Polaris A07TH50AU Manuel d'utilisateur

2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFISERVICE MANUALFOREWORDThis service manual is designed primarily for use by certified Polaris Master Service D

1.6GENERAL INFORMATION2007 SPORTSMAN 450Model Number: A07MH46AA, AZEngine Model: EH46PLETable 1-4: Sportsman 450 General SpecificationsCategory

3.42ENGINE2. Slide the main puller body over the outer portion of themechanical seal as shown in Ill. 2 and turn T-Handleclockwise until it contacts w

3.43ENGINE3Cam Chain Drive Sprocket Installation1. Install the Woodruff key, drive sprocket, and slotted nut.Tighten the nut to the specified torque.T

3.44ENGINEPiston Installation1. Clean the gasket surfaces on the cylinder and crankcase.Remove all traces of old gasket material.2. Make sure the cyli

3.45ENGINE310. Apply clean engine oil liberally to the cylinder bore andtapered area of the sleeve. Install the cylinder with a slightrocking motion u

3.46ENGINEIMPORTANT CAMSHAFT TIMING NOTE: In order totime the camshaft to the crankshaft, the piston must beprecisely located at Top Dead Center (TDC)

3.47ENGINE36. Install the sprocket on the camshaft. Apply Loctite™ 242(PN 2871949) to the cam sprocket bolts and torque tospecification.7. Verify TDC

3.48ENGINECAMSHAFT TIMINGDotsCrankshaft to Camshaft CentrelineSprocket Alignment PinSingle TDC Mark AlignedTDC MarkRotationDo Not Use Advance Marks

3.49ENGINE3Cam Chain Tensioner Installation1. Release the ratchet pawl (A) and push the tensionerplunger (B) all the way into the tensioner body.2. In

3.50ENGINEgear.2. Apply starter drive grease to the drive bushing in thecrankcase and all moving surfaces of the starter drivemechanism. Install the s

3.51ENGINE3RECOILRecoil Disassembly/InspectionReplace any parts found to be worn or damaged.1. Remove bolts and recoil from the engine.2. Pull recoil

1.7GENERAL INFORMATION1Table 1-5: Sportsman 450ENGINEPlatform Fuji Single CylinderEngine Model Number EH46PLE010Engine Displacement 455ccNumber of Cyl

3.52ENGINERecoil AssemblyTo install a new spring:1. Place spring in housing with the end positioned so thespring spirals inward in a counterclockwise

3.53ENGINE3TROUBLESHOOTINGSpark Plug Fouling• Spark plug cap loose or faulty• Choke cable adjustment or plunger/cable sticking• Foreign material on ch

3.54ENGINEEngine Has Low Power• Spark plug fouled• Cylinder, piston, ring, or valve wear or damage(check compression)• PVT not operating properly• Res

FUEL SYSTEM4.1CHAPTER 4FUEL SYSTEM4ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 - 4.30CARBURETOR (SP

4.2FUEL SYSTEM

FUEL INJECTION4.3CHAPTER 4FUEL INJECTION4SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4FUEL INJECTIONFUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23FUEL STARVATION / LEAN MIX

4.5FUEL INJECTION4SPECIAL TOOLSPart Numbers / DescriptionsFuel Pressure Tester - PU-43506IMPORTANT: The EFI fuel system remains under highpressure, ev

4.6FUEL INJECTIONDigital Wrench SmartLink Module Kit - PU-47471Available to Polaris dealers through our tool supplier, SPX (1-800-328-6657) This modu

4.7FUEL INJECTION4EFI SERVICE NOTESGeneral Service Information• For more convenient and accurate testing of EFI components, it is recommended dealers

1.8GENERAL INFORMATION2007 SPORTSMAN 500 EFIModel Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC (Standard Models) (Deluxe Models) (Inte

4.8FUEL INJECTIONEFI SYSTEM EXPLODED VIEW1. Electronic Control Module (ECM)2. Manifold Absolute Pressure Sensor (MAP) 3. Intake Air Temperature

4.9FUEL INJECTION4EFI SYSTEM Component Locations/Identification1. Electronic Control Module (ECM)2. Manifold Absolute Pressure Sensor (MAP)3. Intake

4.10FUEL INJECTIONFUEL TANKExploded ViewELECTRONIC FUEL INJECTIONGeneral InformationThe Electronic Fuel Injection (EFI) system is a complete enginefue

4.11FUEL INJECTION4Initial Priming / Starting ProcedureNOTE: The Injection system must be purged of allair prior to the initial start up, and/or any

4.12FUEL INJECTIONELECTRONIC CONTROL MODULE (ECM)Operation OverviewThe ECM is the brain or central processing computer of theentire EFI fuel/ignition

4.13FUEL INJECTION4FUEL PUMP ASSEMBLYOperation / TestingNOTE: All EFI units utilize quick connect fuel lines.An electric fuel pump assembly is used t

4.14FUEL INJECTION3. If the pump did not activate (Step 2), disconnect the plugfrom the fuel pump. Connect a DC voltmeter acrossterminals “A” and “C”

4.15FUEL INJECTION47. Loosen the fuel tank hose and pull the fuel line from thetank. NOTE: A small amount of fuel may come out of thefuel line or tan

4.16FUEL INJECTIONFUEL FILTERSGeneral InformationNOTE: All EFI units utilize quick connect fuel lines.EFI Engines use a non-serviceable, high-volume,

4.17FUEL INJECTION4Injector problems due to dirt or clogging are unlikely due to thedesign of the injectors, the high fuel pressure, the use of filter

1.9GENERAL INFORMATION1Table 1-10: Sportsman 500 EFIENGINEPlatform Fuji Single CylinderEngine Model Number EH50PLE210Engine Displacement 499ccNumber o

4.18FUEL INJECTION3. Disconnect crankshaft sensor connector from wiringharness. Test resistance between the terminals. A readingof 185  20% at roo

4.19FUEL INJECTION4INTAKE AIR TEMPERATURE SENSOR (IAT)Operation OverviewThe intake air temperature sensor (IAT) is used to indicatecharge air temperat

4.20FUEL INJECTIONTHROTTLE POSITION SENSOR (TPS)Operation OverviewThe throttle position sensor (TPS), mounted to the throttle body,is used to indicate

4.21FUEL INJECTION4Tps Tester - Correct Reference VoltageA 5 volt reference voltage signal from the test harness isrequired for the TPS test to be acc

4.22FUEL INJECTIONENGINE TEMPERATURE SENSORGeneral InformationMounted on the cylinder, the engine temperature sensormeasures coolant temperature. The

4.23FUEL INJECTION4FUEL SYSTEM TROUBLESHOOTINGFUEL STARVATION / LEAN MIXTURESymptoms: Hard start or no start, bog, backfire, poppingthrough intake /

4.24FUEL INJECTIONEFI DIAGNOSTICS USING ‘BLINK CODES’Blink Codes - OperationTo enable the blink codes, turn the ignition from “OFF” to“ON” 3 times,

4.25FUEL INJECTION4Table 4-1: DIAGNOSTIC “BLINK CODES” CHARTBLINK CODENAMEMIL LIGHT ON?12 BEGIN SEQUENCE --21 Loss of Synchronization Yes22 TPS Circu

4.26FUEL INJECTIONTROUBLESHOOTING DIAGRAMSEFI CIRCUIT - Power OnEFI CIRCUIT - Crank Position Sensor

4.27FUEL INJECTION4EFI CIRCUIT - Fuel PumpEFI CIRCUIT - Ignition Coil

1.10GENERAL INFORMATION2007 SPORTSMAN X-2 500 EFIModel Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA(Standard Models) (Deluxe Model) (Intl’ Quad

4.28FUEL INJECTIONEFI CIRCUIT - Idle Air ControlEFI CIRCUIT - Throttle Position Sensor

4.29FUEL INJECTION4EFI CIRCUIT - Manifold Absolute Pressure SensorEFI CIRCUIT - Engine Coolant Temperature

4.30FUEL INJECTIONEFI CIRCUIT - Air Temperature SensorEFI CIRCUIT - Malfunction Indicator Light

CARBURETOR - SPORTSMAN 4504.31CHAPTER 4CARBURETOR - SPORTSMAN 4504GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .

4.32CARBURETOR - SPORTSMAN 450GENERAL INFORMATION AND SPECIFICATIONSSpecial ToolsNOTE: It is strongly recommended that Polaris CarbonClean be added

4.33CARBURETOR - SPORTSMAN 4504CARBURETIONBST 34 Carburetor Exploded View 1 of 2Table 4-1: Carburetor ComponentsREFERENCE DESCRIPTION REFERENCE DESCRI

4.34CARBURETOR - SPORTSMAN 450BST 34 Carburetor Exploded View 2 of 2Table 4-2: Carburetor ComponentsREFERENCE DESCRIPTION REFERENCE DESCRIPTIONA Throt

4.35CARBURETOR - SPORTSMAN 4504CV Carburetor System Function Carburetor VentingThe carburetor float bowl vent lines supply atmosphericpressure to the

4.36CARBURETOR - SPORTSMAN 450When the pressure above and below the diaphragm are nearlyequal, the slide moves downward under spring pressure. Raising

4.37CARBURETOR - SPORTSMAN 4504Main SystemAs throttle valve (1) is opened, engine speed rises, and thisincreases negative pressure in the venturi. Con

1.11GENERAL INFORMATION1Table 1-14: Sportsman X2 500 EFIENGINEPlatform Fuji Single CylinderEngine Model Number EH50PLE210Engine Displacement 499ccNumb

4.38CARBURETOR - SPORTSMAN 450Pilot ScrewThe pilot system supplies fuel during engine operation with thethrottle valve closed or slightly opened. The

4.39CARBURETOR - SPORTSMAN 4504Jet NeedleThe jet needle has five adjustment grooves cut into the upperportion, and is tapered from approximately the m

4.40CARBURETOR - SPORTSMAN 450and float pin can be removed.3. Remove inlet needle seat retaining screw along with plate,and carefully remove needle se

4.41CARBURETOR - SPORTSMAN 4504Carburetor Inspection1. Inspect jet needle and needle jet for wear. Look fordiscoloration, shiny spots, or an area that

4.42CARBURETOR - SPORTSMAN 450the engine running. Refer to Page 2.10.Float Height Adjustment1. Illustration 1: Place the throttle side of the carburet

4.43CARBURETOR - SPORTSMAN 4504Fuel Level TestA fuel level test can be performed on some models if the drainhose fitting is accessible. Be sure to re–

4.44CARBURETOR - SPORTSMAN 450FUEL TANK/FUEL DELIVERY SYSTEMFuel System Exploded View

4.45CARBURETOR - SPORTSMAN 4504FUEL PUMPFuel Pump TestingThis ATV is equipped with a pressure regulated fuel pump (1-3 PSI). The pump is located unde

4.46CARBURETOR - SPORTSMAN 450Fuel Pump Inspection and Reassembly1. Inspect inlet and outlet check valves for cracks, warping ordamage.2. Inspect the

4.47CARBURETOR - SPORTSMAN 45046. Remove the 5 screws that secure the fuel sender to the tank.7. Slowly lift the sender out of the tank. Lift the send

1.12GENERAL INFORMATIONMISC. NUMBERS/CHARTSStandard Torque SpecificationsThe following torque specifications are to be used as a general guideline. Th

4.48CARBURETOR - SPORTSMAN 450POOR IDLEIdle Too High• Idle adjusted improperly/idle mixture screwdamaged• Sticky vacuum slide• Throttle cable sticking

BODY / STEERING / SUSPENSION5.1CHAPTER 5BODY / STEERING / SUSPENSION5GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2BODY / STEERING / SUSPENSIONGENERAL INFORMATIONTorque SpecificationsNOTE: Refer to exploded views throughout thischapter for identification and loc

5.3BODY / STEERING / SUSPENSION5Plastic Insert Removal / InstallationSome Polaris ATVs use a two piece plastic insert in place of ametal screw. The p

5.4BODY / STEERING / SUSPENSIONBODYSide Panel RemovalSide panel removal is quick and easy, use the followinginstructions for removal and installation.

5.5BODY / STEERING / SUSPENSION5Foot Well Removal / Installation1. Remove the four plastic inserts (A) that secure the wheelwell to the front and rear

5.6BODY / STEERING / SUSPENSIONFront Storage Removal1. Remove the front radiator cap cover (A) by lifting upwardon the cover.2. Remove the four bolts

5.7BODY / STEERING / SUSPENSION5Winch Installation Area5. Remove the front cover piece by lifting up on sides of thetwo locking tabs as shown. Pull th

5.8BODY / STEERING / SUSPENSIONFront Storage Installation1. Place the front storage rack onto the frame.2. Install the four bolts (A) into the inside

5.9BODY / STEERING / SUSPENSION53. Place spacers on frame.4. Install rear rack onto rear frame and cab.5. Install the two bolts (B) and six (A) T-27 s

1.13GENERAL INFORMATION1SAE Tap Drill SizesMetric Tap Drill SizesDecimal Equivalents1/64 . . . . . . . . . . .. . . . . . . .01561/32 . . . . . . ..

5.10BODY / STEERING / SUSPENSIONSportsman Rear Cab / Fender Removal / Installation1. Follow the “REAR RACK REMOVAL” procedure toremove the rear rack.2

5.11BODY / STEERING / SUSPENSION5Sportsman Rear Storage Removal / Installation1. Follow the “REAR RACK REMOVAL” and “REARCAB REMOVAL” procedure to rem

5.12BODY / STEERING / SUSPENSIONSportsman Body Assembly Exploded ViewRear Cab AssemblyPull UP on rear of seat andback to disengage tabs at frontof sea

5.13BODY / STEERING / SUSPENSION5X2 Body Assembly Exploded ViewRear Cab AssemblyFrameFront Brush GuardSupportSide CoverSplash ShieldsFront CabFront Co

5.14BODY / STEERING / SUSPENSIONBody / Rack Exploded ViewsRack RailsRear RackRear Rack SupportFrameFront Brush GuardRadiator ShieldRadiator ScreenGril

5.15BODY / STEERING / SUSPENSION5Headlight Pod Exploded ViewDisassembly• Remove two side Phillips screws (A)• Remove one rear Phillips screw (B)• Lift

5.16BODY / STEERING / SUSPENSIONSTEERINGHandlebar Block Installation Procedure1. The pin (A) on the bottom side of the top handlebar block faces down

5.17BODY / STEERING / SUSPENSION5Steering / A-arm Exploded ViewNOTE: To avoid damage to tie rods and other steering components, be sure to install ti

5.18BODY / STEERING / SUSPENSIONA-Arm Replacement1. Elevate and safely support vehicle with weight removed from front wheel(s).2. Remove cotter pin fr

5.19BODY / STEERING / SUSPENSION5Ball Joint ReplacementNOTE: Refer to the illustration on the previous pagefor this procedure.1. Loosen front wheel n

1.14GENERAL INFORMATIONConversion Table°C to °F: 9 (°C + 40) 5 - 40 = °F °F to °C: 5 (°F + 40)  9 - 40 = °CUnit of Measure Multiplied by Converts t

5.20BODY / STEERING / SUSPENSIONSteering Post Removal1. Remove the front cab. 2. Remove the handle bar pod. 3. Remove the handle bar. 4. Remove the fu

5.21BODY / STEERING / SUSPENSION5Strut AssemblyNut - 15 ft.lbs.(21 Nm)WasherSpacer RubberUpper Pivot BallSpacer NutLower Pivot BallSpring RetainerSpri

5.22BODY / STEERING / SUSPENSIONSportsman Rear Suspension Assembly17 ft.lbs. (24 Nm)Stabilizer Bar35 ft.lbs. (48 Nm)30 ft.lbs.(41 Nm)Rear ShockLower C

5.23BODY / STEERING / SUSPENSION5X2 Rear Suspension Exploded ViewUpper Control ArmLower Control ArmRear ShockBushingsRear Compression SpringPreload Ad

5.24BODY / STEERING / SUSPENSIONX2 Torsion Bar Exploded ViewLinkage BushingStabilizer BarTorsion MountLinkage Asm.BushingStabilizer Bushing

5.25BODY / STEERING / SUSPENSION5X2 CARGO BOXExploded View

5.26BODY / STEERING / SUSPENSIONRemoval / InstallationIMPORTANT: Before attempting to remove the cargobox, be sure that the cargo box is not set up fo

5.27BODY / STEERING / SUSPENSION56. Lift up firmly in the cargo box release lever on either sideof the ATV. 7. Remove the four bolts attaching the rea

5.28BODY / STEERING / SUSPENSIONX2 SEAT ASSEMBLYExploded Views

5.29BODY / STEERING / SUSPENSION5X2 Seat Operation - Configuring Cargo Box For Passenger Riding1. Unlatch the driver seat backrest by turning the enga

1.15GENERAL INFORMATION1Glossary Of TermsABDC: After bottom dead center.ACV: Alternating current voltage.ADC: Active Descent Control.Alternator: E

5.30BODY / STEERING / SUSPENSIONDriver Seat Backrest Removal / Installation1. Configure the seating for 2-UP riding. With the passengerseat bottom in

CLUTCH SYSTEM6.1CHAPTER 6CLUTCH SYSTEM6SPECIAL TOOLS AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2SPEC

6.2CLUTCH SYSTEMSPECIAL TOOLS AND SPECIFICATIONSSpecial ToolsComponent Fastener TorquesTOOL DESCRIPTION PART NUMBERClutch Puller 2870506Clutch Holding

6.3CLUTCH SYSTEM6PVT EXPLODED VIEWSPVT Sealing And Ducting ComponentsDrive Clutch Exploded Views (Standard and Deluxe)Clutch Inlet DuctClampsBoot Duct

6.4CLUTCH SYSTEMDriven Clutch Exploded Views (Standard and Deluxe)STANDARD - NON EBS1. Torx Screw2. Cam Assembly3. Retaining Ring4. E-clip5. Washer6.

6.5CLUTCH SYSTEM6Engine Braking System (EBS) Exploded View WasherOne Way Clutch DriveWasherSpacer Shift WeightsRoller/BushingAssembly - Torque200 ft.l

6.6CLUTCH SYSTEMPVT SYSTEMPVT Operation OverviewThe Polaris Variable Transmission (PVT) consists of threemajor assemblies: 1) The Drive Clutch; 2) Th

6.7CLUTCH SYSTEM6EBS Clutch OperationThis EBS driven clutch provides the same engine brakingabilities as the EBS drive clutch.When the ATV is moving t

6.8CLUTCH SYSTEMDrive Clutch SpringThe drive clutch spring has two primary functions:1. Controls clutch engagement RPM. The springs whichhave a highe

6.9CLUTCH SYSTEM6Optional Shift WeightsShown below are optional shift weights which may be used in the PVT system. These shift weights have many diff

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONSThroughout this manual, important information is brought to your attention by the following symbols:S

NOTESGENERAL INFORMATION1.16

6.10CLUTCH SYSTEMPVT DryingIMPORTANT: If operating the ATV through water, besure to check the PVT cover and other ATVcomponents for water ingestion.

6.11CLUTCH SYSTEM68. Remove driven clutch offset spacers from the transmissioninput shaft. NOTE: Remember to keep spacers in order forproper clutch of

6.12CLUTCH SYSTEM7. Install clutch offset spacer(s) on transmission input shaft.8. Clean splines inside driven clutch and on the transmissioninput sha

6.13CLUTCH SYSTEM66. Measure the distance where the side straight edges intersectthe top, as shown in the illustration.7. Inspect belt for loose cords

6.14CLUTCH SYSTEMClutch Alignment1. Remove belt and install the Clutch Offset Alignment Tool(PN 2872292) as shown.2. With tool touching rear of driven

6.15CLUTCH SYSTEM6EBS DRIVE CLUTCH SERVICEDrive Clutch Disassembly1. Using a permanent marker, mark the cover, spider, andmoveable and stationary shea

6.16CLUTCH SYSTEMNOTE: It is important that the same number andthickness of washers are reinstalled beneath thespider during assembly. Be sure to not

6.17CLUTCH SYSTEM6Button To Tower Clearance Inspection1. Inspect for any clearance between spider button to tower.If clearance exists, replace all but

6.18CLUTCH SYSTEM2. Lift one-way clutch (3) and thrustwasher (4) off shaft.Replace as an assembly if worn, damaged, or if problemswere noted.3. Inspec

6.19CLUTCH SYSTEM6NOTE: Bushings are installed at the factory usingLoctite 609. In order to remove bushings it will benecessary to apply heat evenly

MAINTENANCE2.1CHAPTER 2MAINTENANCE2MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20CLUTCH SYSTEMCover Bushing Removal1. Install main adapter (Item 8) on puller.2. Install adapter reducer (Item 9).3. From outside of clutch cover,

6.21CLUTCH SYSTEM6C) “X”, or the marks that were made earlier under weight2. Install moveable sheave onto fixed sheave.3. Install spider spacers. Use

6.22CLUTCH SYSTEMEBS DRIVEN CLUTCH SERVICEDriven Clutch Disassembly 1. Remove driven clutch from the transmission input shaft.Do not attempt disassemb

6.23CLUTCH SYSTEM66. Remove the inside spider plate (D) and spider dampener(E). Inspect the spider dampener (E) for wear and replacedif needed.7. Rem

6.24CLUTCH SYSTEM12. Inspect the bearing for wear. Spin the bearing, if thebearing does not spin smoothly replace as needed. Toremove the bearing, s

6.25CLUTCH SYSTEM6Driven Clutch Bushing Installation1. Install puller adapter (Item 10) onto puller.2. Install adapter (Item 9) onto puller.3. Apply L

6.26CLUTCH SYSTEM3. Install the small and large retaining rings into the outersheave above the bearing.4. Line up the “X” on the moveable sheave with

6.27CLUTCH SYSTEM68. Install the spacer washer.9. Install the spring over the shaft (arrow).10. Install the clutch rollers (D) onto each side of the o

6.28CLUTCH SYSTEM15. Install the cam assembly (helix) over the shaft. Line up the“X” on the cam, “X” on spider, and “X” on the stationarysheave or us

6.29CLUTCH SYSTEM6Spider Removal1. Remove the limiter nut using the Clutch Spider Nut SocketPN 2870338. Install clutch in holding fixture and loosent

2.2MAINTENANCEAUXILIARY BRAKE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30AUXILIARY BRAKE ADJU

6.30CLUTCH SYSTEM4. Rubber backed buttons can and should be used in all ATVclutches if the hollow roller pin is changed to a solid rollerpin.NOTE: Th

6.31CLUTCH SYSTEM6Sheave / Bushing InspectionInspect the Teflon coating on the sheave bushings and coverbushing. Inspect BOTH sheaves for signs of we

6.32CLUTCH SYSTEMDrive Clutch Bushing Installation1. Place main adapter on puller.2. Apply Loctite 609 evenly to bushing bore insidemoveable sheave.3

6.33CLUTCH SYSTEM65. Install limiter nut on top of spider using the Clutch SpiderNut Socket (PN 2870338). Torque to specification. 6. Reinstall shift

6.34CLUTCH SYSTEMSTANDARD DRIVEN CLUTCHDisassembly1. Using special tool PN 8700220, apply and hold downwardpressure on the outer spring retainer and r

6.35CLUTCH SYSTEM64. Inspect the rollers in the stationary sheave for signs of wear.NOTE: Rollers and helix are non-serviceable items.Replacement of c

6.36CLUTCH SYSTEMPVT TROUBLESHOOTINGOverheatingIMPORTANT: During routine maintenance orwhenever PVT system overheating is evident, it'simportant

6.37CLUTCH SYSTEM6Problem, Cause and Remedy ChartTable 6-2: Problem, Cause and RemedySITUATION POSSIBLE CAUSE REMEDYEngine RPM below specified operati

6.38CLUTCH SYSTEMBelt burnt, thin spots-Abuse (continued throttle application when vehicle is stationary, excess load)-Caution operator to operate mac

FINAL DRIVE7.1CHAPTER 7FINAL DRIVE7SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3MAINTENANCE2MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest, most reliable condition. I

7.2FINAL DRIVESPECIFICATIONSTorque TableIMPORTANT: Verify which type of wheel ATV isequipped with (aluminum or steel) when torquingwheel nuts.Specia

7.3FINAL DRIVE78. Remove hub.9. Remove cotter pin and nut from lower A-arm ball joint.Remove lower A-arm from ball joint.10. Pull strut assembly out w

7.4FINAL DRIVEInstallation1. Install new spring ring on drive shaft. Apply an anti-seizecompound to splines. Align splines of drive shaft withfront

7.5FINAL DRIVE73. Disconnect A-arm from ball joint using a tie rod fork.4. Slide strut off end of drive shaft and tie it up out of the wayof the shaft

7.6FINAL DRIVE13. Install the small clamp on the boot.FRONT HUBDisassembly1. Remove outer snap ring.2. From the back side, tap on the outer bearing ra

7.7FINAL DRIVE7PROP SHAFT - FRONT OR REARRemoval and Installation1. Using Roll Pin Removal Tool (PN 2872608), remove theroll pin from prop shaft at re

7.8FINAL DRIVE3. Support U-joint in vise as shown and drive inner yoke downto remove remaining bearing ca4. Force U-joint cross to one side and lift o

7.9FINAL DRIVE74. Install snap ring to contain bearing cap just installed.Repeat procedure for other side.5. Install snap ring to contain bearing cap

7.10FINAL DRIVEDRIVE AXLE EXPLODED VIEWSDrive Shafts and PropshaftsNOTE: Refer to your parts manual for the proper replacement parts.CirclipInner CV

7.11FINAL DRIVE7FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS)Exploded View (Standard Models)Ref. # Description Qty Ref. # Description Qty1 B

2.4MAINTENANCEPeriodic Maintenance ChartPerform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (

7.12FINAL DRIVEOperationEngaging front gearcase: The AWD switch may be turned onor off while the vehicle is moving. AWD will not enable untilthe eng

7.13FINAL DRIVE75. Remove cotter pin, lower ball joint nut and A-arm fromball joint.6. Pull the hub and strut assembly out and pull the drive-shaftout

7.14FINAL DRIVE2. Remove bolts retaining the outer cover plate assembly.3. Remove the outer cover plate assembly.NOTE: Thrust bearing located between

7.15FINAL DRIVE76. Remove the LH output hub. Inspect the bearing andcontact surfaces of the output hub for signs of wear ordamage. Replace component i

7.16FINAL DRIVE11. Inspect the magnetic coil (A) in the outer cover plateassembly. Inspect the backlash pad (B) for excessive wear.NOTE: See “FRONT GE

7.17FINAL DRIVE7Reassembly / Inspection1. Replace all O-rings, seals, and worn components.2. Press the pinion shaft seal into the pinion cover, until

7.18FINAL DRIVE8. Install the ring gear and roll cage assembly into thegearcase housing.9. Install the armature plate on top of the roll cage / ring g

7.19FINAL DRIVE72. Using a 3/32 hex wrench, turn the back-lash screw out 3-4turns. Re-apply Loctite 262 onto the bottom screwthreads. 3. Turn the sc

7.20FINAL DRIVE4. Check to make sure the coil is seated in the U-shaped insertthat is pressed into the gearcase cover. The top of the coilshould be s

7.21FINAL DRIVE7FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS)ADC Gearcase Exploded View (Deluxe Models)Ref. # Description Qty Ref. # Descrip

2.5MAINTENANCE2Periodic Maintenance ChartPerform these procedures more often for vehicles subjected to severe use. E Emission Control System Service

7.22FINAL DRIVEOperationEngaging Front Gearcase: Active Descent Control (ADC) iscontrolled by the ECU and will not enable until the followingconditio

7.23FINAL DRIVE7ADC Coil TestingRefer to the following tests in Chapter 10:See “ALL WHEEL DRIVE (AWD) COIL” on page 10.24.See “ACTIVE DESCENT CONTROL

7.24FINAL DRIVE4. Remove the outer cover plate assembly. Remove andinspect the cover o-ring (1). Inspect thrust bearing (2) forwear. Replace items as

7.25FINAL DRIVE78. Remove the ring gear (1) and spacer (2).9. Remove and inspect the bearing surfaces of the output hub. 10. Thoroughly clean all part

7.26FINAL DRIVE14. Inspect the magnetic coil (1) in the outer cover plateassembly. Inspect the backlash pad (2) for excessive wear.NOTE: See “FRONT G

7.27FINAL DRIVE719. Remove the snap ring retaining the input shaft assembly.20. Remove the input shaft assembly. Inspect the pinion gear(1) for chipp

7.28FINAL DRIVE4. Coat new piston and o-rings with a moderate amount ofwhite lithium grease or assembly lube. Coat the edges of thepiston cavities. In

7.29FINAL DRIVE7Assembly1. Thoroughly clean the gearcase components beforebeginning reassembly. 2. Install a new seal in the main gearcase halve.3. In

7.30FINAL DRIVE8. Install a new seal (1) in the outer cover plate assembly.Install a new o-ring on the backlash pad (2) stem .NOTE: Ring gear backlash

7.31FINAL DRIVE712. Install new cover o-ring (1) on the cover plate assemblyand a new passage o-ring (2) on the gear case.13. Install the remaining o

2.6MAINTENANCEPeriodic Maintenance ChartPerform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (

7.32FINAL DRIVEREAR HUBRemoval1. Place the ATV in Park and lock the parking brake.Remove rear hub cap.2. Remove cotter pin (A).3. Loosen the hub retai

7.33FINAL DRIVE711. Remove both lower control arm bolts.12. Remove bearing carrier.Disassembly1. Remove outer snap ring.2. From the back side, tap on

7.34FINAL DRIVEAssembly1. Support bottom of bearing carrier housing.2. Start bearing in housing.3. Press bearing into place until outer race bottoms o

7.35FINAL DRIVE74. Lift bearing carrier until top aligns with upper control arm.Install and torque upper control arm bolt and torque tospecification.5

7.36FINAL DRIVEService1. Remove clamps from rubber boot(s) using the CV BootClamp Pliers (PN 8700226) (A).2. Photo below is shown without shaft for cl

7.37FINAL DRIVE75. Refit CV joint on interconnecting shaft by tapping with aplastic hammer on the joint housing. Take care not todamage threads on th

7.38FINAL DRIVE8. While pulling out on the CV shaft, fully extend the CV jointand slide a straight O-ring pick or a small slotted screwdriver between

7.39FINAL DRIVE76. Install rear wheel and torque wheel nuts to specification.7. Grease all fittings thoroughly with Premium U-JointLubricant (PN 2871

NOTESFINAL DRIVE7.40

GENERAL INFORMATION8.1CHAPTER 8GENERAL INFORMATION8TRANSMISSION - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7MAINTENANCE2LUBRICATION / FLUIDSSPORTSMAN Component Locations(Sportsman Only)(Deluxe)

8.2GENERAL INFORMATIONTRANSMISSION - GENERALMounting Exploded Viewx2x3x4x4x2x1x1x1

8.3GENERAL INFORMATION8Torque SpecificationsSpecial ToolsLubricationRefer to Chapter 2 for transmission lubricant type and capacity.Gear Selector Remo

8.4GENERAL INFORMATION11. Remove all fasteners (X) attaching the torsion mount, andcompletely remove the mount (Z) from the ATV.12. Remove both upper

8.5GENERAL INFORMATION8Transmission Installation1. Apply Polaris Premium All Season Grease (PN 2871423)to splines of front output shaft ,install new O

8.6GENERAL INFORMATION11. Once the PVT system is installed. Tighten all remainingtransmission mounting bolts to 40 ft.lbs. (57Nm). See page8.2 for tra

8.7GENERAL INFORMATION8TRANSMISSION SERVICEExploded View262242= THREAD LOCKING AGENT FOR ALL ‘FT. LBS.’ FASTENERS = THREAD LOCKING AGENT FOR ‘INCH LBS

8.8GENERAL INFORMATION242262262262262262

8.9GENERAL INFORMATION8Transmission Disassembly1. Place the transmission in the Neutral gear beforedisassembly.2. Drain and properly dispose of transm

8.10GENERAL INFORMATION10. Remove all cover bolts. Using suitable pry tools, removethe cover using the designated pry points. Tap cover withsoft face

8.11GENERAL INFORMATION815. Remove the T27 screws that secure the output gear (21)with a T27 hex socket or driver.16. Remove the shift drum (22) from

2.8MAINTENANCESPORTSMAN X2 Component locationsAWD/Turf SwitchThrottleIgnition/KeyInstrument ClusterWorklightDiagnosticReverseBrake Fluid ReservoirBrak

8.12GENERAL INFORMATION22. The reverse shaft should slide out of the silent chain (4) toseparate the assembly. 23. Remove the rest of the bearings fro

8.13GENERAL INFORMATION829. Use a 2 3/8” wrench to loosen and remove the front driveshaft snorkel tube (11).30. If needed, remove the seal from the fr

8.14GENERAL INFORMATION33. To remove the remaining bearing on the snorkel shaft (15),remove the retaining ring and press the bearing off.Transmission

8.15GENERAL INFORMATION86. Install the output gear assembly. Be sure to properly meshthe snorkel shaft bevel gear with the output bevel gear.Install t

8.16GENERAL INFORMATION2. Once the gear backlash is found, to install the snorkel lockscrew, you may have to rotate the snorkel tube clockwiseor count

8.17GENERAL INFORMATION86. Inspect the shift drum for any damage or wear. Inspect thesplines of the shift drum. Replace the O-rings on the end ofthe s

8.18GENERAL INFORMATION11. Install the oil deflector shield into the gearcase. ApplyLoctite™ 242 to the threads of the screws. Torque thescrews to 16-

8.19GENERAL INFORMATION815. Apply a continuous bead of Crankcase Sealant (3-Bond)(PN 2871557) to the LH gearcase mating surface and installthe cover.

8.20GENERAL INFORMATION22. Install the bellcrank onto the shift shaft. Note the keysplined on the bellcrank and shaft. Install the nut. Torquethe nut

BRAKES9.1CHAPTER 9BRAKES9SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.9MAINTENANCE2Polaris Lubricants, Maintenance and Service ProductsTable 2-1: PART NUMBERDESCRIPTIONEngine Lubricant2870791 Fogging Oil (12 oz. Aeroso

9.2BRAKESSPECIFICATIONSTorque TableNOTE: Refer to tightening procedures in this chapter. Some special procedures are used when torquingcertain bolts

9.3BRAKES9BRAKE SYSTEM EXPLODED VIEWSX2 System Component Exploded View1) Master Cylinder Cover Screws: 7 in.lbs. (0.79 Nm)2) Banjo Style Fitting: 15 f

9.4BRAKESSportsman System Component Exploded ViewAll Banjo Style Fittings: 15 ft.lbs. (21 Nm)All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm)All Bl

9.5BRAKES9BRAKE CALIPER EXPLODED VIEWSSportsman and X2 Front Caliper AssemblyX2 Rear Caliper AssemblyA. Socket Set ScrewB. Bleeder Screw C. Calip

9.6BRAKESSportsman Rear Caliper AssemblyHYDRAULIC BRAKE SYSTEMOperation OverviewThe Polaris disc brake system consists of the followingcomponents or a

9.7BRAKES9This system also incorporates a diaphragm (E) as part of thecover gasket; and a vent port (F) located between the gasket andthe cover. The

9.8BRAKES3. Inspect vent slots (A) in cover and remove any debris orblockage.4. If changing fluid, remove old fluid from reservoir with aMity Vac pum

9.9BRAKES912. Install diaphragm, sight glass, cap and screws. 13. Wiggle and press down on the cap to be sure it fits evenlyand snug. 14. Torque

9.10BRAKES2. Place new sealing washers on each side of banjo fitting onthe brake line and torque banjo bolt to specification.3. Fill reservoir with DO

9.11BRAKES95. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed.NOTE: Brake fluid will be forced thro

1GENERAL2MAINTENENCE3ENGINE4FUEL SYSTEM5BODY / SUSPENSION6CLUTCH7TRANSMISSION8FINAL DRIVE9BRAKES10ELECTRICAL11INTERNATIONAL

2.10MAINTENANCEPolaris Lubricant Symbol IdentificationNOTE: The symbols used are for quick reference in identifyingwhich lubricant/grease to use on e

9.12BRAKES2. Compress mounting bracket and make sure dust boots arefully seated. Install pads with friction material facing eachother. 3. Install ca

9.13BRAKES92. Measure the disc thickness at eight different points aroundthe pad contact surface. Replace disc if worn beyondservice limit.3. Mount d

9.14BRAKESFRONT CALIPERRemoval1. Loosen and remove brake line to caliper. Place a containerunder caliper to catch fluid draining from brake line.2. P

9.15BRAKES9Inspection1. Inspect caliper body for nicks, scratches or wear. Measurebore size and compare to specifications. Replace if damageis eviden

9.16BRAKES4. Compress the mounting bracket and make sure the dustseals are fully seated. Install the brake pads. Clean the discand pads with brake p

9.17BRAKES9REAR BRAKE PADX2 Pad Removal1. Elevate and support the rear of the ATV. 2. Remove the rear wheel3. Loosen pad adjuster screw 2-3 turns. 4.

9.18BRAKES9. Measure the thickness of the pad material. Replace pads ifworn beyond the service limit.X2 Pad Installation1. Lubricate mounting bracket

9.19BRAKES9Sportsman Rear Pad Removal1. Support the machine. Remove the rear tire.2. Remove the slide pin clips from the slide bolt.3. Loosen the sli

9.20BRAKESSportsman Rear Pad Installation1. Install new brake pads in caliper body.2. Install and tighten the slide pin with a hex wrench.3. Install c

9.21BRAKES9X2 REAR CALIPERRemoval1. Clean caliper area before removal.2. Place a container below the caliper to catch brake fluid thatwill drain from

2.11MAINTENANCE2Lubrication Components* More often under severe use, such as operated in water or under severe loads. 1 Semi-annually or 50 hours of o

9.22BRAKESInspection1. Inspect caliper body for nicks, scratches or wear. Measurebore size and compare to specifications. Replace if damageis evident

9.23BRAKES94. Compress the mounting bracket and make sure the dustseals are fully seated. Install the brake pads. Clean the discand pads with brake

9.24BRAKES9. Measure the inside diameter of the rear caliper. The caliperbody is a 2-step piston. The rear step is measured as wellas the outside st

9.25BRAKES9NOTE: The slide pins should be torqued wheninstalled on caliper mount.4. Install caliper and torque mounting bolts to specification.5. Inst

9.26BRAKESREAR MASTER CYLINDERX2 Exploded ViewABDEFGIHCDEJA. Master Cylinder BoltsB. Rear Brake Line C. Rear Master CylinderD. Bushing(s)

9.27BRAKES9OverviewPolaris disc brake systems are light weight, low maintenanceand perform well in the conditions ATV’s routinely encounter.However, t

9.28BRAKESSportsman Rear Master Cylinder Removal / Installation1. Remove the RH footwell to gain access to the rear mastercylinder.2. Remove the rear

9.29BRAKES9Pedal Removal and Installation1. Remove the RH footwell to gain access to the rear mastercylinder.2. Remove the cotter key.3. Remove the wa

NOTESBRAKES9.30

ELECTRICAL10.1CHAPTER 10ELECTRICAL10GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.12MAINTENANCEFront Gearcase LubricationThe front gearcase lubricant level should be checked andchanged in accordance with the maintenance schedule.

10.2ELECTRICALLIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36HIGH

10.3ELECTRICAL10GENERAL INFORMATIONSpecial ToolsIgnition System / Basic Electrical ComponentsTable 10-1: PART NUMBER TOOL DESCRIPTIONPV-43568Fluke77

10.4ELECTRICALElectrical Service NotesKeep the following notes in mind when diagnosing an electricalproblem:• Refer to wiring diagram for stator and e

10.5ELECTRICAL10POWER DISTRIBUTION MODULES (PDM)Sportsman EFI OverviewThe Power Distribution Module (PDM) integrates these electronic features found o

10.6ELECTRICALBattery Protected Output The battery protected output (BAT_PROT) provides solid-state-circuit-breaker (SSCB) outputs and enables most of

10.7ELECTRICAL10CONNECTOR 1 - PIN # SIGNAL NAME DESCRIPTION - IPS = Intelligent Power SwitchJ1-A ACC_PWR IPS that provides power to the accessoriesJ1

10.8ELECTRICAL10CHARACTERISTIC PARAMETER UNIT NOTEOperating Temperature -40 to +55 CAmbient temperatures at which moduleshould remain within specifie

10.9ELECTRICAL10ECM_MEM OUTPUT (constant power for ECM and Instrument Cluster)MEM Circuit Limit 0.2 1.2 Amp Current capability of the outputREVERSE PO

10.10ELECTRICALSportsman 450 OverviewThe Power Distribution Module (PDM) integrates these electronic features found on the Sportsman 450; rectifier/re

10.11ELECTRICAL10the micro-controller will remain 'ON' until RUN input goes lowby disconnection of the BAT_PROT via the key switch or on/off

2.13MAINTENANCE2Transmission LubricationThe transmission lubricant level should be checked and changedin accordance with the maintenance schedule. To

10.12ELECTRICALCHARACTERISTIC PARAMETER UNIT NOTEOperating Temperature -40 to +55 CAmbient temperatures at which moduleshould remain within specified

10.13ELECTRICAL10INSTRUMENT CLUSTEROverviewIntroduction Refer To Illustration 1: The Polaris ATV Instrument Cluster is powered by batteryvoltage (12 V

10.14ELECTRICAL4. High/Low Battery Voltage• This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charge

10.15ELECTRICAL10Screen 2: Tachometer (Ill. 3) indicates engine rpm.Screen 3: AWD diagnostic screen. This screen indicateswhether or not current is f

10.16ELECTRICAL5. Programmable Service Interval:The purpose of the programmable service interval is to providethe consumer and dealer with a convenie

10.17ELECTRICAL10Screen 6: Miles/Kilometers: The display in the trip meter and odometer can be changed todisplay either kilometers or miles. The cur

10.18ELECTRICALSpeedometer Removal1. Remove the three screws that secure the headlight podcover and disconnect the wire connectors from theinstrument

10.19ELECTRICAL10ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTINGTEST 1 - No All Wheel Drive

10.20ELECTRICALTEST 2 - No Speedometer DisplayTEST 3 - No Reverse Speed Limit

10.21ELECTRICAL10TEST 4 - No AWD Hub Safety Limit

2.14MAINTENANCEADC Differential Hydraulic Circuit Fluid Change1. Make sure vehicle is parked on flat ground and allowed tosit at least 30 minutes prio

10.22ELECTRICALTEST 5 - Reverse Speed Limiter Activated In Forward GearTEST 6 - Wheel Speed Sensor

10.23ELECTRICAL10TEST 7 - Fuel Gauge Display Not WorkingTEST 8 - Shift Indicator Not Working

10.24ELECTRICALACTIVE DESCENT CONTROL (ADC) COILOperation Overview• AWD switch must be ‘ON’.• PDM pin ‘M’ on SSCB #1 controls the power to the ADC hub

10.25ELECTRICAL10COOLING SYSTEM COMPONENTSFan Control Circuit OperationPower is supplied to the fan via the Orange/Black wire when therelay is ON. Th

10.26ELECTRICALCoolant Temperature SensorThe coolant temperature sensor can be tested using an ohmmeteror voltmeter.If the ECT circuit is open the eng

10.27ELECTRICAL10ELECTRONIC THROTTLE CONTROL (ETC) SWITCHOperation OverviewThe Electronic Throttle Control (ETC) system is designed tostop the engine

10.28ELECTRICALIGNITION SYSTEMOverviewThe Sportsman has incorporated into it's design a DC/ CDI ignition system. The DC/ ignition system relies o

10.29ELECTRICAL10Components of EFI Alternator and DC / CDI Ignition System

10.30ELECTRICALEFI Ignition System Testing Flow Chart

10.31ELECTRICAL10Crankshaft Position Sensor GapMeasure trigger coil gap with a feeler gauge. The gap should be0.4 - 1.2 mm (0.015 - .047 in.).Ignitio

2.15MAINTENANCE2Throttle InspectionCheck for smooth throttle opening and closing in all handlebarpositions. Throttle lever operation should be smooth

10.32ELECTRICALCHARGING SYSTEMCurrent Draw - Key OffConnect an ammeter in series with the negative battery cable.Check for current draw with the key o

10.33ELECTRICAL10TEST 1: Resistance Value of Each Stator Leg1. Measure the resistance value of each of the three stator legs: Y1 to Y2, Y1 to Y3, and

10.34ELECTRICALCharging System Testing DiagramsWhenever charging system problems are suspected, proceed with the following system check after verifyin

10.35ELECTRICAL10(PDM)

10.36ELECTRICALDIFFERENTIAL SOLENOIDTestingDisconnect from the wire harness. Using a digital ohmmeter,test the solenoid at the connector leads and com

10.37ELECTRICAL104. Turn the headlight lamp socket counter-clockwise andremove.5. Carefully remove head lamp bulb from housing.6. Remove the head lamp

10.38ELECTRICAL8. Reverse the steps to install the new housing and reassemblethe pod.NOTE: he distance from the head lamp parting lineto the end of th

10.39ELECTRICAL102. Pull the harness assembly out from the headlight assembly.3. Remove the lamp and replace with a new head lamp.NOTE: Do not touch

10.40ELECTRICALWork Light SwitchRemove the headlight pod cover to locate the switch wires. Theswitch (A) snaps out by pushing in on the tabs on both

10.41ELECTRICAL103. X2 and Sportsman - Carefully pull out the red locking tabon the connector. 4. X2 and Sportsman - Once the red tab is pulled out, p

2.16MAINTENANCEFuel System• Always stop the engine and refuel outdoors or in a wellventilated area.• Do not smoke or allow open flames or sparks in or

10.42ELECTRICALSPEED SENSORTestingUsing the special tools listed, test the speed sensor according tothe tester instructions. Remove sensor and inspect

10.43ELECTRICAL10ACCESSORY POWERWire ConnectionsWinch InstallationThe Sportsman models have the main winch cables routed andinstalled from the factory

10.44ELECTRICALSTARTER SYSTEM TroubleshootingStarter Motor Does Not Run• Battery discharged. Low specific gravity• Loose or faulty battery cables or

10.45ELECTRICAL10Starter Lockout Diagram- EFIStarter Lockout Diagram- Sportsman 450

10.46ELECTRICALStarter Motor Removal / DisassemblyNOTE: Use electrical contact cleaner to clean startermotor parts. Some solvents may leave a residu

10.47ELECTRICAL104. Inspect surface of commutator for wear or discoloration.See Steps 3-6 of ‘Armature Testing’.Brush Inspection1. Measure length of e

10.48ELECTRICALStarter Reassembly1. Inspect permanent magnets in starter housing. Make surethey are not cracked or separated from housing. Placearmat

10.49ELECTRICAL10STARTER DRIVEPinion Gear - Anti-Kick Out Shoe, Garter Spring ReplacementIf the garter spring is damaged, the overrun clutch may fail

10.50ELECTRICALSTARTER SYSTEM TESTING FLOW CHARTCondition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before pr

10.51ELECTRICAL10BASIC WINCH WIRINGPre-wired Models

2.17MAINTENANCE2Fuel FilterThe fuel filter should be replaced in accordance with thePeriodic Maintenance Chart.1. Locate filter at the front of the AT

10.52ELECTRICALTROUBLESHOOTING DIAGRAMSPower On - EFIStart Circuit - EFITo ECU Pin 12

10.53ELECTRICAL10Ignition Coil - EFIFuel Pump - EFI

10.54ELECTRICALFan - EFICharging System - EFI

10.55ELECTRICAL10All Wheel Drive - EFITransmission Switch - EFI

10.56ELECTRICALReverse Override - EFIDifferential Solenoid - X2

10.57ELECTRICAL10BATTERYBattery IdentificationNOTE: It is important to identify what type of batteryyou have installed in your ATV. Different types

10.58ELECTRICAL4. Add electrolyte to bring level back to upper level mark oncase.NOTE: This is the last time that electrolyte shouldbe added. If the

10.59ELECTRICAL104. Install clear battery vent tube from vehicle to battery vent. 5. Reinstall the holder strap.Off Season StorageTo prevent battery

10.60ELECTRICALcell battery. Readings of 1.270 or greater should be observed ina fully charged battery. Differences of more than .025 betweenthe lowe

10.61ELECTRICAL106. Install clear battery vent tube from vehicle to battery vent.7. Route cables so they are tucked away in front and behindbattery.Lo

2.18MAINTENANCESpark Plug1. Remove spark plug high tension lead. Clean plug area sono dirt and debris can fall into engine when plug isremoved.2. Remo

10.62ELECTRICALLow Maintenance Battery - OCV- Open Circuit Voltage TestBattery voltage should be checked with a digital multitester.Readings of 12.8 v

11.1500 EFI INTERNATIONAL / QUADRICYCLE11500 EFI INTERNATIONAL / QUADRICYCLE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 11.2OVERVIEW . . . . .

11.2500 EFI INTERNATIONAL / QUADRICYCLE11500 EFI INTERNATIONAL / QUADRICYCLE BRAKE SYSTEMOverviewThe Sportsman International / Quadricycle brake syste

11.3500 EFI INTERNATIONAL / QUADRICYCLE11Exploded ViewFoot Brake SupplyHand Brake Supply

11.4500 EFI INTERNATIONAL / QUADRICYCLE11500 EFI INTERNATIONAL / QUADRICYCLE STEERING POST AND LOCKSteering Assembly Exploded ViewThe 500 EFI Internat

11.5500 EFI INTERNATIONAL / QUADRICYCLE11500 EFI QUADRICYCLE EMISSIONS SYSTEMOverview500 EFI Quadricycle model ATVs are equipped with an emissions sys

11.6500 EFI INTERNATIONAL / QUADRICYCLE500 INTERNATIONAL & QUADRICYCLE ELECTRICALTurn / Hazard Signal Diagram

IX.1IXAA-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 1

IX.2Crankshaft Position Sensor Gap . . . . . . . . . . . . . . . . . .10.31Crankshaft Straightening . . . . . . . . . . . . . . . . . . . . . . . . .

IX.3IXHHandlebar Block Installation Procedure . . . . . . . . . . . . . 5.16Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.19MAINTENANCE2New Batteries: Batteries must be fully chargedbefore use or battery life can be reduced by 10-30%of full potential. Charge battery fo

IX.4Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5Special Tools, Engine . . . . . . . . . . . . . . . . . . . .

IX.5IXWheels, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32Wheels, Tire Pressure . . . . . . . . . . . . . . . . . . . . .

IX.6

WD-1WIRE DIAGRAM2007 SPORTSMAN ACTIVE DESCENT CONTROL (ADC) WIRE DIAGRAM

WD-2WIRE DIAGRAMINTENTIONAL BLANK PAGE

WD-3WIRE DIAGRAM2007 SPORTSMAN 450 WIRE DIAGRAM

WD-4WIRE DIAGRAM

WD-5WIRE DIAGRAM2007 SPORTSMAN 500 EFI ‘STANDARD’ WIRE DIAGRAM

WD-6WIRE DIAGRAM

WD-7WIRE DIAGRAM2007 SPORTSMAN 500 EFI ‘DELUXE’ WIRE DIAGRAM

NOTES

2.20MAINTENANCECooling System Pressure TestRefer to Chapter 3 for pressure test procedure.Coolant Level InspectionThe recovery bottle, located on the

WD-8WIRE DIAGRAM

WD-9WIRE DIAGRAM2007 SPORTSMAN 500 EFI INTERNATIONAL WIRE DIAGRAM

WD-10WIRE DIAGRAM

WD-11WIRE DIAGRAM2007 SPORTSMAN 500 EFI X2 WIRE DIAGRAM

WD-12WIRE DIAGRAM

WD-13WIRE DIAGRAM2007 SPORTSMAN 500 EFI X2 QUADRICYCLE WIRE DIAGRAM

WD-14WIRE DIAGRAM

2.21MAINTENANCE24. Loosen clamp and remove air filter assembly.Cleaning:5. Slip the pre-filter element off of main element. Clean thepre filter with h

2.22MAINTENANCEBreather Filter InspectionFour-cycle ATV engines are equipped with a breather filter. Thein-line filter is similar in appearance to a f

2.23MAINTENANCE2Engine Oil LevelThe oil tank is located on the left side of the vehicle. To checkthe oil level:1. Set machine on a level surface.2. Cl

2.24MAINTENANCE5. Place a drain pan beneath oil tank and remove the drain plug(A). CAUTION: Oil may be hot. Do not allow hot oil tocome into contact w

2.25MAINTENANCE223. Re-check the oil level on the dipstick and add oil asnecessary to bring the level to the upper mark on thedipstick.24. Dispose of

2.26MAINTENANCE7. Verify accurate TDC positioning by observing the “T”mark aligned with the pointer in the timing inspection hole.In this position the

2.27MAINTENANCE2Tie Rod End/Steering Inspection • To check for play in the tie rod end, grasp the steeringtie rod, pull in all directions feeling for

2.28MAINTENANCEToe Alignment AdjustmentIf toe alignment is incorrect, measure the distance betweenvehicle center and each wheel. This will tell you wh

2.29MAINTENANCE23. If some carbon is expelled, cover the exhaust outlet andlightly tap on the pipe around the clean out plugs with arubber mallet whil

GENERAL INFORMATION1.1CHAPTER 1GENERAL INFORMATION1MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.30MAINTENANCEBrake Pad InspectionPads should be changed when the friction material is worn to.180” / 4.6 mm, or about the thickness of a dime.Hose/F

2.31MAINTENANCE2Suspension Spring Preload AdjustmentOperator weight and vehicle loading affect suspension springpreload requirements. Adjust as necess

2.32MAINTENANCEWheel, Hub, And Spindle Torque TableWheel Removal Front or Rear1. Stop the engine, place the transmission in Park and lockthe parking b

2.33MAINTENANCE2Tire Inspection• Improper tire inflation may affect ATVmaneuverability.• When replacing a tire always use original equipmentsize and t

2.34MAINTENANCEWinch Operation (If Equipped)This information is for Sportsman models equipped with awinch in the front.Winch Handlebar ControlsThe win

2.35MAINTENANCE2Yellow (6 Ga.) wires to the winch. Refer to the installationinstructions for more details.Locate the Red wire (6 Ga.) with the yellow

2.36MAINTENANCEATV Cleaning & StorageCleaning the ATVKeeping your ATV clean will not only improve its appearancebut it can also extend the life of

2.37MAINTENANCE25. Turn the engine over several times with the recoil only toensure coverage of piston rings, cylinder walls andcrankshaft bearings.6.

2.38MAINTENANCEMaintenance ScheduleService Date Hours / Miles Service Performed Serviced By:

3.1CHAPTER 3ENGINE3ENGINESPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2GENERAL INFORMATIONMODEL NUMBER INFORMATIONModel NumberThe machine model number must be used with any correspondence regarding warranty or service.

3.2ENGINEOIL PUMP REMOVAL/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33OIL PUMP ASSEMBLY . . . . . . .

3.3ENGINE3SPECIFICATIONSTorque SpecificationsSpecial ToolsEngine Fastener Torque PatternsTighten cylinder head, cylinder base, and crankcase fasteners

3.4ENGINEEngine Service DataCylinder Head / ValveEH50PLERocker Arm Rocker arm ID .8669-.8678" (22.020-22.041 mm)Rocker shaft OD .8656-.8661"

3.5ENGINE3Engine Service DataKEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;PTO: Power Take Off.Cyli

3.6ENGINEGENERAL ENGINE SERVICEPiston IdentificationThe piston may have an identification mark or the piston maynot have an identification mark for pi

3.7ENGINE3Cooling SystemSystem Pressure Test1. Remove radiator cap cover located in storage box.2. Remove recovery bottle hose from coolant filler.3.

3.8ENGINERECOMMENDED COOLANTUse only high quality antifreeze/coolant mixed with distilledwater in a 50/50 or 60/40 ratio, depending on freeze protecti

3.9ENGINE3Engine Installation NotesAfter the engine is installed in the frame, review this checklistand perform all steps that apply.General Items1. I

3.10ENGINEA finished cylinder should have a cross-hatch pattern to ensurepiston ring seating and to aid in the retention of the fuel/oilmixture during

3.11ENGINE33. If the crank rod pin location is 180o from the dial indicator(opposite that shown above), it will be necessary to spreadthe crankshaft a

1.3GENERAL INFORMATION1PublicationsPaint CodesReplacement KeysReplacement keys can be made from the original key (Phoenix excluded). To identify whic

3.12ENGINEEH50PL Oil Flow DiagramEH50PL Oil Flow ChartVent HoseOil TankOil FilterOil feed to filterFrom filter to One way valvecrankshaftTop fitting i

3.13ENGINE3EH50PL Engine Exploded ViewsCrankshaft Cylinder/and PistonCylinder HeadCrankcaseValvetrain

3.14ENGINEENGINE DISASSEMBLYCam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal1. Remove ignition timing inspection plug from recoilhousing.To position c

3.15ENGINE32. Push ratchet pawl and hold it. The plunger should movesmoothly in and out of the tensioner body.3. Release ratchet pawl and push inward

3.16ENGINE4. Measure I.D. of each rocker arm and compare tospecifications.5. Measure I.D. of both rocker arm shaft supports and visuallyinspect surfac

3.17ENGINE38. Secure cam chain with a wire to prevent it from falling intothe crankcase.9. Inspect cam sprocket teeth for wear or damage. Replace ifne

3.18ENGINEAutomatic Compression Release Installation1. Slide spring onto shaft.2. Apply engine oil to release lever shaft.The actuator ball must be he

3.19ENGINE33. Measure height of each cam lobe using a micrometer.Compare to specifications.4. Measure camshaft journal outside diameter (O.D.)5. Measu

3.20ENGINECylinder Head Exploded View, EH50PLEH50PLA

3.21ENGINE3Cylinder Head Inspection1. Thoroughly clean cylinder head (A) surface to remove alltraces of gasket material and carbon. Cylinder Head War

1.4GENERAL INFORMATIONSportsman ‘Deluxe’ and ‘Standard’ Model Component ComparisonFor Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were

3.22ENGINE4. Measure free length of spring with a Vernier caliper. Checkspring for squareness. Compare to specifications. Replacespring if either meas

3.23ENGINE3Combustion ChamberClean all accumulated carbon deposits from combustionchamber and valve seat area with a soft wire brush.Valve Seat Recond

3.24ENGINE3. Place cylinder head on cylinder head table. NOTE: Be surecylinder head is still at 212o F (100o C) before installingnew guides.4. Place a

3.25ENGINE313. Remove valve and check where the Prussian Blue™indicates seat contact on the valve face. The valve seatshould contact the middle of the

3.26ENGINECylinder Head AssemblyNOTE: Assemble the valves one at a time to maintainproper order.1. Install new valve seals on valve guides.2. Apply e

3.27ENGINE3Cylinder/Piston Removal and InspectionNOTE: Follow engine disassembly procedures toremove valve cover, camshaft and rocker arms, andcylin

3.28ENGINEPiston Removal1. Remove circlip. Note piston directional arrow pointingtoward the right (Mag) side of engine.1. Remove piston circlip and pu

3.29ENGINE33. Inspect cylinder for wear, scratches, or damage.4. Inspect cylinder for taper and out of round with atelescoping gauge or a dial bore ga

3.30ENGINE2. Measure piston pin O.D. Replace piston and/or piston pinif out of tolerance.3. Measure connecting rod small end ID.4. Measure piston ring

3.31ENGINE3Starter Drive Removal/Inspection1. Remove recoil housing bolts and remove housing.2. Remove starter drive assembly. Note the thrust washerl

1.5GENERAL INFORMATION1Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component ComparisonFor Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were of

3.32ENGINE7. Remove large sealing O-Ring from outer edge of statorplate.Cam Chain/Tensioner Blade1. Remove bolt securing tensioner blade to crankcase

3.33ENGINE3Crankcase Separation1. Remove flange bolts (10) from magneto side crankcaseevenly in a criss-cross pattern.2. Separate crankcase by tapping

3.34ENGINE9. Measure pump end clearance using a feeler gauge andstraight edge.10. Measure clearance between outer feed rotor and pump bodywith a feele

3.35ENGINE33. Turn the shaft until balancer counter weights clear thecrankshaft and remove the balancer shaft from thecrankcase.4. Inspect the balance

3.36ENGINECrankcase Bearing Inspection 1. Remove the seal from the PTO side crankcase.2. Inspect the crankshaft main bearings, balancer shaftbearings,

3.37ENGINE3Bearing InstallationNOTE: To ease bearing installation, warm thecrankcase until hot to the touch. Place the bearings in afreezer.1. Instal

3.38ENGINE6. Measure the distance from the Magneto crankcase matingsurface to the main bearing using the same method andrecord.7. Subtract the thickne

3.39ENGINE314. Measure the distance from the Mag crankcase matingsurface to the balance shaft bearing using a dial caliper anda straight edge. Subtra

3.40ENGINEENGINE REASSEMBLYPump Shaft Oil Seal Installation1. Install the seal from the outside of the crankcase (waterpump side) with the spring faci

3.41ENGINE3Crankcase Assembly1. Apply Crankcase Sealant (PN 2871557) to the crankcasemating surfaces. Be sure the alignment pins are in place.2. Set t