2006 Polaris Sportsman 450 500 EFI X-2 Repair Service Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPORTSMAN ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON . . 1.4 SPORTSMAN X2 ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON1.5 2006 SPORTSMAN 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2006 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2006 SPORTSMAN X-2 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

1.2 GENERAL INFORMATION MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Vehicle Identification Number (VIN) Transmission I.d. Location Engine And Machine Serial Numbers The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. The machine serial number is stamped on the lower left side of the frame tube (B). A 07 MN 50 AU } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier } Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 4 X A M N 5 0 A * 7 P 0 0 0 0 0 0 The transmission I.D.number is located on top of the transmission snorkel, right side of machine.

1.3 GENERAL INFORMATION 1 Publications Paint Codes Replacement Keys Replacement keys can be made from the original key (Phoenix excluded). To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required. Table 1-1: Publications Year Model Model No. Owner's Manual PN Parts Manual PN Parts Micro Fiche PN 2006 Sportsman 500 EFI A07MN50A (Deluxe) A07MH50A (Standard) A07MH50F (Standard Intl’) 9920364 9920365 N/A 2006 Sportsman X2 500 EFI A07TN50A (Deluxe) A07TH50A (Standard) 9920632 9920902 N/A 2006 Sportsman 450 EFI A07MH46A 9920629 9920557 N/A 2006 Sportsman X2 500 EFI Quadricycle A07MH46E 9920650 9920899 N/A Table 1-2: Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman Frame Black 9440 P-067 Table 1-3: Key Numbers Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Cover PN 5433534

1.4 GENERAL INFORMATION Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2006, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘STANDARD’ MODEL Winch 1 No Winch PXT Tires 2 Titan Tires PVT w/EBS 3 Non-EBS (X2 excluded) Rear Work Lights 4 No Work Lights Front Drive w/ Active Descent Control (ADC) 5 No Active Descent Control (ADC) Speed Sensor Wiring for ADC 6 No Sensor Wiring Change Rear Rack Extension 7 No Rack Extension Cast Aluminum Wheels 8 Steel Wheels Single Exhaust 9 Single Exhaust Wire Harness w/ Active Descent Control (ADC) 10 Standard Wire Harness PDM w/ Active Descent Control (ADC) 10 Standard PDM 1 2 3 4 5 6 7 8 9 10 Deluxe Model Pictured

1.5 GENERAL INFORMATION 1 Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2006, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL Winch 1 No Winch Rear Work Lights 2 No Work Lights Front Drive w/ Active Descent Control (ADC) 3 No Active Descent Control (ADC) Cast Aluminum Wheels 4 Steel Wheels 1 2 3 4 Standard Model Pictured

1.6 GENERAL INFORMATION 2006 SPORTSMAN 450 Model Number: A07MH46AA, AZ Engine Model: EH46PLE Table 1-4: Sportsman 450 General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11 in./27.94 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1210 lbs./549 kg Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

1.7 GENERAL INFORMATION 1 Table 1-5: Sportsman 450 ENGINE Platform Fuji Single Cylinder Engine Model Number EH46PLE010 Engine Displacement 455cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 75 mm Compression Ratio 9.8:1 Compression Pressure 50-90 psi W/Compression Release Engine Idle Speed 1100 ± 50 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.25 qt / 2.1 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Carburetor Mikuni BST 34mm Main Jet 167.5 Pilot Jet 42.5 Jet Needle / Clip Position 4IB33 - 3 Needle Jet P-6M (829) Pilot Screw 2 3/4 Turns Out (initial) Pilot Air Jet 1.3 Float Height 13mm ± 1 (.51 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal US / 19.9 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 260 w @ 3000 RPM Voltage Regulator 3-phase - PDM Lights : Pod 50 watts Grill 2 x 37 watts Brake 26.9 watts Tail 8.26 watts Worklight 13 watts Indicator 1 watt Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Maintenance-Free / 12 Amp Hr. Circuit Protection Solid State - PDM Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD Table 1-6: Sportsman 450 Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low Rev High Front Drive 23.91:1 16.30:1 10.49:1 3.82:1 Clutch Type PVT Non-EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent - w/ 2" Coil-over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only Table 1-7: Sportsman 450 Jetting Altitude AMBIENT TEMPERATURE Below 40 ° F Below 5 ° C +40 to +80 ° F +5 to +28 ° C Meters (Feet) 0-1800 (0-6000) 175 167.5 1800-3700 (6000-12000) 162.5 157.5 Table 1-8: Sportsman 450 Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven- Helix Meters (Feet) 0-1800 (0-6000) 10 WH (5630710) Blu/Grey (7042202) Black (7041782) 40° 2+2 (5131446) 1800-3700 (6000-12000) 20-40 (5631356) Blu/Grey (7042202) Black (7041782) 40° 2+2 (5131446)

1.8 GENERAL INFORMATION 2006 SPORTSMAN 500 EFI Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC (Standard Models) (Deluxe Models) (International) Engine Model: EH50PLE Table 1-9: Sportsman 500 EFI General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1200 lbs./544 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

1.9 GENERAL INFORMATION 1 Table 1-10: Sportsman 500 EFI ENGINE Platform Fuji Single Cylinder Engine Model Number EH50PLE210 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 50-90 psi W/Compression Release Engine Idle Speed 1100 ± 200 RPM Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.5 qt / 2.4 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved Fuel System Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 10 micron in-line 30 micron in tank - (not replaceable) Fuel Injector(s) Visteon EFI Controller Visteon VP5U1U-12A650-AA Fuel Capacity / Requirement 6 gal US / 22.7 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt Operating RPM 6000 RPM Ignition System DC/CDI Ignition Ignition Timing 13°± 3 BTDC @ 1150 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10 amp / Fuel Pump 10 amp / ECU 15 amp / Ignition Coil 10 amp / Accessory Power 10 amp / Lights 20 Amp Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD Table 1-11: Sportsman 500 EFI Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low Rev High Front Drive 23.91:1 21.74:1 10.57:1 3.82:1 Clutch Type PVT (Standard Models) PVT w/EBS (Deluxe Models) Belt 3211113 EBS 3211077 Non-EBS Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156 Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only Table 1-12: Sportsman 500 EFI Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix* *No Adjustment Meters (Feet) 0-1800 (0-6000) 10 WH (5630710) Blu/Green (7041157) White/Yel (7041635) EBS (5131674) 1800-3700 (6000-12000) 10 RH (5630709) Blu/Green (7041157) White/Yel (7041635) EBS (5131674)

1.10 GENERAL INFORMATION 2006 SPORTSMAN X-2 500 EFI Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA (Standard Models) (Deluxe Model) (Intl’ Quadricycle) Engine Model: EH50PLE Table 1-13: Sportsman X-2 500 EFI General Specifications Category Dimension / Capacity Length 93 in./236 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 798 lbs./362 kg Gross Vehicle Weight 1500 lbs./680 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg Rear box capacity and tongue weight not to exceed 400 lbs./181kg

2006 Polaris Sportsman 450 500 EFI X-2 Repair Service Manual

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