
- Pedal Removal and Installation
TROUBLESHOOTING
- Brakes Squeal
- Poor Brake Performance
- Lever Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
GENERAL INFORMATION
- Special Tools
- Ignition System / Basic Electrical Components
- Electrical Service Notes
- Troubleshooting
POWER DISTRIBUTION MODULES (PDM)
- Sportsman EFI Overview
- Sportsman 450 Overview
INSTRUMENT CLUSTER
- Overview
- Instrument Cluster Diagnostic Mode
- Setting A New Service Interval
- EFI Diagnostic Mode
- Speedometer Removal
- Speedometer Installation
ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING
- TEST 1 - No All Wheel Drive
- TEST 2 - No Speedometer Display
- TEST 3 - No Reverse Speed Limit
- TEST 4 - No AWD Hub Safety Limit
- TEST 5 - Reverse Speed Limiter Activated In Forward Gear
- TEST 6 - Wheel Speed Sensor
- TEST 7 - Fuel Gauge Display Not Working
- TEST 8 - Shift Indicator Not Working
ACTIVE DESCENT CONTROL (ADC) COIL
- Operation Overview
- Diagnosing System Failures
ALL WHEEL DRIVE (AWD) COIL
- Operation Overview
- Diagnosing System Failures
COOLING SYSTEM COMPONENTS
- Fan Control Circuit Operation
- Fan Control Bypass Test
- Fan Motor Current Draw Test
- Coolant Temperature Sensor
GEAR POSITION INDICATOR SWITCH
- Test Diagram
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
- Operation Overview
- ETC Test
IGNITION SYSTEM
- Overview
- Components of EFI Alternator and DC / CDI Ignition System
- EFI Ignition System Testing Flow Chart
- Crankshaft Position Sensor Gap
- Ignition Troubleshooting
- Ignition Output Test Using Gap Tester
CHARGING SYSTEM
- Current Draw - Key Off
- Break Even Test
- Alternator Output Test
- Charging System Testing Diagrams
DIFFERENTIAL SOLENOID
- Testing
- Replacement
LIGHTING
- High Beam Headlight Bulb Replacement
- Headlight Housing Relacement
- High Beam Headlight Adjustment
- Lower Headlamp Removal / Installation
- Low Beam Headlight Adjustment
- Headlamp Switch Test
- Work Light Switch
- Brake Light / Work Light Replacement
- Brake Light Switch Test
SPEED SENSOR
- Testing
- Replacement
FUEL SENDER
- Testing
ACCESSORY POWER
- Wire Connections
STARTER SYSTEM
- Troubleshooting
- VOLTAGE DROP TEST
- Starter Lockout Troubleshooting- EFI Models
- Starter Lockout Troubleshooting- Sportsman 450
- Starter Lockout Diagram- EFI
- Starter Lockout Diagram- Sportsman 450
- Starter Motor Removal / Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter Solenoid Bench Test
- Starter Exploded View
STARTER DRIVE
- Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
STARTER SYSTEM TESTING FLOW CHART
- Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing...
BASIC WINCH WIRING
- Pre-wired Models
TROUBLESHOOTING DIAGRAMS
- Power On - EFI
- Start Circuit - EFI
- Ignition Coil - EFI
- Fuel Pump - EFI
- Fan - EFI
- Charging System - EFI
- All Wheel Drive - EFI
- Transmission Switch - EFI
- Reverse Override - EFI
- Differential Solenoid - X2
BATTERY
- Battery Identification
- Battery Activation
- Terminal Preparation
- Battery Removal
- Battery Installation
- Off Season Storage
- Low Maintenance Battery Off-Season Storage
- Battery Testing
- Conventional Battery OCV - Open Circuit Voltage Test
- Conventional Battery Specific Gravity Test
- Battery Load Test
- Charging Procedure
- Low Maintenance Battery Check:
- Low Maintenance Battery Charging
- Low Maintenance Battery - OCV- Open Circuit Voltage Test
- Low Maintenance Battery Load Test
- Low Maintenance Battery Charging Procedure