Polaris 2007 Sportsman 450 EFI User manual

Category
Offroad Vehicle
Type
User manual
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.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.
WARNING
CAUTION
CAUTION
1
GENERAL
2
MAINTENENCE
3
ENGINE
4
FUEL SYSTEM
5
BODY / SUSPENSION
6
CLUTCH
7
TRANSMISSION
8
FINAL DRIVE
9
BRAKES
10
ELECTRICAL
11
INTERNATIONAL
NOTES
GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
ENGINE DESIGNATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
ENGINE AND MACHINE SERIAL NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
SPORTSMAN ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON . .1.4
SPORTSMAN X2 ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON1.5
2007 SPORTSMAN 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL NUMBER: A07MH46AA, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
2007 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
MODEL NUMBER: A07MH50AX, AY, AZ / A07MN50AQ, AF / A07MH50FC. . . . . . . . .1.8
2007 SPORTSMAN X-2 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MODEL NUMBER: A07TH50AU, AZ / A07TN50AF, AQ / A07TH50EA . . . . . . . . . . . .1.10
MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
1.2
GENERAL INFORMATION
MODEL NUMBER INFORMATION
Model Number
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Numbers
EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start
Vehicle Identification Number (VIN)
Transmission I.d. Location
Engine And Machine Serial Numbers
The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number
and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side
of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow.
The machine serial number is stamped on the lower left side of the frame tube (B).
A07 MN50 AU
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Descriptor
Vehicle Identifier
Check Digit
Model
Year
Body Style
Plant No
Individual Serial Number
* This could be either
a number or a letter
Powertrain
Emissions
4 X A M N 5 0 A * 7 P 0 0 0 0 0 0
The transmission I.D.number is located on top of
the transmission snorkel, right side of machine.
1.3
GENERAL INFORMATION
1
Publications
Paint Codes
Replacement Keys
Replacement keys can be made from the original key (Phoenix excluded). To identify which series the key is, take the first two digits
on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch
replacement is required.
Table 1-1: Publications
Year Model Model No.
Owner's
Manual PN
Parts
Manual PN
Parts
Micro Fiche PN
2007 Sportsman 500 EFI
A07MN50A
(Deluxe)
A07MH50A (Standard)
A07MH50F (Standard Intl’)
9920364 9920365 N/A
2007 Sportsman X2 500 EFI
A07TN50A
(Deluxe)
A07TH50A (Standard)
9920632 9920902 N/A
2007 Sportsman 450 EFI A07MH46A 9920629 9920557 N/A
2007
Sportsman X2 500 EFI
Quadricycle
A07MH46E 9920650 9920899 N/A
Table 1-2: Paint Codes
PAINTED PART
COLOR
DESCRIPTION
DITZLER
NUMBER
POLARIS
NUMBER
Sportsman Frame Black 9440 P-067
Table 1-3: Key Numbers
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
Key Cover
PN 5433534
1.4
GENERAL INFORMATION
Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison
For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide:
SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘STANDARD’ MODEL
Winch 1 No Winch
PXT Tires 2 Titan Tires
PVT w/EBS 3 Non-EBS (X2 excluded)
Rear Work Lights 4 No Work Lights
Front Drive w/ Active Descent Control (ADC) 5 No Active Descent Control (ADC)
Speed Sensor Wiring for ADC 6 No Sensor Wiring Change
Rear Rack Extension 7 No Rack Extension
Cast Aluminum Wheels 8 Steel Wheels
Single Exhaust 9 Single Exhaust
Wire Harness w/ Active Descent Control (ADC) 10 Standard Wire Harness
PDM w/ Active Descent Control (ADC) 10 Standard PDM
1
2
3
4
5
6
7
8
9
10
Deluxe Model Pictured
1.5
GENERAL INFORMATION
1
Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison
For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide:
X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL
Winch 1 No Winch
Rear Work Lights 2 No Work Lights
Front Drive w/ Active Descent Control (ADC) 3 No Active Descent Control (ADC)
Cast Aluminum Wheels 4 Steel Wheels
1
2
3
4
Standard Model Pictured
1.6
GENERAL INFORMATION
2007 SPORTSMAN 450
Model Number: A07MH46AA, AZ
Engine Model: EH46PLE
Table 1-4: Sportsman 450 General
Specifications
Category Dimension / Capacity
Length 83 in./211 cm
Width 48 in./122 cm
Height 48 in./122 cm
Wheel Base 50.5 in./128.3 cm
Ground Clearance 11 in./27.94 cm
Dry Weight 715 lbs./324 kg
Gross Vehicle Weight 1210 lbs./549 kg
Front Rack Capacity 90 lbs./40.8 kg
Rear Rack Capacity 180 lbs./81.6 kg
Towing Capacity 1225 lbs./555.6 kg
Body Style Spirit
Hitch Tongue Capacity 120 lbs./54.4 kg
1.7
GENERAL INFORMATION
1
Table 1-5: Sportsman 450
ENGINE
Platform Fuji Single Cylinder
Engine Model Number EH46PLE010
Engine Displacement 455cc
Number of Cylinders 1
Bore & Stroke (mm) 87.9 x 75 mm
Compression Ratio 9.8:1
Compression Pressure 50-90 psi
W/Compression Release
Engine Idle Speed
1100
50 RPM
Engine Max Operating Rpm
6000 Rpm
200 Rpm
Cooling System / Capacity Liquid - 2.25 qt / 2.1 ltr
Overheat Warning HOT on Instrument Cluster
Lubrication Pressurized Dry Sump
Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr
Exhaust System Single Pipe USFS Approved
Fuel System
Carburetor Mikuni BST 34mm
Main Jet 167.5
Pilot Jet 42.5
Jet Needle / Clip Position 4IB33 - 3
Needle Jet P-6M (829)
Pilot Screw 2 3/4 Turns Out (initial)
Pilot Air Jet 1.3
Float Height
13mm
1 (.51 0.40")
Fuel Delivery Fuel Pump
Fuel Capacity / Requirement 4.25 gal US / 19.9 liters
87 Octane (minimum)
or 89 Oxygenated
Electrical
Alternator Output 260 w @ 3000 RPM
Voltage Regulator 3-phase - PDM
Lights : Pod 50 watts
Grill 2 x 37 watts
Brake 26.9 watts
Tail 8.26 watts
Worklight 13 watts
Indicator 1 watt
Operating RPM
6000 RPM
Ignition System DC/CDI Ignition
Ignition Timing
30
°2° BTDC @ 5000 RPM
Spark plug / Gap BKR6E / .035 in. / 0.9 mm
Battery / Amp Hr Maintenance-Free / 12 Amp Hr.
Circuit Protection Solid State - PDM
Starting Electric / Recoil
Instrument Cluster Analog Speedo w/ LCD
Table 1-6: Sportsman 450
Drivetrain
Transmission Type Drumshift - H/L/N/R/P
Transmission Capacity 32 oz. / 948 ml
Front Gearcase Capacity 8.97 oz. / 265 ml
Gear Ratio : Low
Rev
High
Front Drive
23.91:1
16.30:1
10.49:1
3.82:1
Clutch Type PVT Non-EBS
Belt 3211077
Steering / Suspension
Front Suspension / Shock A-arm / MacPherson Strut
Front Travel 8.2 in. / 20.8 cm
Rear Suspension / Shock Progressive Rate Independent -
w/ 2
" Coil-over shock
Rear Travel 9.5 in. / 24.13 cm
Ground Clearance 11 in. / 27.94 cm
Shock Preload Adjustment
Front / Rear
Front -Non Adjustable.
Rear - Ratchet Style- Std.
Turning Radius 65 in./165.10 cm unloaded
Toe Out 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156
Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156
Recommended Air Pressure Front & Rear - 5 psi
Brake - Front Dual Hydraulic Disc
Brake - Rear Single Hydraulic Disc
Brake Fluid DOT - approved only
Table 1-7: Sportsman 450 Jetting
Altitude
AMBIENT TEMPERATURE
Below 40
° F
Below 5 ° C
+40 to +80 ° F
+5 to +28 ° C
M e t e r s
(Feet)
0-1800
(0-6000)
175 167.5
1800-3700
(6000-12000)
162.5 157.5
Table 1-8: Sportsman 450 Clutching
Altitude
Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Driven-
Helix
M e t e r s
(Feet)
0-1800
(0-6000)
10 WH
(5630710)
Blu/Grey
(7042202)
Black
(7041782)
40
°
2+2
(5131446)
1800-3700
(6000-12000)
20-40
(5631356)
Blu/Grey
(7042202)
Black
(7041782)
40
°
2+2
(5131446)
1.8
GENERAL INFORMATION
2007 SPORTSMAN 500 EFI
Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC
(Standard Models) (Deluxe Models) (International)
Engine Model: EH50PLE
Table 1-9: Sportsman 500 EFI General
Specifications
Category Dimension / Capacity
Length 83 in./211 cm
Width 48 in./122 cm
Height 48 in./122 cm
Wheel Base 50.5 in./128.3 cm
Ground Clearance 11.25 in./28.6 cm
Dry Weight 715 lbs./324 kg
Gross Vehicle Weight 1200 lbs./544 kg
Front Rack Capacity 90 lbs./40.8 kg
Rear Box Capacity 180 lbs./81.6 kg
Towing Capacity 1225 lbs./555.6 kg
Body Style Spirit
Hitch Tongue Capacity 120 lbs./54.4 kg
1.9
GENERAL INFORMATION
1
Table 1-10: Sportsman 500 EFI
ENGINE
Platform Fuji Single Cylinder
Engine Model Number EH50PLE210
Engine Displacement 499cc
Number of Cylinders 1
Bore & Stroke (mm) 92 x 75 mm
Compression Ratio
10.2:1
Compression Pressure 50-90 psi W/Compression Release
Engine Idle Speed
1100
200 RPM
Engine Max Operating Rpm
6000 Rpm
200 Rpm
Cooling System / Capacity Liquid - 2.5 qt / 2.4 ltr
Overheat Warning HOT on Instrument Cluster
Lubrication Pressurized Dry Sump
Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr
Exhaust System Single Pipe USFS Approved
Fuel System
Fuel System Electronic Fuel Injection (EFI)
Fuel Pump (in tank assembly) 25L per hr. at 39 psi
Fuel Filter(s) 10 micron in-line
30 micron in tank -
(not replaceable)
Fuel Injector(s) Visteon
EFI Controller Visteon VP5U1U-12A650-AA
Fuel Capacity / Requirement 6 gal US / 22.7 liters
87 Octane (minimum)
or 89 Oxygenated
Electrical
Alternator Output 350 w @ 6000 RPM
Lights : Pod 50 watts
Grill 2 x 37 watts
Brake 2 x 8.26 watts
Tail 2 x 26.9 watts
Worklight 2 x 13 watts
Indicator 1 watt
Operating RPM
6000 RPM
Ignition System DC/CDI Ignition
Ignition Timing
13
° BTDC @ 1150 RPM
Spark plug / Gap BKR6E / .035 in. / 0.9 mm
Battery / Amp Hr Lead Acid / 30 Amp Hr.
Circuit Breakers Fan 12 amp / Switched Power 10
amp / Fuel Pump 10 amp / ECU
15 amp / Ignition Coil 10 amp /
Accessory Power 10 amp /
Lights 20 Amp
Starting Electric / Recoil
Instrument Cluster Analog Speedo w/ LCD
Table 1-11: Sportsman 500 EFI
Drivetrain
Transmission Type Drumshift - H/L/N/R/P
Transmission Capacity 32 oz. / 948 ml
Front Gearcase Capacity- CH 8.97 / 265 ml
Front Gearcase Capacity- ADC 9.3 / 275 ml
Gear Ratio : Low
Rev
High
Front Drive
23.91:1
21.74:1
10.57:1
3.82:1
Clutch Type PVT (Standard Models)
PVT w/EBS (Deluxe Models)
Belt 3211113 EBS
3211077 Non-EBS
Steering / Suspension
Front Suspension / Shock A-arm / MacPherson Strut
Front Travel 8.2 in. / 20.8 cm
Rear Suspension / Shock Progressive Rate Independent -
Coil - over shock
Rear Travel 9.5 in. / 24.13 cm
Ground Clearance 11 in. / 27.94 cm
Shock Preload Adjustment
Front / Rear
Front -Non Adjustable.
Rear - Ratchet Style- Std.
Turning Radius 65 in./165.10 cm unloaded
Toe Out 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156
Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156
Recommended Air Pressure Front & Rear - 5 psi
Brake - Front Dual Hydraulic Disc
Brake - Rear Single Hydraulic Disc
Brake Fluid DOT - approved only
Table 1-12: Sportsman 500 EFI Clutching
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
*No
Adjustment
M e t e r s
(Feet)
0-1800
(0-6000)
10 WH
(5630710)
Blu/Green
(7041157)
White/Yel
(7041635)
EBS
(5131674)
1800-3700
(6000-12000)
10 RH
(5630709)
Blu/Green
(7041157)
White/Yel
(7041635)
EBS
(5131674)
1.10
GENERAL INFORMATION
2007 SPORTSMAN X-2 500 EFI
Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA
(Standard Models) (Deluxe Model) (Intl’ Quadricycle)
Engine Model: EH50PLE
Table 1-13: Sportsman X-2 500 EFI General
Specifications
Category Dimension / Capacity
Length 93 in./236 cm
Width 48 in./122 cm
Height 48 in./122 cm
Wheel Base 57 in./145 cm
Ground Clearance 11 in./28 cm
Dry Weight 798 lbs./362 kg
Gross Vehicle Weight 1500 lbs./680 kg
Front Rack Capacity 90 lbs./40.8 kg
Rear Box Capacity 400 lbs./81.6 kg
Towing Capacity 1225 lbs./555.6 kg
Body Style Spirit
Hitch Tongue Capacity 120 lbs./54.4 kg
Rear box capacity and tongue weight
not to exceed 400 lbs./181kg
1.11
GENERAL INFORMATION
1
Table 1-14: Sportsman X2 500 EFI
ENGINE
Platform Fuji Single Cylinder
Engine Model Number EH50PLE210
Engine Displacement 499cc
Number of Cylinders 1
Bore & Stroke (mm) 92 x 75 mm
Compression Ratio 10.2:1
Compression Pressure 60-90 psi
W/Compression Release
Engine Idle Speed
1150
50 RPM
Engine Max Operating Rpm
6000 Rpm
200 Rpm
Cooling System / Capacity Liquid - 2.5 qt / 2.4 ltr
Overheat Warning HOT on Instrument Cluster
Lubrication Pressurized Dry Sump
Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr
Exhaust System Single Pipe USFS Approved
Fuel System
Fuel System Electronic Fuel Injection (EFI)
Fuel Pump (in tank assembly) 25L per hr. at 39 psi
Fuel Filter(s) 10 micron in-line
30 micron in tank -
(not replaceable)
Fuel Injector(s) Visteon
EFI Controller Visteon VP5U1U-12A650-AA
Fuel Capacity / Requirement 6 gal US / 22.7 liters
87 Octane (minimum)
or 89 Oxygenated
Electrical
Alternator Output 350 w @ 6000 RPM
Lights : Pod 50 watts
Grill 2 x 37 watts
Brake 2 x 8.26 watts
Tail 2 x 26.9 watts
Worklight 2 x 13 watts
Indicator 1 watt
Operating RPM
6000 RPM
Ignition System DC/CDI Ignition
Ignition Timing
10
° BTDC @ 1150 RPM
Spark plug / Gap BKR6E / .035 in. / 0.9 mm
Battery / Amp Hr Lead Acid / 30 Amp Hr.
Circuit Breakers Fan 12 amp / Switched Power 10
amp / Fuel Pump 10 amp / ECU
15 amp / Ignition Coil 10 amp /
Accessory Power 10 amp /
Lights 20 Amp
Starting Electric / Recoil
Instrument Cluster Analog Speedo w/ LCD
Table 1-15: Sportsman X2 500 EFI
Drivetrain
Transmission Type Drumshift - H/L/N/Rev/Park
Transmission Capacity 32 oz. / 948 ml
Front Gearcase Capacity- CH 8.97 / 265 ml
Front Gearcase Capacity- ADC 9.3 / 275 ml
Gear Ratio : Low
Rev
High
Front Drive
23.91:1
21.74:1
10.57:1
3.82:1
Clutch Type PVT w/EBS
Belt 3211113
Steering / Suspension
Front Suspension / Shock A-arm / MacPherson Strut
Front Travel 8.2 in. / 20.8 cm
Rear Suspension / Shock Progressive Rate Independent -
Coil - over shock
Rear Travel 8.75 in. / 22.2 cm
Ground Clearance 11 in. / 28 cm
Shock Preload Adjustment
Front / Rear
Front -Non Adjustable.
Rear - Ratchet Style- Std.
Turning Radius 82 in./208 cm unlocked
Toe Out 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Wheel Size / Pattern - Front Steel 12x6 / 4-156
Wheel Size / Pattern - Rear Steel 12x8 / 4-156
Front Tire Size 25x8-12
Rear Tire Size 25x11-12
Recommended Air Pressure Front & Rear - 5 psi
Brake - Front Dual Hydraulic Disc
Brake - Rear Dual Hydraulic Disc
Table 1-16: Sportsman X2 500 EFI
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
*No
Adjustment
M e t e r s
(Feet)
0-1800
(0-6000)
10 WH
(5630710)
Blu/Green
(7041157)
White/Yel
(7041635)
EBS
(5131674)
1800-3700
(6000-12000)
10 RH
(5630709)
Blu/Green
(7041157)
White/Yel
(7041635)
EBS
(5131674)
1.12
GENERAL INFORMATION
MISC. NUMBERS/CHARTS
Standard Torque Specifications
The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine
areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.
1.13
GENERAL INFORMATION
1
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
1/64 . . . . . . . . . . .. . . . . . . .0156
1/32 . . . . . . .. . . . . . . .0312 . . 1 mm= .0394"
3/64 . . . . . . . . . . .. . . . . . . .0469
1/16 . . . . . . .. . . . . . . .0625
5/64 . . . . . . . . . . .. . . . . . . .0781 . . 2 mm = .0787"
3/32 . . . . . . .. . . . . . . .0938
7/64 . . . . . . . . . . .. . . . . . . .1094 . . 3 mm =.1181"
1/8 . . . . . . . . .1250
9/64 . . . . . . . . . . .. . . . . . . .1406
5/32 . . . . . . .. . . . . . . .1563 . . 4 mm = .1575"
11/64 . . . . . . . . . . .. . . . . . . .1719
3/16 . . . . . . .. . . . . . . .1875 . . 5mm= .1969"
13/64 . . . . . . . . . . .. . . . . . . .2031
7/32 . . . . . . .. . . . . . . .2188
15/64 . . . . . . . . . . .. . . . . . . .2344 . . 6 mm = .2362"
1/4 . . . . . . . . .25
17/64 . . . . . . . . . . .. . . . . . . .2656 . . 7 mm = .2756"
9/32 . . . . . . .. . . . . . . .2813
19/64 . . . . . . . . . . .. . . . . . . .2969
5/16 . . . . . . .. . . . . . . .3125 . . 8mm= .3150"
21/64 . . . . . . . . . . .. . . . . . . .3281
11/32 . . . . . .. . . . . . . .3438 . . 9 mm = .3543"
23/64 . . . . . . . . . . .. . . . . . . .3594
3/8 . . . . . . . . .375
25/64 . . . . . . . . . . .. . . . . . . .3906 . . 10 mm = .3937"
13/32 . . . . . .. . . . . . . .4063
27/64 . . . . . . . . . . .. . . . . . . .4219 . . 11 mm =.4331"
7/16 . . . . . . .. . . . . . . .4375
29/64 . . . . . . . . . . .. . . . . . . .4531
15/32 . . . . . .. . . . . . . .4688 . . 12 mm = .4724"
31/64 . . . . . . . . . . .. . . . . . . .4844
1/2 . . . . . . . . .5 . . . . . . . . . . . 13mm = .5118"
33/64 . . . . . . . . . . .. . . . . . . .5156
17/32 . . . . . .. . . . . . . .5313
35/64 . . . . . . . . . . .. . . . . . . .5469 . . 14 mm = .5512"
9/16 . . . . . . .. . . . . . . .5625
37/64 . . . . . . . . . . .. . . . . . . .5781 . . 15 mm = .5906"
19/32 . . . . . .. . . . . . . .5938
39/64 . . . . . . . . . . .. . . . . . . .6094
5/8 . . . . . . . . .625 . . . . . . . . . 16mm=. 6299"
41/64 . . . . . . . . . . .. . . . . . . .6406
21/32 . . . . . .. . . . . . . .6563 . . 17 mm =.6693"
43/64 . . . . . . . . . . .. . . . . . . .6719
11/16 . . . . . .. . . . . . . .6875
45/64 . . . . . . . . . . .. . . . . . . .7031 . . 18 mm = .7087"
23/32 . . . . . .. . . . . . . .7188
47/64 . . . . . . . . . . .. . . . . . . .7344 . . 19 mm = .7480"
3/4 . . . . . . . . .75
49/64 . . . . . . . . . . .. . . . . . . .7656
25/32 . . . . . .. . . . . . . .7813 . . 20 mm = .7874"
51/64 . . . . . . . . . . .. . . . . . . .7969
13/16 . . . . . .. . . . . . . .8125 . . 21 mm =.8268"
53/64 . . . . . . . . . . .
. . . . . . . .8281
27/32 . . . . . .. . . . . . . .8438
55/64 . . . . . . . . . . .. . . . . . . .8594 . . 22 mm = .8661"
7/8 . . . . . . . . .875
57/64 . . . . . . . . . . .. . . . . . . .8906 . . 23 mm = .9055"
29/32 . . . . . .. . . . . . . .9063
59/64 . . . . . . . . . . .. . . . . . . .9219
15/16 . . . . . .. . . . . . . .9375 . . 24 mm = .9449"
61/64 . . . . . . . . . . .. . . . . . . .9531
31/32 . . . . . .. . . . . . . .9688 . . 25 mm = .9843"
63/64 . . . . . . . . . . .. . . . . . . .9844
1. . . . . . . . . . 1.0
Thread Size/ Drill Size Thread Size / Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64 5/8-18 37/64
#3-56 45 3/4-10 21/32
#4-40 43 3/4-16 11/16
#4-48 42 7/8-9 49/64
#5-40 38 7/8-14 13/16
#5-44 37 1-8 7/8
#6-32 36 1-12 59/64
#6-40 33 1 1/8-7 63/64
#8-32 29 1 1/8-12 1 3/64
#8-36 29 1 1/4-7 1 7/64
#10-24 24 1 1/4-12 1 11/64
#10-32 21 1 1/2-6 1 11/32
#12-24 17 1 1/2-12 1 27/64
#12-28 4.6mm 1 3/4-5 1 9/16
1/4-20 7 1 3/4-12 1 43/64
1/4-28 3 2-4 1/2 1 25/32
5/16-18 F 2-12 1 59/64
5/16-24 I 2 1/4-4 1/2 2 1/32
3/8-16 O 2 1/2-4 2 1/4
3/8-24 Q 2 3/4-4 2 1/2
7/16-14 U 3-4 2 3/4
7/16-20 25/64
Tap Size Drill Size
Decimal
Equivalent
Nearest
Fraction
3x.50 #39 0.0995 3/32
3x.60 3/32 0.0937 3/32
4x.70 #30 0.1285 1/8
4x.75 1/8 0.125 1/8
5x.80 #19 0.166 11/64
5x.90 #20 0.161 5/32
6x1.00 #9 0.196 13/64
7x1.00 16/64 0.234 15/64
8x1.00 J 0.277 9/32
8x1.25 17/64 0.265 17/64
9x1.00 5/16 0.3125 5/16
9x1.25 5/16 0.3125 5/16
10x1.25 11/32 0.3437 11/32
10x1.50 R 0.339 11/32
11x1.50 3/8 0.375 3/8
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32
1.14
GENERAL INFORMATION
Conversion Table
°C to °F: 9 (°C + 40) 5 - 40 = °F
°F to °C: 5 (°F + 40)
9 - 40 = °C
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
(3.14)xR
2
x H (height) = Cylinder Volume
1.15
GENERAL INFORMATION
1
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
ADC: Active Descent Control.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between
centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare
wire touching the chassis).
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Ft. lb. / Foot Pound: A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
Left Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040,.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
PDM: Power Distribution Module.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
RPM:
Revolutions per minute.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat.
Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
NOTES
GENERAL INFORMATION
1.16
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120
  • Page 121 121
  • Page 122 122
  • Page 123 123
  • Page 124 124
  • Page 125 125
  • Page 126 126
  • Page 127 127
  • Page 128 128
  • Page 129 129
  • Page 130 130
  • Page 131 131
  • Page 132 132
  • Page 133 133
  • Page 134 134
  • Page 135 135
  • Page 136 136
  • Page 137 137
  • Page 138 138
  • Page 139 139
  • Page 140 140
  • Page 141 141
  • Page 142 142
  • Page 143 143
  • Page 144 144
  • Page 145 145
  • Page 146 146
  • Page 147 147
  • Page 148 148
  • Page 149 149
  • Page 150 150
  • Page 151 151
  • Page 152 152
  • Page 153 153
  • Page 154 154
  • Page 155 155
  • Page 156 156
  • Page 157 157
  • Page 158 158
  • Page 159 159
  • Page 160 160
  • Page 161 161
  • Page 162 162
  • Page 163 163
  • Page 164 164
  • Page 165 165
  • Page 166 166
  • Page 167 167
  • Page 168 168
  • Page 169 169
  • Page 170 170
  • Page 171 171
  • Page 172 172
  • Page 173 173
  • Page 174 174
  • Page 175 175
  • Page 176 176
  • Page 177 177
  • Page 178 178
  • Page 179 179
  • Page 180 180
  • Page 181 181
  • Page 182 182
  • Page 183 183
  • Page 184 184
  • Page 185 185
  • Page 186 186
  • Page 187 187
  • Page 188 188
  • Page 189 189
  • Page 190 190
  • Page 191 191
  • Page 192 192
  • Page 193 193
  • Page 194 194
  • Page 195 195
  • Page 196 196
  • Page 197 197
  • Page 198 198
  • Page 199 199
  • Page 200 200
  • Page 201 201
  • Page 202 202
  • Page 203 203
  • Page 204 204
  • Page 205 205
  • Page 206 206
  • Page 207 207
  • Page 208 208
  • Page 209 209
  • Page 210 210
  • Page 211 211
  • Page 212 212
  • Page 213 213
  • Page 214 214
  • Page 215 215
  • Page 216 216
  • Page 217 217
  • Page 218 218
  • Page 219 219
  • Page 220 220
  • Page 221 221
  • Page 222 222
  • Page 223 223
  • Page 224 224
  • Page 225 225
  • Page 226 226
  • Page 227 227
  • Page 228 228
  • Page 229 229
  • Page 230 230
  • Page 231 231
  • Page 232 232
  • Page 233 233
  • Page 234 234
  • Page 235 235
  • Page 236 236
  • Page 237 237
  • Page 238 238
  • Page 239 239
  • Page 240 240
  • Page 241 241
  • Page 242 242
  • Page 243 243
  • Page 244 244
  • Page 245 245
  • Page 246 246
  • Page 247 247
  • Page 248 248
  • Page 249 249
  • Page 250 250
  • Page 251 251
  • Page 252 252
  • Page 253 253
  • Page 254 254
  • Page 255 255
  • Page 256 256
  • Page 257 257
  • Page 258 258
  • Page 259 259
  • Page 260 260
  • Page 261 261
  • Page 262 262
  • Page 263 263
  • Page 264 264
  • Page 265 265
  • Page 266 266
  • Page 267 267
  • Page 268 268
  • Page 269 269
  • Page 270 270
  • Page 271 271
  • Page 272 272
  • Page 273 273
  • Page 274 274
  • Page 275 275
  • Page 276 276
  • Page 277 277
  • Page 278 278
  • Page 279 279
  • Page 280 280
  • Page 281 281
  • Page 282 282
  • Page 283 283
  • Page 284 284
  • Page 285 285
  • Page 286 286
  • Page 287 287
  • Page 288 288
  • Page 289 289
  • Page 290 290
  • Page 291 291
  • Page 292 292
  • Page 293 293
  • Page 294 294
  • Page 295 295
  • Page 296 296
  • Page 297 297
  • Page 298 298
  • Page 299 299
  • Page 300 300
  • Page 301 301
  • Page 302 302
  • Page 303 303
  • Page 304 304
  • Page 305 305
  • Page 306 306
  • Page 307 307
  • Page 308 308
  • Page 309 309
  • Page 310 310
  • Page 311 311
  • Page 312 312
  • Page 313 313
  • Page 314 314
  • Page 315 315
  • Page 316 316
  • Page 317 317
  • Page 318 318
  • Page 319 319
  • Page 320 320
  • Page 321 321
  • Page 322 322
  • Page 323 323
  • Page 324 324
  • Page 325 325
  • Page 326 326
  • Page 327 327
  • Page 328 328
  • Page 329 329
  • Page 330 330
  • Page 331 331
  • Page 332 332
  • Page 333 333
  • Page 334 334
  • Page 335 335
  • Page 336 336
  • Page 337 337
  • Page 338 338
  • Page 339 339
  • Page 340 340
  • Page 341 341
  • Page 342 342
  • Page 343 343
  • Page 344 344
  • Page 345 345
  • Page 346 346
  • Page 347 347
  • Page 348 348
  • Page 349 349
  • Page 350 350
  • Page 351 351
  • Page 352 352
  • Page 353 353
  • Page 354 354
  • Page 355 355
  • Page 356 356
  • Page 357 357
  • Page 358 358
  • Page 359 359
  • Page 360 360
  • Page 361 361
  • Page 362 362
  • Page 363 363
  • Page 364 364
  • Page 365 365
  • Page 366 366
  • Page 367 367
  • Page 368 368
  • Page 369 369
  • Page 370 370
  • Page 371 371
  • Page 372 372
  • Page 373 373
  • Page 374 374
  • Page 375 375
  • Page 376 376
  • Page 377 377
  • Page 378 378
  • Page 379 379
  • Page 380 380
  • Page 381 381
  • Page 382 382
  • Page 383 383
  • Page 384 384
  • Page 385 385
  • Page 386 386
  • Page 387 387
  • Page 388 388
  • Page 389 389
  • Page 390 390
  • Page 391 391
  • Page 392 392
  • Page 393 393
  • Page 394 394
  • Page 395 395
  • Page 396 396
  • Page 397 397
  • Page 398 398
  • Page 399 399
  • Page 400 400
  • Page 401 401
  • Page 402 402
  • Page 403 403
  • Page 404 404
  • Page 405 405
  • Page 406 406

Polaris 2007 Sportsman 450 EFI User manual

Category
Offroad Vehicle
Type
User manual

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI