Intake Valve Clearance Adjustment; Exhaust Valve Clearance Adjustment; Steering - Polaris 2007 Sportsman 500 EF Service Manual

MAINTENANCE
7. Verify accurate TDC positioning by observing the "T"
mark aligned with the pointer in the timing inspection hole.
In this position there should be clearance on all valves.

Intake Valve Clearance Adjustment

1. Insert a .006" (.15mm) feeler gauge between end of intake
valve stem and clearance adjuster screw.
2. Using a 10 mm wrench and a screwdriver, loosen adjuster
lock nut and turn adjusting screw until there is a slight drag
on the feeler gauge.
3. Hold adjuster screw and tighten adjuster lock nut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.
6. Repeat this step for the other intake valve.
INTAKE VALVE CLEARANCE
.006" (.15 mm)

Exhaust Valve Clearance Adjustment

Feeler gauge for both valves
NOTE: The exhaust valves share a common rocker
arm, and must be adjusted using two feeler gauges.
2.26
1. Insert a .006" (.15mm) feeler gauge between end of
exhaust valve stem and adjuster screw(s).
2. Loosen locknut(s) and turn adjuster screw(s) until there is
a slight drag on feeler gauge(s). The Valve/Clutch Adjuster
Tool (PA-44689) can be used to adjust the engines valves.
NOTE: Both feeler gauges should remain inserted
during adjustment of each valve.
EXHAUST VALVE CLEARANCE
.006" (.15 mm)
3. When clearance is correct, hold adjuster screw and tighten
locknut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

Steering

The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering
should move freely through entire range of travel without
binding. Check routing of all cables, hoses, and wiring to be sure
the steering mechanism is not restricted or limited. NOTE:
Whenever steering components are replaced, check front end
alignment. Use only genuine Polaris parts.
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
MSD-certified technician when replacing worn or
damaged steering parts.
Use only genuine Polaris replacement parts.