2006 Polaris Sportsman 500 EFI ATV OEM Service & Repair Manual

1.1 GENERAL INFORMATION 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 2006 SPORTSMAN X-2 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL NUMBER: A06MN50AW, A06MN50AU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECMIAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

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 06 MN 50 AU 4 X A M N 5 0 A * 6 P 0 0 0 0 0 0 } 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 The transmission I.D.number is located on top of the transmission

1.3 GENERAL INFORMATION 2006 SPORTSMAN X-2 500 EFI MODEL NUMBER: A06MN50AW, A06MN50AU ENGINE MODEL: EH50PLE Table 1-1: 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

1.4 GENERAL INFORMATION Table 1-2: 2006 Sportsman X2 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 60-90 psi W/Compression Release Engine Idle Speed 1150 ± 50 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 10°± 1 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 1-3: 2006 Sportsman X2 500 EFI Drivetrain Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity 5 oz. / 150 ml Gear Ratio : Low Rev High Front Drive 23.91:1 21.74:1 10.57:1 3.82:1 Clutch Type PVT w/EBS Belt 3211091 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 8.75 in. / 22.2 cm Ground Clearance 11 in. / 28 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 82 in./208 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Wheel Size / Pattern - Front Steel 12x6 / 4-156 Wheel Size / Pattern - Rear Steel 12x8 / 4-156 Front Tire Size 25x8-12 Rear Tire Size 25x11-12 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc Table 1-4: 2006 Sportsman X2 500 EFI 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)

1.5 GENERAL INFORMATION MISC. NUMBERS/CHARTS 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 1-5: Publications Year Model Model No. Owner's Manual PN Parts Manual PN Parts Micro Fiche PN 2006 Sportsman X2 500 EFI A06MN50AW,AU 9920361 9920406 9920407 Table 1-6: Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman X2 500 EFI Frame Black 9440 P-067 Table 1-7: 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 5533534

1.6 GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

1.7 GENERAL INFORMATION CONVERSION TABLE °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: (°F + 40) ÷ 9 - 40 = °C

1.8 GENERAL INFORMATION SAE TAP DRILL SIZES METRIC TAP DRILL SIZES DECMIAL EQUIVALENTS

1.9 GENERAL INFORMATION GLOSSARY OF TERMS ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. DCV: Direct current voltage. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Ft. lb. / Foot Pound: A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. Left Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040,. Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat. Right Side: Always referred to based on normal operating position of the driver. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

NOTES GENERAL INFORMATION 1.10

2006 Polaris Sportsman 500 EFI ATV OEM Service & Repair Manual

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