Download 2007 Polaris Sportsman 450/500 EFI Repair Manual PDF

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The 2007 Sportsman is a high-performance utility All-Terrain Vehicle (ATV) designed for both recreational and working applications. Available in 450 EFI, 500 EFI, and X2 500 EFI trim levels, this...

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Tipo: Atv

Proveedor:

SKU: 51555

Etiquetas: 2007 450 Atv Case Construction Polaris Skid Steer Loaders Sportsman 450 EFI Sportsman 500 EFI

Variantes de producto

Descripción

The 2007 Sportsman is a high-performance utility All-Terrain Vehicle (ATV) designed for both recreational and working applications. Available in 450 EFI, 500 EFI, and X2 500 EFI trim levels, this ATV is powered by a liquid-cooled, SOHC, 4-valve engine featuring Electronic Fuel Injection (EFI) for enhanced throttle response and efficiency. Its robust construction and advanced features, including Independent Front and Rear Suspension (IFS/IRS) on most models and an On-Demand All-Wheel Drive (AWD) system with a 2WD option, provide exceptional capability and traction across varied terrain. A manufacturer with a strong heritage in powersports, engineered the Sportsman line to deliver reliability and performance, making it a competitive choice in the utility ATV market. This comprehensive service manual provides essential information for the repair and maintenance of your 2007 Sportsman ATV. Covering a wide array of systems, including the engine, drivetrain, suspension, brakes, and electrical components, this manual details scheduled maintenance, component removal and installation, and in-depth troubleshooting procedures. It is intended for use by professional technicians and DIY mechanics alike, offering guidance on diagnostics, common issues, and technical specifications. The manual's detailed instructions and clear explanations are designed to assist owners and technicians in keeping their Sportsman operating at peak performance and ensuring its longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman

Year:

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:

Searchable:

Yes (typical for high-quality PDFs)

Printable:

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.