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Contents
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Table of Contents
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Troubleshooting
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Bookmarks
Quick Links
2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFI
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100
Hwy 55 Medina Minnesota 55340.
2007 Sportsman 450 / 500 EFI / 500 X2 EFI Service Manual PN 9920560
© Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
Chapters
Troubleshooting
Summary of Contents for Polaris 2007 Sportsman 500 EF
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All Off Road
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BY USE
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Adventure
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Desert/Dune Riding
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Farming
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Hunting
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Mudding
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Property Maintenance
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Ranching
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Trail Riding
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BY RIDER
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2 to 3 Seat Vehicles
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4 to 6 Seat Vehicles
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Youth Vehicles
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BY BRAND
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RZR Sport Side-by-Sides
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Polaris XPEDITION Adventure Side-by-Sides
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GENERAL Rec/Utility Side-by-Sides
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RANGER Utility Side-by-Sides
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Sportsman ATVs
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Polaris Off Road Home
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SHOPPING TOOLS
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Find a Dealer
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Help Me Choose
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Compare Models
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Build
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Get Local Price
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Estimate Trade-In
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Special Offers
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Search New Inventory
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Search Used Inventory
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Payment Calculator
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Financing
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Insurance
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Catalogs
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RZR Models
- Model Lineup
- Build & Price
- Compare Models
- Reviews
- RZR Homepage
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TRAIL
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RZR Trail
Starting at
$15,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Take on 50″ trails with the most agile, comfortable ride for tight turns. With the quickest acceleration, plush all-day riding, and available industry-leading technology to explore more.
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RZR Trail S
Starting at
$17,899
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Class-leading 60″ trail capability delivers uncompromised agility and comfort. With the quickest acceleration, plush all-day riding, and available industry-leading technology to explore more.
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MULTI-TERRAIN
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RZR XP
Starting at
$20,999
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The next revolution of the industry’s best-selling sport side-by-side with a rugged design, all-day comfort, and legendary performance.
Seating Options: 2 Seat — 4 Seat
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RZR Pro XP
Starting at
$24,599
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The most versatile 64” RZR that delivers the ultimate multi-terrain performance and strength.
Seating Options: 2 Seat — 4 Seat
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WIDE OPEN
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RZR Turbo R
Starting at
$27,799
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
A wide stance (74″), turbocharged (181 HP) and easily maneuverable side-by-side delivering rugged strength straight from the factory to take on the roughest terrain.
Seating Options: 2 Seat — 4 Seat
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RZR Pro R
Starting at
$37,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
For those looking to reach the next level, Pro R features 225 HP, a 74″ width and 29″ of usable travel, this machine delivers revolutionary power and total control.
Seating Options: 2 Seat — 4 Seat
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LIMITED INVENTORY REMAINING
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RZR XP 1000
Starting at
$21,899
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The industry’s best selling performance side-by-side with power, suspension and agility for the trail.
Seating Options: 2 Seat — 4 Seat
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Polaris XPEDITION Models
- Model Lineup
- Build & Price
- Compare Models
- Polaris XPEDITION Homepage
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Polaris XPEDITION XP
Starting at
$28,999
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Get ready for your next adventure that will take your crew and all the gear you can fit in the large dumping cargo box beyond the trailhead.
Seating Options: 2 Seat — 5 Seat -
Polaris XPEDITION ADV
Starting at
$29,999
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Load up your gear, break away from the crowd, and start your next adventure with a fully covered cab and cargo box to take your crew and gear deep into the backcountry.
Seating Options: 2 Seat — 5 Seat
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GENERAL Models
- Model Lineup
- Build & Price
- Compare Models
- Reviews
- GENERAL Homepage
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GENERAL 1000
Starting at
$17,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Unlock more adventure with the performance, versatility and comfort you need in the industry’s premier crossover side-by-side. Equipped with an ultra-responsive 100 HP engine, True On-Demand AWD, 600 lb. dumping cargo box, 1,500 lb. towing capacity and rider-optimized premium interior packed into a 60″ stance machine.
Seating Options: 2 Seat -
GENERAL XP 1000
Starting at
$24,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The GENERAL XP 1000 is the most capable crossover side-by-side. With a 64″ stance and an upgrade to high clearance A-Arms, 30″ tires, Walker Evans shocks, front bumper and a 4,500 lb. HD Plus winch, it will elevate your experience and take you to adventures that break new ground.
Seating Options: 2 Seat — 4 Seat
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RANGER Models
- Model Lineup
- Build & Price
- Compare Models
- Reviews
- RANGER Homepage
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MID-SIZE
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RANGER SP 570
Starting at
$11,699
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Great for work, fun to ride, and the perfect fit. Get more done and have more fun with 44 HP, 1,500 Lb. towing and 11″ ground clearance.
Seating Options: 2 Seat — 4 Seat
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RANGER SP 570 NorthStar Edition
Starting at
$19,299
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The RANGER SP 570 NorthStar brings more comfort with fully enclosed heated cab, so you can stay warm from the trails to tasks around the property.
Seating Options: 2 Seat — 4 Seat
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FULL-SIZE
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RANGER 570 Full-Size
Starting at
$12,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
It helps you do more and spend less.
Seating Options: 3 Seat — 6 Seat
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RANGER 1000
Starting at
$14,799
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Built to deliver capability, comfort and last longer.
Seating Options: 3 Seat — 6 Seat
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RANGER XP 1000
Starting at
$20,299
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Make zero compromises with the power and comfort to tackle any job and any trail.
Seating Options: 3 Seat — 6 Seat
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RANGER XP 1000 NorthStar Edition
Starting at
$27,899
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The performance of a RANGER XP 1000, with a full cab system and factory installed heating and air conditioning.
Seating Options: 3 Seat — 6 Seat
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SPECIAL EDITIONS
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RANGER XP 1000 NorthStar Edition Trail Boss
Starting at
$34,399
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Features the comfort of the RANGER XP 1000 NorthStar Edition plus enhanced capability with high-clearance arched A-Arms, self-leveling suspension, and Active Descent Control to help you do even more.
Seating Options: 3 Seat — 6 Seat
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RANGER CREW XP 1000 Texas Edition
Starting at
$24,299
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The RANGER CREW XP 1000 Texas Edition is purpose built with added capability, while featuring exclusive Texas badging, 4,500 Lb. winch, 29″ tires and sport roof for a premium and refined look.
Seating Options: 6 Seat
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ELECTRIC
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RANGER XP Kinetic
Starting at
$24,999
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $500 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The RANGER XP Kinetic provides the power to do more with uncompromised capability, unrivaled durability, and the refined performance of an all-electric powertrain.
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Sportsman Models
- Model Lineup
- Build & Price
- Compare Models
- Reviews
- Sportsman Homepage
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RECREATION & UTILITY
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Starting at
$6,999
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Reliable Sportsman power, performance, and comfort, all at a best-in-class value.
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Sportsman 570
Starting at
$7,999
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The best-selling automatic 4×4 ATV with a powerful 44 HP ProStar Engine, proven independent suspension, and True On-Demand AWD.
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Sportsman 850
Starting at
$10,699
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The Sportsman 850 continues the tradition of do-it-all capability and toughness for a legendary sport-utility experience.
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Sportsman XP 1000
Starting at
$15,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Confidence for the road less traveled with the Sportsman XP 1000 with superior capability and handling to take on the outdoors.
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TOURING
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Sportsman Touring 570
Starting at
$9,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The Sportsman Touring 570 gives you the legendary ride and handling you demand with an integrated passenger seat system for 2-Up versatility with premium comfort.
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Sportsman Touring 850
Starting at
$13,599
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The Sportsman Touring 850 delivers hardest working, smoothest riding performance and comes fully loaded with premium performance features and integrated passenger seat system for 2-Up versatility.
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SPORTSMAN TOURING XP 1000 TRAIL
Starting at
$15,599
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Experience the great outdoors with the power, capability and comfort of the Sportsman Touring XP 1000 Trail. It’s the perfect vehicle for you and passengers to discover what lies beyond the next turn of the trail.
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SPORT
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Sportsman XP 1000 S
Starting at
$17,799
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The Industry’s most capable ATV — primed with 55″ stance that delivers superior stability, performance and terrain conquering mastery.
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Scrambler 850
Starting at
$12,399
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Race-proven sport performance features including sculpted sport seat to reduce fatigue, wide floorboards, and the Industry’s only sport-tuned rolled Independent Rear Suspension.
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Scrambler XP 1000 S
Starting at
$17,799
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Conquer the off-road with 55″ wide race platform that delivers unrivalled performance and terrain dominating abilities with premium 3-way Walker Evans adjustable shocks.
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SPECIAL EDITIONS
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Sportsman 6×6 570
Starting at
$13,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
The Sportsman 6×6 built for 2-up versatility. Equipped with the industry’s largest cargo system.
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Sportsman RIDE COMMAND Edition
Starting at
$12,399
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Ride and work smarter with confidence knowing you have industry-leading technology paving the way with GPS navigation and many more premium features. Available in Sportsman 570 and XP 1000 Ride Command Editions.
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Sportsman High Lifter Edition
Starting at
$12,199
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Purpose built for the mud, packed with power, mud specific tires and high clearance arched dual A-Arms suspension to help you get through your favorite mud hole. Available in Sportsman 850 and XP 1000 High Lifter Editions.
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Youth Models
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SIDE-BY-SIDES
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RZR 200 EFI
Starting at
$6,799
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Commodity surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Off road performance for the next generation with safety features parents need and confidence-inspiring performance. For riders age 10 and up.
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RANGER 150 EFI
Starting at
$6,299
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Logistics surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
150cc youth RANGER with cutting-edge Youth Ride Control and industry-first safety features.
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ATVS
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Outlaw 70 EFI
Starting at
$2,399
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Logistics surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
Industry’s only EFI vehicle with enhanced safety and kid-friendly performance features for youth riders age 6 and older.
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Outlaw 110 EFI
Starting at
$3,599
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Logistics surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
112cc 2×4 with standard features for youth riders ages 10 and older.
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Sportsman 110
Starting at
$3,599
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Logistics surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
112cc ATV with standard safety features. Perfect for youth riders ages 10 and older.
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Phoenix 200
Starting at
$4,499
US MSRP
Manufacturer’s suggested retail price (MSRP) subject to change. MSRP also excludes destination and handling fees, tax, title, license and registration. Dealer prices may vary. Logistics surcharge of $250 will apply. Plus destination charge and set-up. May be shown with additional modifications or accessories.
196cc 2×4 with automatic PVT transmission for young riders ages 14 and older.
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