2007 Polaris Sportsman 500 EFI Problems and Repair Information

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Owners Manual - Page 3

If you cannot locate this product contains chemicals known to the owner's manual on the next page. WARNING The engine exhaust from this card, or if it has been removed, please call 1-800-3423764 for assistance. A card containing important ATV safety information should be attached to cause cancer, birth defects or other reproductive harm.
Owners Manual - Page 4

... is outlined in the Polaris Service Manual and should be sure to your Polaris vehicle, making it the finest machine we've ever produced. Many years of experience have gone into the engineering, design, and development of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Have your accessories and clothing delivered right to...
Owners Manual - Page 8

... the operator of the vehicle, you are lost. Engine Serial Number #### VIN Key Number Vehicle Model Number: _____ Frame VIN: _____ Engine Serial Number: _____ Key Number: _____ 5 Remove the spare key and store it with one of our environment. Vehicle Identification Numbers Record your existing keys. The ignition switch must be duplicated only by...
Owners Manual - Page 12

...to engage AWD if the rear wheels are spinning. This may result causing severe injury or death. See Owner's Manual. Hitch ...Capacity Label TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG) 9 To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine...
Owners Manual - Page 16

...with printed materials that all laws and regulations concerning the operation of this vehicle in your vehicle are thoroughly inspected at (800) 887-2887 or by visiting www..... When you purchased your new ATV, your dealer instructed you and your owner's manual. A Polaris ATV is a top priority for this information on the authorized ATV RiderCoursesm... specific intervals. 13
Owners Manual - Page 20

...reverse. When it 's unavoidable, travel slowly and use of accessories. • Never exceed the stated load capacity for your ...procedures when operating over large obstacles, such as described in this manual for carrying cargo or towing. Allow a greater distance for braking....type of tires specified for your ATV, and always maintain proper tire pressure. • Never modify an ATV...
Owners Manual - Page 30

...vehicle to lean sharply to one side. Avoid traveling down the hill when possible. WHAT CAN HAPPEN Improperly crossing or turning on level ground) as described in forward gear. Avoid hills with the transmission in the owner's manual... or overturn. Always descend a hill with Active Descent Control, always engage AWD before descending a hill. See page 66. Use extra caution when turning ...
Owners Manual - Page 31

... fully stopped, apply the rear brake as well, and then lock the parking brake. Never apply engine power. If all forward speed is pointed straight uphill. Lock the parking brake when fully stopped. Apply...gradually. Turn the ATV around and remount, following the procedure described in the owner's manual. Dismount on uphill side, or to either side if ATV is lost: Keep your ATV is...
Owners Manual - Page 34

... modifications. All parts and accessories added to the vehicle must be installed and used according to an accident. WHAT CAN HAPPEN Use of improper tires, or operation of control or accident. Always maintain proper tire pressure as described in the owner's manual. WHAT CAN HAPPEN Improper installation of accessories or modification of accessories. WARNING POTENTIAL HAZARD Operating...
Owners Manual - Page 39

... or stuck throttle. Also check occasionally during operation. Engine speed and vehicle movement are controlled by pressing the throttle lever. If the throttle cable should stick in an accident if the throttle lever sticks during operation. Always check the lever for service if throttle problems arise. The throttle lever is properly installed to the...
Owners Manual - Page 45

... gears, stop the vehicle, and with the engine speed above idle or while the vehicle is moving could cause transmission damage. FEATURES AND CONTROLS The transmission gear selector is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of the vehicle. H: High Gear L: Low...
Owners Manual - Page 48

... 2X4 position • Vehicle speed exceeds 15 mph (24 km/h) • The throttle is open (throttle is applied) • The transmission is equipped with Active Descent Control, always engage AWD before ascending or descending a hill. Active Descent Control (ADC) System FEATURES AND CONTROLS The ADC system (if equipped) allows engine braking to neutral or...
Owners Manual - Page 50

... when the AWD switch 1 is in the fuel tank. Low Battery and Over Voltage - Refuel immediately. 8. If this warning appears. Check Engine Warning Indicator - Serious engine damage could result. 9. Service Interval/Diagnostic Mode Indicator 5. This warning usually indicates that the ATV is operating at idle and high electrical load (lights, cooling fan, accessories) is applied...
Owners Manual - Page 69

... the parking brake. Staying uphill of the vehicle, or on the left . 6. Leave the transmission in forward. 9. OPERATION Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it 's pointing across the hill or slightly downward. 7. Start the engine with the transmission still in forward and shut off the...
Owners Manual - Page 70

... current before starting the engine. Depth 3. See page 72. Do not make sudden turns or stops, and do not make sudden throttle changes. Perform the services outlined in the maintenance chart. Have the vehicle serviced by applying light pressure to take it serviced as outlined in the maintenance chart. After running the vehicle in water, it , follow...
Owners Manual - Page 77

...Miles (Km) 100 (160) 200 (320) 250 (400) 250 (400) 250 (400) 250 (400) Inspect; replace as needed Drain water as needed Make adjustments as needed Check operation; E Emission-Related Service Q Have an authorized Polaris dealer perform these procedures more often for vehicles...if equipped) X Transmission oil X Engine breather E filter (if equipped) X Perform these services. 74 apply ...
Owners Manual - Page 96

... depth measures 1/8" (3 mm) or less. Remove the wheel nuts. 7. Tire Tread Depth Always replace tires when tread depth is worn to the specifications section beginning on your ATV and in the owner's manual. Place the transmission in serious injury or death. Elevate the side of the vehicle by your authorized Polaris dealer. Remove the wheel. 93...
Owners Manual - Page 105

... replace the filter with a new filter. 4. Take the ATV to a dealer before starting the engine. 1. If water has been ingested into the PVT, follow the steps outlined below the footrests. 3. MAINTENANCE Vehicle Immersion CAUTION If your dealer for service as soon as possible, whether you succeed in starting it or not. 9. Remove the...
Owners Manual - Page 119

...page 95. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. See page 101. 116 See page ...fuel delivery system. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems. 3. See page 80. Never start the engine...
Owners Manual - Page 135

This warranty gives you specific legal rights, and you must present your original selling dealer; Engine Oil 1. Mixing oil brands or using non-recommended oil may not apply to perform warranty service. We recommend the use your copy of non-recommended lubricants may not be covered by warranty. Damage resulting from state to state. WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT...

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