Polaris Sportsman 450-500 (2007)
POLARIS SPORTSMAN 450-500 (2007) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
POLARIS SPORTSMAN 450-500 (2007) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual and Wiring Diagrams, to ATV Polaris Sportsman 450-500 (2007). CONTENTS: MODEL NUMBER INFORMATION - Model Number - Engine Designation Numbers - Vehicle Identification Number (VIN) - Transmission I.d. Location - Engine And Machine Serial Numbers - Publications - Paint Codes - Replacement Keys - Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison - Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison 2007 SPORTSMAN 450 - Model Number: A07MH46AA, AZ 2007 SPORTSMAN 500 EFI - Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC 2007 SPORTSMAN X-2 500 EFI - Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA MISC. NUMBERS/CHARTS - Standard Torque Specifications - SAE Tap Drill Sizes - Metric Tap Drill Sizes - Decimal Equivalents - Conversion Table - Glossary Of Terms MAINTENANCE - Periodic Maintenance Chart - Maintenance Chart Key - Periodic Maintenance Chart LUBRICATION / FLUIDS - SPORTSMAN Component Locations - SPORTSMAN X2 Component locations - Polaris Lubricants, Maintenance and Service Products - Polaris Lubricant Symbol Identification - Pre-ride / Daily Inspection - Lubrication Components - Front Gearcase Lubrication - Transmission Lubrication - ADC Differential Hydraulic Circuit Fluid Change 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 SPECIFICATIONS - Torque Specifications - Special Tools - Engine Fastener Torque Patterns - Engine Service Data - Engine Service Data 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 - Recoil Disassembly/Inspection - Recoil Assembly TROUBLESHOOTING - Spark Plug Fouling - Engine - Cooling System SPECIAL TOOLS - Part Numbers / Descriptions EFI SERVICE NOTES - General Service Information EFI SYSTEM EXPLODED VIEW EFI SYSTEM - Component Locations/Identification FUEL TANK - Exploded View ELECTRONIC FUEL INJECTION - General Information - EFI Operation Overview - Initial Priming / Starting Procedure FUEL LINES - Quick Connect Removal/Installation ELECTRONIC CONTROL MODULE (ECM) - Operation Overview - ECM Replacement - ECM Service FUEL PUMP ASSEMBLY - Operation / Testing - FUEL PUMP TEST - Fuel Pump / Tank Assembly Replacement FUEL PRESSURE REGULATOR - General Information FUEL FILTERS - General Information FUEL INJECTOR - General Information CRANKSHAFT POSITION SENSOR (CPS) - General Information MANIFOLD AIR PRESSURE SENSOR (MAP) - Operation Overview - Map Sensor Test - Map Sensor Replacement INTAKE AIR TEMPERATURE SENSOR (IAT) - Operation Overview - Intake Air Temperature Sensor Test - Intake Air Temperature Sensor Replacement I DLE AIR CONTROL (IAC) - General Information THROTTLE POSITION SENSOR (TPS) - Operation Overview - Throttle Position Sensor Test - Throttle Position Sensor Replacement - Throttle Position Sensor (Tps) Initialization ENGINE TEMPERATURE SENSOR - General Information - Engine Temperature Sensor Test - Engine Temperature Sensor Replacement FUEL SYSTEM TROUBLESHOOTING - FUEL STARVATION / LEAN MIXTURE EFI DIAGNOSTICS USING ‘BLINK CODES’ - Blink Codes - Operation 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 GENERAL INFORMATION AND SPECIFICATIONS - Special Tools - Carburetor Jetting - Mikuni Jet Part Numbers - Carburetor 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 System Exploded View FUEL PUMP - Fuel Pump Testing - Fuel Pump Disassembly - Fuel Pump Inspection and Reassembly - Fuel Filter Replacement FUEL GAUGE SENDING UNIT - Sending Unit Removal - Testing - Sending Unit Installation TROUBLESHOOTING - Fuel Starvation/Lean Mixture GENERAL INFORMATION - Torque Specifications - Special Tools - Decal Replacement - Plastic Insert Removal / Installation 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 - Handlebar Block Installation Procedure - Steering / A-arm Exploded View - A-Arm Replacement - Ball Joint Replacement - Steering Post Removal - Steering Post Assembly SUSPENSION - Front Strut Cartridge Replacement - Strut Assembly - Sportsman Rear Suspension Assembly - X2 Rear Suspension Exploded View - X2 Torsion Bar Exploded View X2 CARGO BOX - Exploded View - Removal / Installation X2 SEAT ASSEMBLY - Exploded Views - X2 Seat Operation - Configuring Cargo Box For Passenger Riding - Driver Seat Backrest Removal / Installation - Passenger Seat Backrest Removal / Installation SPECIAL TOOLS AND SPECIFICATIONS - Special Tools - Component Fastener Torques PVT EXPLODED VIEWS - PVT Sealing And Ducting Components - Drive Clutch Exploded Views (Standard and Deluxe) - Driven Clutch Exploded Views (Standard and Deluxe) - Engine Braking System (EBS) Exploded View PVT SYSTEM - PVT Operation Overview - Drive Clutch Operation - Driven Clutch Operation - EBS Clutch Operation - PVT Maintenance / Inspection - Drive Clutch Spring - Optional Shift Weights - PVT Drying - PVT Disassembly - PVT Installation - Drive Belt Removal / Inspection - DRIVE BELT INSTALLATION - Clutch Alignment - Clutch Offset EBS DRIVE CLUTCH SERVICE - Drive Clutch Disassembly - Spider Removal - Button To Tower Clearance Inspection - Shift Weight Inspection - Drive Clutch Inspection - Moveable Sheave Bushing Inspection - Drive Clutch Bushing Service - One-Way Clutch Inspection (Drive Clutch) - Drive Clutch Reassembly EBS DRIVEN CLUTCH SERVICE - Driven Clutch Disassembly - DRIVEN CLUTCH BUSHING REMOVAL/ INSTALLATION - EBS DRIVEN CLUTCH REASSEMBLY STANDARD DRIVE CLUTCH - Drive Clutch Disassembly - Spider Removal - Button To Tower Clearance Inspection - Shift Weight Inspection - Sheave / Bushing Inspection - Drive Clutch Bushing Service - Drive Clutch Reassembly STANDARD DRIVEN CLUTCH - 500 X2, 700, 800 EFI MODELS - Disassembly - Inspection - Assembly STANDARD DRIVEN CLUTCH - 500 EFI AND 450 - Exploded View - Clutch Disassembly / Inspection - Bushing Service - Moveable Sheave - Bushing Installation - Clutch Assembly PVT TROUBLESHOOTING - Overheating - Problem, Cause and Remedy Chart SPECIFICATIONS - Torque Table - Special Tools - Gearcase Fluid / Capacity FRONT DRIVE AXLE - Removal - Installation FRONT DRIVE SHAFT (CV) BOOT - Inspection - Replacement FRONT HUB - Disassembly - Assembly PROP SHAFT - FRONT OR REAR - Removal and Installation U-JOINT - Disassembly - Assembly DRIVE AXLE EXPLODED VIEWS - Drive Shafts and Propshafts FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS) - Exploded View (Standard Models) - Operation - Gearcase Removal - Disassembly / Inspection - Reassembly / Inspection - Setting Ring Gear Backlash - Front Gearcase Diagnosis - Gearcase Installation FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS) - ADC Gearcase Exploded View (Deluxe Models) - Operation - ADC Coil Testing - ADC Differential Hydraulic Circuit Bleeding - Disassembly / Inspection - ADC Gearcase Piston Replacement Procedure - Assembly REAR HUB - Removal - Disassembly - Assembly - Installation REAR DRIVE (CV) SHAFT - Removal - Service - CV Boot Replacement - INSTALLATION - Drive Shaft and CV Joint Handling Tips TRANSMISSION - GENERAL - Mounting Exploded View - Torque Specifications - Special Tools - Lubrication - Gear Selector Removal - Transmission Removal - Transmission Installation - Troubleshooting Checklist TRANSMISSION SERVICE - Exploded View - Transmission Disassembly - Transmission Assembly - Transmission Front Output Shaft Backlash Procedure and Reassembly SPECIFICATIONS - Torque Table - Component Service Limits BRAKE SYSTEM EXPLODED VIEWS - X2 System Component Exploded View - Sportsman System Component Exploded View BRAKE CALIPER EXPLODED VIEWS - Sportsman and X2 Front Caliper Assembly - X2 Rear Caliper Assembly - Sportsman Rear Caliper Assembly HYDRAULIC BRAKE SYSTEM - Operation Overview - Brake Noise Troubleshooting - Brake Bleeding / Fluid Change FRONT MASTER CYLINDER - Removal - Installation FRONT BRAKES - Pad Removal - Assembly - Brake Burnishing Procedure FRONT BRAKE DISC - Inspection - Removal / Replacement FRONT CALIPER - Removal - Inspection - Reassembly - Installation REAR BRAKE PAD - X2 Pad Removal - X2 Pad Installation - Sportsman Rear Pad Removal - Sportsman Rear Pad Installation - Brake Burnishing Procedure X2 REAR CALIPER - Removal - Inspection - Reassembly SPORTSMAN REAR CALIPER - Removal and Inspection - Assembly REAR BRAKE DISC - Inspection REAR MASTER CYLINDER - X2 Exploded View - Overview - X2 Rear Master Cylinder Removal and Installation - Sportsman Rear Master Cylinder Removal / Installation - Pedal Removal and Installation TROUBLESHOOTING - Brakes Squeal - Poor Brake Performance - Lever Vibration - Caliper Overheats (Brakes Drag) - Brakes Lock GENERAL INFORMATION - Special Tools - Ignition System / Basic Electrical Components - Electrical Service Notes - Troubleshooting POWER DISTRIBUTION MODULES (PDM) - Sportsman EFI Overview - Sportsman 450 Overview INSTRUMENT CLUSTER - Overview - Instrument Cluster Diagnostic Mode - Setting A New Service Interval - EFI Diagnostic Mode - Speedometer Removal - Speedometer Installation ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING - TEST 1 - No All Wheel Drive - TEST 2 - No Speedometer Display - TEST 3 - No Reverse Speed Limit - TEST 4 - No AWD Hub Safety Limit - TEST 5 - Reverse Speed Limiter Activated In Forward Gear - TEST 6 - Wheel Speed Sensor - TEST 7 - Fuel Gauge Display Not Working - TEST 8 - Shift Indicator Not Working ACTIVE DESCENT CONTROL (ADC) COIL - Operation Overview - Diagnosing System Failures ALL WHEEL DRIVE (AWD) COIL - Operation Overview - Diagnosing System Failures COOLING SYSTEM COMPONENTS - Fan Control Circuit Operation - Fan Control Bypass Test - Fan Motor Current Draw Test - Coolant Temperature Sensor GEAR POSITION INDICATOR SWITCH - Test Diagram ELECTRONIC THROTTLE CONTROL (ETC) SWITCH - Operation Overview - ETC Test IGNITION SYSTEM - Overview - Components of EFI Alternator and DC / CDI Ignition System - EFI Ignition System Testing Flow Chart - Crankshaft Position Sensor Gap - Ignition Troubleshooting - Ignition Output Test Using Gap Tester CHARGING SYSTEM - Current Draw - Key Off - Break Even Test - Alternator Output Test - Charging System Testing Diagrams DIFFERENTIAL SOLENOID - Testing - Replacement LIGHTING - High Beam Headlight Bulb Replacement - Headlight Housing Relacement - High Beam Headlight Adjustment - Lower Headlamp Removal / Installation - Low Beam Headlight Adjustment - Headlamp Switch Test - Work Light Switch - Brake Light / Work Light Replacement - Brake Light Switch Test SPEED SENSOR - Testing - Replacement FUEL SENDER - Testing ACCESSORY POWER - Wire Connections 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 - Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement STARTER SYSTEM TESTING FLOW CHART - Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing... BASIC WINCH WIRING - Pre-wired Models TROUBLESHOOTING DIAGRAMS - Power On - EFI - Start Circuit - EFI - Ignition Coil - EFI - Fuel Pump - EFI - Fan - EFI - Charging System - EFI - All Wheel Drive - EFI - Transmission Switch - EFI - Reverse Override - EFI - Differential Solenoid - X2 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
Polaris Sportsman 450-500 (2007) - Repair, Workshop Manual and Electrical Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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