2007 Polaris 500 6x6 ATV Complete Service Manual

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🏷️ Basic Information Identification Make: Polaris Model: 500 6x6 Year: 2007 Vehicle Type: All-Terrain Vehicle (ATV) Configuration: 6x6 Codes Model Code Family: Polaris Sportsman 500 series. 👋 Introduction Market Position...

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Type: Atv

Vendor:

Sku: 5701

Tags: 2007 500 6x6 ATV Polaris Powersports

Product variants

Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

500 6x6

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Configuration:

Codes

Model Code Family:

Polaris Sportsman 500 series.

👋 Introduction

Market Position

Offering:

Comprehensive digital service manual for the 2007 Polaris 500 6x6 ATV, aimed at owners and technicians seeking in-depth repair and maintenance information.

Competitive Analysis

Differentiation:

Distinguished from simpler owner's manuals by its technical depth, covering repair and overhaul procedures, making it a valuable resource for DIY mechanics and professional service.

Key Features

Advantages:

Instant download, printable format, comprehensive coverage, avoids physical wear and tear of traditional manuals, readily available when needed.

📋 Manual Details

Coverage Areas

Page Count:

Manual Type:

Complete Service, Repair, and Maintenance Workshop Manual

Language:

English

Format:

PDF Download

Delivery Method:

Instant Delivery via Email

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, disassembly, assembly, tuning, cooling system, lubrication system, starting system, ignition system, fuel system (carburetor, fuel pump), exhaust system.

Transmission:

Gearbox, clutch, drive shafts, CVT system (if applicable), lubrication, maintenance, repair, and overhaul.

Drivetrain:

Front and rear differentials, driveshafts, U-joints, final drives, lubrication, maintenance, and repair specific to the 6x6 configuration.

Suspension:

Front and rear suspension components, shocks, springs, A-arms, bushings, alignment, maintenance, and repair.

Steering:

Steering column, tie rods, steering rack/gearbox, bearings, maintenance, and adjustment.

Brakes:

Front and rear brake systems (hydraulic disc brakes), brake fluid, master cylinders, calipers, brake pads, rotors, bleeding procedure, maintenance, and repair.

Electrical:

Wiring diagrams, battery, alternator/stator, starter motor, lighting system, ignition system components, fuses, relays, switches, troubleshooting, and diagnostics.

Bodywork:

Frame, plastics, fenders, seats, racks, body panel removal and installation, fasteners, and cosmetic repairs.

Wheels Tires:

Tire pressure recommendations, wheel bolt patterns (if applicable), wheel bearing maintenance.

Procedures Included

Maintenance:

Routine maintenance, scheduled service intervals, fluid changes (oil, coolant, brake fluid, differential fluid), filter replacements, lubrication points.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical system diagnostics.

Repair:

Step-by-step repair instructions for all major components and systems, including detailed disassembly and reassembly sequences.

Rebuild:

Comprehensive guides for engine rebuilds, transmission overhauls, and other major component restorations.

Inspection:

Pre-ride inspections, component wear checks, safety inspections.

Torque Specifications:

Essential torque values for critical fasteners (engine, suspension, wheels) are provided.

Assembly Disassembly:

Step-by-step instructions for the removal and installation of all major components and sub-assemblies.

Engine Specifications:

Detailed specifications for engine parts such as pistons, rings, crankshaft, cylinder head, valves, and camshafts.

Diagrams Illustrations:

Likely includes exploded diagrams and illustrations to aid in component identification and assembly/disassembly procedures.

Technical Depth

Depth:

Highly detailed technical service, repair, and maintenance. Covers aspects beyond a simple owner's manual, including detailed diagnostics, overhaul procedures, and component-level repair.

📊 Manual Specifications

File Format

Type:

Quality:

High-resolution, easily printable

Searchability:

Likely searchable text-based PDF, allowing for quick information retrieval.

Print Quality

Printability:

Printable, allowing users to create physical copies for workshop use.

Binding Type

Provided Binding:

N/A (Digital Download)

Paper Type

Provided Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 4-valve

Displacement:

499cc (approximate - specific model variant may vary slightly)

Bore X Stroke:

Specifics would be detailed in the manual, typically around 92mm x 77mm for this engine family.

Performance

Horsepower:

Around 30-35 HP, though exact figures are model-specific and often not officially published by Polaris for ATVs.

Torque:

Specific torque figures are detailed in the manual, crucial for engine reassembly.

Fuel System

Carburetor:

Typically a Mikuni BSR series carburetor (e.g., BSR42), detailed tuning and jetting information is critical and found in the manual.

Fuel Type:

Unleaded Gasoline

Ignition

System:

CDI (Capacitor Discharge Ignition)

Cooling

System:

Liquid-cooled

Lubrication

System:

Wet Sump

🔧 Transmission

Standard

Type:

Automatic (PVT - Polaris Variable Transmission) with engine braking.

Optional

Gears:

High, Low, Neutral, Reverse (with park lock)

Features

Drive System:

6x6 selectable all-wheel drive, on-demand engagement of front and rear driveshafts.

📐 Dimensions

Exterior

Length:

Specifics are within the manual, typically around 83 inches (211 cm).

Width:

Specifics are within the manual, typically around 48 inches (122 cm).

Height:

Specifics are within the manual, typically around 47 inches (119 cm).

Weights

Dry Weight:

Specifics are within the manual, typically around 650-700 lbs (295-318 kg).

Ground Clearance:

Specifics are within the manual, typically around 10-11 inches (25-28 cm).

Cargo

Rack Capacity Front:

Specifics are within the manual, usually around 50 lbs (23 kg).

Rack Capacity Rear:

Specifics are within the manual, usually around 100 lbs (45 kg).

Towing Capacity:

Specifics are within the manual, typically around 1,500 lbs (680 kg).

🛡️ Safety Features

Ratings

Atv Safety:

ATVs are inherently high-risk; adherence to manual safety guidelines is paramount. The manual will detail safe operation practices.

Active Features

Braking System:

Hydraulic disc brakes on all wheels (6-wheel braking system).

Engine Braking:

Engaged through the PVT system, providing deceleration on descents.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, odometer, fuel gauge, warning lights). No advanced infotainment systems found on this model.

Driver Assistance

Features:

No electronic driver assistance systems. Focus is on mechanical performance and reliability.

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 100 hours or 6 months, refer to manual for exact hours/mileage and conditions.

Gearbox Oil Change:

Typically every 200 hours or 12 months, refer to manual for exact hours/mileage and conditions.

Air Filter Cleaning:

Frequent checks recommended, especially in dusty conditions; cleaning/replacement intervals detailed in manual.

Spark Plug Inspection:

Recommended at specific hour intervals, specified in manual.

Fluid Specifications

Engine Oil:

SAE 10W-40 or 20W-50 (depending on ambient temperature), API SG or higher. Specific Polaris-branded oils recommended. Capacity: ~2.1 quarts (2.0 liters).

Gearbox Oil:

Polaris AGL (Advanced Gear Lube) or equivalent. Capacity: ~10.2 fl oz (0.3 liters).

Coolant:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Capacity: ~2.6 quarts (2.5 liters).

Brake Fluid:

DOT 3 or DOT 4 brake fluid. Manual specifies exact type and procedures for bleeding.

Known Issues

Pvttypical:

Pre-mature wear of the CVT belt and drive clutches can occur with heavy use or improper maintenance. Manual provides inspection and replacement procedures.

Fuel System:

Carburetor jetting can require adjustment for altitude or modifications. Carburetor cleaning and rebuilding procedures are covered.

Electrical:

Intermittent electrical connections or charging system issues are sometimes reported; detailed wiring diagrams in the manual are crucial for diagnosis.

📚 Vehicle History

Brand Heritage

Polaris Offroad:

Polaris has a long history in the powersports industry, known for its innovation in ATVs and snowmobiles.

Model Evolution

Sportsman Line:

The Sportsman line is Polaris's flagship ATV range, known for its utility and off-road capabilities. The 6x6 variants are specifically designed for maximum traction and load-carrying capacity.

Production

Model Year 2007:

The 2007 model represents a refinement of the Sportsman 500 platform, incorporating Polaris's established technologies and design principles for that era.

🏆 Awards & Recognition

Recognitions

Model Specific:

While the 2007 Sportsman 500 6x6 itself may not have specific awards listed, the Polaris Sportsman line has consistently been recognized for its utility, performance, and reliability in the ATV market.