Polaris A07Mh46Aa Users Manual
2007 Polaris Sportsman 450 - 500 EFI - 500 X2 EFI Service Manual 2007 Polaris Sportsman 450 - 500 EFI - 500 X2 EFI Service Manual
A07TH50AU to the manual 19bb7604-cab7-4d9f-b81c-459330863138
2015-01-26
: Polaris Polaris-A07Mh46Aa-Users-Manual-335303 polaris-a07mh46aa-users-manual-335303 polaris pdf
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- FOREWORD
- CHAPTER INDEX
- CH 1 - GENERAL INFORMATION
- CH 2 - MAINTENENCE
- MAINTENANCE
- LUBRICATION / FLUIDS
- VEHICLE INSPECTION
- Shift Link Rod Inspection
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
- Fuel System
- Fuel Lines
- Vent Lines
- Fuel Filter
- Compression Test
- Engine Mounts
- Spark Plug
- Active Descent Control (ADC) Reservoir Level
- Battery Maintenance
- Liquid Cooling System Overview
- Coolant Strength / Type
- Cooling System Hoses
- Radiator/Grill Screen
- Cooling System Pressure Test
- Coolant Level Inspection
- Radiator Coolant Level Inspection
- Air Filter/Pre-Filter Service
- Air Box Sediment Tube
- Breather Filter Inspection
- Breather Hose
- Recoil Housing
- Engine Oil Level
- Oil and Filter Change
- Oil Pump Priming Procedure
- Valve Clearance
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Steering
- Tie Rod End/Steering Inspection
- Camber and Caster
- Wheel Alignment
- Toe Alignment Adjustment
- Exhaust Pipe
- Brake System Inspection
- Brake Pad Inspection
- Hose/Fitting Inspection
- Auxiliary Brake Testing
- Auxiliary Brake Adjustment (Hydraulic)
- Suspension Spring Preload Adjustment
- Front Suspension
- CV Shaft Boot Inspection
- Controls
- Wheels
- Wheel, Hub, And Spindle Torque Table
- Wheel Removal Front or Rear
- Wheel Installation
- Tire Pressure
- Tire Inspection
- Frame, Nuts, Bolts, Fasteners
- Storage Compartments
- Winch Operation (If Equipped)
- ATV Cleaning & Storage
- Maintenance Schedule
- CH 3 - ENGINE
- Specifications
- GENERAL ENGINE SERVICE
- Piston Identification
- Cooling System Specifications
- Cooling System
- Accessible Components
- Engine Removal (TYPICAL)
- Engine Installation Notes
- Cylinder Hone Selection/ Honing Procedure
- Honing To Oversize
- Cleaning the Cylinder After Honing
- Crankshaft Straightening
- Engine Lubrication- EH 50PL
- Oil Pressure Test - EH 50PL
- Oil Pump Priming Procedure
- Oil Flow - EH50PL
- EH50PL Oil Flow Diagram
- EH50PL Engine Exploded Views
- ENGINE DISASSEMBLY
- Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal
- Cam Chain Tensioner Inspection
- Rocker Arm/Shaft Inspection
- Camshaft Removal
- Automatic Compression Release Removal/ Inspection
- Automatic Compression Release Installation
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Exploded View, EH50PL
- Cylinder Head Inspection
- Cylinder Head Warp
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat ReconditionING
- Cylinder Head Assembly
- Valve Sealing Test
- Valve Clearance Adjustment
- Cylinder/Piston Removal and Inspection
- Piston Removal
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Piston/Rod Inspection
- Piston Ring Installed Gap
- Crankcase Disassembly
- Starter Drive Removal/Inspection
- Flywheel/Stator Removal/Inspection
- Cam Chain/Tensioner Blade
- One Way Valve Removal
- Crankcase Separation
- Oil Pump Removal/Inspection
- Oil Pump Assembly
- Counter Balancer Shaft Removal/Inspection
- Crankshaft Removal/Inspection
- Crankcase Bearing Inspection
- Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled)
- Crankcase Inspection
- Bearing Installation
- End Play Inspection/Adjustment
- Crankshaft End Play Adjustment
- Counter Balancer Shaft End Play Adjustment.
- Oil Pump Shaft End Play Adjustment
- ENGINE REASSEMBLY
- Pump Shaft Oil Seal Installation
- Crankshaft/Counter Balance/Oil Pump Installation
- Crankcase Assembly
- Water Pump Mechanical Seal Installation
- Water Pump Mechanical Seal Removal - Engine Installed
- One Way Valve Installation
- Cam Chain Drive Sprocket Installation
- Tensioner Blade Installation
- Piston Ring Installation
- Piston Installation
- Cylinder Installation
- Cylinder Head Installation
- Cam Chain/Camshaft Installation
- Camshaft Timing
- CAMSHAFT TIMING
- Cam Chain Tensioner Installation
- Stator, Flywheel and Starter Drive Installation
- Rocker Shaft/Rocker Arm Assembly Installation
- Thermostat Installation
- Oil Pipes
- RECOIL
- TROUBLESHOOTING
- CH 4 - ELECTRONIC FUEL INJECTION
- SPECIAL TOOLS
- EFI SERVICE NOTES
- EFI SYSTEM EXPLODED VIEW
- EFI SYSTEM
- FUEL TANK
- ELECTRONIC FUEL INJECTION
- FUEL LINES
- ELECTRONIC CONTROL MODULE (ECM)
- FUEL PUMP ASSEMBLY
- FUEL PRESSURE REGULATOR
- FUEL FILTERS
- FUEL INJECTOR
- CRANKSHAFT POSITION SENSOR (CPS)
- MANIFOLD AIR PRESSURE SENSOR (MAP)
- INTAKE AIR TEMPERATURE SENSOR (IAT)
- I DLE AIR CONTROL (IAC)
- THROTTLE POSITION SENSOR (TPS)
- ENGINE TEMPERATURE SENSOR
- FUEL SYSTEM TROUBLESHOOTING
- EFI DIAGNOSTICS USING ‘BLINK CODES’
- TROUBLESHOOTING DIAGRAMS
- EFI CIRCUIT - Power On
- EFI CIRCUIT - Crank Position Sensor
- EFI CIRCUIT - Fuel Pump
- EFI CIRCUIT - Ignition Coil
- EFI CIRCUIT - Idle Air Control
- EFI CIRCUIT - Throttle Position Sensor
- EFI CIRCUIT - Manifold Absolute Pressure Sensor
- EFI CIRCUIT - Engine Coolant Temperature
- EFI CIRCUIT - Air Temperature Sensor
- EFI CIRCUIT - Malfunction Indicator Light
- CH 4 - CARBURETOR - SPORTSMAN 450
- General Information and Specifications
- Carburetion
- BST 34 Carburetor Exploded View 1 of 2
- BST 34 Carburetor Exploded View 2 of 2
- CV Carburetor System Function
- Carburetor Venting
- Mikuni CV Carb Operation
- Starter System (Choke or Enrichment)
- Pilot (Idle and Slow) System
- Main System
- Float System
- Pilot Screw
- Air/Fuel Mixture Ratio
- Jet Needle
- Needle Jet
- Throttle Opening vs. Fuel Flow
- Carburetor Disassembly - Mikuni CV
- Carburetor Cleaning
- Carburetor Inspection
- Carburetor Assembly
- Float Height Adjustment
- Needle and Seat Leakage Test
- Fuel Level Test
- Fuel Tank/Fuel Delivery System
- Fuel Pump
- Fuel Gauge Sending unit
- Troubleshooting
- CH 5 - BODY/STEERING/SUSPENSION
- GENERAL INFORMATION
- BODY
- Side Panel Removal
- Front Cover Removal / Installation
- Foot Well Removal / Installation
- X2 Foot Well Removal / Installation
- Front Storage Removal
- Front Storage Installation
- Sportsman Rear Rack Removal / Installation
- Front Cab/Fender Removal/Installation
- Sportsman Rear Cab / Fender Removal / Installation
- X2 Rear Quarter Panel Removal / Installation
- Sportsman Rear Storage Removal / Installation
- Radiator Screen Removal
- Sportsman Body Assembly Exploded View
- X2 Body Assembly Exploded View
- Body / Rack Exploded Views
- Headlight Pod Exploded View
- STEERING
- SUSPENSION
- X2 CARGO BOX
- X2 SEAT assembly
- CH 6 - CLUTCH SYSTEM
- CH 7 - FINAL DRIVE
- CH 8 - TRANSMISSION
- CH 9 - BRAKES
- CH 10 - ELECTRICAL
- GENERAL INFORMATION
- POWER DISTRIBUTION MODULES (PDM)
- INSTRUMENT CLUSTER
- ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING
- ACTIVE DESCENT CONTROL (ADC) COIL
- ALL WHEEL DRIVE (AWD) COIL
- COOLING SYSTEM COMPONENTS
- GEAR POSITION INDICATOR SWITCH
- ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
- IGNITION SYSTEM
- CHARGING SYSTEM
- DIFFERENTIAL SOLENOID
- LIGHTING
- SPEED SENSOR
- FUEL SENDER
- ACCESSORY POWER
- STARTER SYSTEM
- Troubleshooting
- VOLTAGE DROP TEST
- Starter Lockout Troubleshooting- EFI Models
- Starter Lockout Troubleshooting- Sportsman 450
- Starter Lockout Diagram- EFI
- Starter Lockout Diagram- Sportsman 450
- Starter Motor Removal / Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter Solenoid Bench Test
- Starter Exploded View
- STARTER DRIVE
- STARTER SYSTEM TESTING FLOW CHART
- BASIC WINCH WIRING
- TROUBLESHOOTING DIAGRAMS
- BATTERY
- Battery Identification
- Battery Activation
- Terminal Preparation
- Battery Removal
- Battery Installation
- Off Season Storage
- Low Maintenance Battery Off-Season Storage
- Battery Testing
- Conventional Battery OCV - Open Circuit Voltage Test
- Conventional Battery Specific Gravity Test
- Battery Load Test
- Charging Procedure
- Low Maintenance Battery Check:
- Low Maintenance Battery Charging
- Low Maintenance Battery - OCV- Open Circuit Voltage Test
- Low Maintenance Battery Load Test
- Low Maintenance Battery Charging Procedure
- CH 11 - INTERNATIONAL
- INDEX
- WIRE DIAGRAMS