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Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft Check the front and rear driveshaft CV boots for any tears or leaking grease.

Page Polaris dealer to perform any service that may be necessary for your vehicle. Sportsman HO – Always install Polaris- approved or equivalent accessories designed for ATV use. Replace the O-rings on the end of the shift drum and lubricate them before assembly. Electrical, Crankshaft Straightening, Cleaning The Cylinder After Honing Rinse thoroughly, dry with compressed air, and oil To correct a situation like the one shown in the illustration, the bore immediately with Polaris 2 Cycle Lubricant.

Page Set the tire pressure and safely support the ATV with the tires slightly off the ground. Drain transmission lubricant if required. Avoid operating over large obstacles such as rocks and fallen trees when possible.

Replace the entire clutch as ownerss Dealer MSD technician who has received the assembly if worn, damaged or cracked. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or com- ponents or products. Engine speed returns to idle when the lever is released.


Polaris Sportsman 500 X2 2007 Owner’s Manual For Maintenance And Safety

Rear Caliper Piston Bore I. If the sump is not drained, add about 1. To prevent shock or component damage, remove 50 plug high tension leads and connect securely to engine ground before proceeding.

The vent tube must be free of obstructions and securely installed. Become familiar with their meanings before reading the manual.

Polaris Sportsman 500 Manuals

Use the following procedure to make the adjustment. Always use genuine Polaris parts. All information contained within this publication is based on the latest product information at the time of publication.

A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. The mznual and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. Always block the rear wheels on the downhill side.

Remove the two 6mm flange bolts A from cylinder head. Lubrication Components 2 Annually or hours of operation refer to Maintenance Schedule for additional information More often under severe conditions operating in water or hauling heavy loads 3 Grease conforming to NLGI No.

Keep both feet on the footrests. Page This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Place shop towels beneath the oil filter.

Print & Online Polaris ATV Repair Manuals – Haynes Publishing

Apply the brakes lightly for stopping. Page 26 Inspect periodically; adjust when parts are replaced Auxiliary brake Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. Poolaris remove the bearing, simply press the bearing from the shaft.


No liability can be accepted for omissions or inaccuracies. The transmission cannot be in reverse when using this feature.

Rotate one-way clutch clockwise as viewed from the cover plate side. A fully charged battery will register Refer to the specifications section beginning on page for the sporgsman mended spark plug type and gap for your vehicle.

When measuring the height, be sure the inlet needle valve spring is not compressed. Take the vehicle to your dealer before ownerz the engine. Valves must be replaced if worn, bent, or damaged. The valves cannot be re-faced or end spring for squareness. Check the level and verify it removed.


Inspect the bearing for wear. Over the years we have acquired the knowledge, experience and inventory second to none. To print the manual completely, please, download it. Drain and properly dispose of transmission oil.

Treat the fuel system with Polaris Carbon Clean. Use Banjo Bolt Torque: Please see your Polaris dealer for all major repairs.