Polaris 2006 Sportsman X2 500 EFI Owner'S Manual Download Page 136

Page: 136 / 136

133

INDEX

Main Switch

. . . . . . . . . . . . . . . . . .

Maintenance

74-114

. . . . . . . . . . . . . . .

Maintenance Chart

74-78

. . . . . . . . . . .

Maintenance Log

130-131

. . . . . . . . . .

Making Turns

. . . . . . . . . . . . . . . . .

Master Cylinder

. . . . . . . . . . . . . . .

Mode/Reverse Override Switch

. . .

Noise Emission Control System

. . .

Odometer

. . . . . . . . . . . . . . . . . . . .

Oil Change

82-84

. . . . . . . . . . . . . . . . .

Oil Filter Change

. . . . . . . . . . . . . .

Oil Level

. . . . . . . . . . . . . . . . . . . . .

Oil Pump Priming

. . . . . . . . . . . . . .

Parking Brake

. . . . . . . . . . . . . . . . .

Parking on an Incline

. . . . . . . . . . .

Passenger

58-59

. . . . . . . . . . . . . . . . . .

Passenger Seat

44-45

. . . . . . . . . . . . . . .

Periodic Maintenance Chart

74-78

. . . .

Polaris Products

117

. . . . . . . . . . . . . .

Pre-Ride Inspection

. . . . . . . . . . . . .

Premium 4 Synthetic Lubricant

. . . .

PVT Break-In

. . . . . . . . . . . . . . . . .

PVT Drying

105

. . . . . . . . . . . . . . . . .

PVT System

104-105

. . . . . . . . . . . . . .

Radiator Coolant Level

. . . . . . . . .

Rear Spring

115

. . . . . . . . . . . . . . . . . .

Reverse Override Switch

. . . . . . . . .

Rider Information Center

47-51

. . . . . .

Rider Safety

14-35

. . . . . . . . . . . . . . . .

Safe Riding Gear

. . . . . . . . . . . . . . .

Safety Decals and Locations

6-11

. . . . .

Safety Training

. . . . . . . . . . . . . . . .

Seat Conversion

. . . . . . . . . . . . . . .

Setting the Parking Brake

. . . . . . . .

Severe Use

. . . . . . . . . . . . . . . . . . .

Side Panel Removal

. . . . . . . . . . . .

Sidehilling

. . . . . . . . . . . . . . . . . . .

Spark Arrestor

103

. . . . . . . . . . . . . . . .

Spark Plugs

101

. . . . . . . . . . . . . . . . . .

Specifications

122-123

. . . . . . . . . . . . .

Starting the Engine

. . . . . . . . . . . . .

Steering Assembly

. . . . . . . . . . . . .

Stop Switch

. . . . . . . . . . . . . . . . . . .

Storage

110-113

. . . . . . . . . . . . . . . . . .

Storage Tips

111-113

. . . . . . . . . . . . . .

Switches

. . . . . . . . . . . . . . . . . . . . .

Tachometer

. . . . . . . . . . . . . . . . . . .

Taillight

100

. . . . . . . . . . . . . . . . . . . . .

Throttle Body

116

. . . . . . . . . . . . . . . .

Throttle Cable Freeplay

116

. . . . . . . . .

Throttle Lever

. . . . . . . . . . . . . . . . .

Tires 94

Toe Alignment

. . . . . . . . . . . . . . . .

Towing Capacities

. . . . . . . . . . . . . .

Transmission Oil

85-86

. . . . . . . . . . . . .

Transporting the ATV

114

. . . . . . . . . .

Trip Meter

. . . . . . . . . . . . . . . . . . . .

Troubleshooting

118-121

. . . . . . . . . . .

Turning Around on a Hill

64-65

. . . . . .

Vehicle Identification Numbers

. . . . .

Vehicle Immersion

102

. . . . . . . . . . . .

Warranty

124-129

. . . . . . . . . . . . . . . . .

Wheel Installation

. . . . . . . . . . . . . .

Wheel Nut Torque Specifications

. .

Wheel Removal

. . . . . . . . . . . . . . .

Worklight

100

. . . . . . . . . . . . . . . . . . .

Worklight Switch

. . . . . . . . . . . . . .

Summary of Contents for 2006 Sportsman X2 500 EFI

Page 1: ......

Page 2: ...02...

Page 3: ...ed to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance The engine exhaust from this product contains chemicals kno...

Page 4: ...For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information...

Page 5: ...r discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabilit...

Page 6: ...ENTIFICATION NUMBERS 5 SAFETY 6 CONTROLS 36 FEATURES 43 OPERATION 52 EMISSION CONTROL SYSTEMS 73 MAINTENANCE 74 ADJUSTMENTS 115 POLARIS PRODUCTS 117 TROUBLESHOOTING 118 SPECIFICATIONS 122 WARRANTY 124...

Page 7: ...4...

Page 8: ...aces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switc...

Page 9: ...rge The part number is printed on the decal WARNING S Never operate this vehicle on HILLS steeper than 15 degrees To prevent flipover on hilly terrain when going up or down use throttle and brakes gra...

Page 10: ...ne passenger passengers affect balance and steering and increase risk of losing control S with a passenger under the age of 12 THE OPERATOR MUST ALWAYS S use proper riding techniques to avoid vehicle...

Page 11: ...er or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and firmly secured to the rack For stability on rough or hilly terrain reduce...

Page 12: ...DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max combined Front Rack and container Load 90 lbs 41 kg 7172569 WARN...

Page 13: ...SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS S use an approved helme...

Page 14: ...vere drive shaft and clutch damage See your Owner s Manual 7079780 7172564 Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of cont...

Page 15: ...harged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of the ATV in your area We strongly advise you to strictly fol...

Page 16: ...r the Snell Memorial Foundation label A passenger s helmet should have a rigid chin guard 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shie...

Page 17: ...Polaris ATV The following signal words and symbols appear in this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before re...

Page 18: ...ar device S Never carry more than one passenger on this 2 up ATV S Always make sure the passenger seat lock out is functioning proper ly before carrying a passenger S Never permit a guest to operate t...

Page 19: ...too steep for the ATV or for your abilities S Never operate this ATV in TURF mode while operating on a hill or other irregular terrain See page 43 S Always follow proper procedures for climbing hills...

Page 20: ...motion Do not make sudden turns or stops and do not make sudden throttle changes S Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly seve...

Page 21: ...inal equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or...

Page 22: ...ual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENTIAL HAZARD Failure to follow the age recommendations for th...

Page 23: ...injury or death HOW TO AVOID THE HAZARD Never operate the 2 up ATV with more than one passenger WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN A passenger riding in the...

Page 24: ...oss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING POTENTIAL HAZARD Operating t...

Page 25: ...event of an accident Riding without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always be sure opera...

Page 26: ...result in an accident causing severe injury or death HOW TO AVOID THE HAZARD DO NOT drink alcohol or use drugs or medications before or while driving the ATV or riding as a passenger WARNING POTENTIA...

Page 27: ...stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of...

Page 28: ...e hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If a person s feet are not firmly planted on the footrests they could come into contac...

Page 29: ...ARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or...

Page 30: ...per procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Operatin...

Page 31: ...climb hills with excessively slippery or loose surfaces Shift body weight uphill A passenger should also shift body weight uphill Never open the throttle suddenly while traveling uphill The ATV could...

Page 32: ...rain carefully before descending a hill Never operate this ATV in TURF mode while operating on a hill or other irregular terrain See page 43 Always descend a hill with the transmission in forward gear...

Page 33: ...TV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 64 Use extra caution when turning on any hill Do not cross a hillside with...

Page 34: ...ll Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 64 If the ATV begins rolling backward...

Page 35: ...fall from the vehicle or vehicle tipover WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV c...

Page 36: ...s and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leav...

Page 37: ...approved instructions See your authorized Polaris ATV dealer for more information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towin...

Page 38: ...le requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle or ride as a passenger have an increased risk of overturn and loss of control wh...

Page 39: ...gine will not start or run when the switch is in the OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency Main Switch 3 To start the engine...

Page 40: ...lly during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 The throttle lever is spring loaded Engine speed returns to idle when the lever is...

Page 41: ...in conditions of reduced visibility such as fog rain and darkness Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are h...

Page 42: ...hen checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 117 for the part numbers of Polaris products WAR...

Page 43: ...rake lock 2 forward to engage the brake Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards S T...

Page 44: ...olaris ATV has an auxiliary brake for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system...

Page 45: ...left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven m...

Page 46: ...AWD switch is on See page 36 When the switch is on TURF right position the differential is open allowing the inside wheel to rotate independently from the outside wheel during turns Operate this vehic...

Page 47: ...r from TURF to 2X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD or to TURF from 2X4 while the rear wheels have traction or are at rest Passe...

Page 48: ...position before it can be secured in the upright position The lowest position is for seat storage only Do not leave the backrest in the lowest position Always adjust the backrest to one of the three o...

Page 49: ...ed to approximately 7 9 mph Refer to page 36 for additional information 1 Rider Information Center 2 Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition...

Page 50: ...Low Battery or Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if t...

Page 51: ...ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button...

Page 52: ...ock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on 5 Release the switch as soon as the display is activated The initial screen...

Page 53: ...ash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increm...

Page 54: ...21 Loss of Synchronization 54 Engine Temp Lamp Short Circuit to Ground 45 Barometric Pressure Sensor Circuit Low Input 54 Engine Temp Lamp Short Circuit to Battery 46 Barometric Pressure Sensor Circu...

Page 55: ...lames or sparks in or near the area where refueling is performed or where gasoline is stored S Do not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediat...

Page 56: ...e oil reservoir level on the dipstick See page 81 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize...

Page 57: ...ure free operation Tires Inspect condition and pressure 94 Wheels fasteners Inspect ensure fastener tightness 95 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 8...

Page 58: ...the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts CAUTION Ope...

Page 59: ...with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up then shift the transmission into gear 8 Check your surroundings and determine your path of...

Page 60: ...p both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest NOTE This technique alters the balance of traction between the rear whe...

Page 61: ...riding See page 44 Make sure the passenger seat lock out is functioning properly 5 Lock the parking brake 6 Mount the vehicle from the left side After the operator is seated the passenger should mount...

Page 62: ...nd both hands on the passenger grab handles at all times The passenger should never hold on to the operator 13 Never secure a passenger to the vehicle or to the operator with a belt rope or similar de...

Page 63: ...e handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear...

Page 64: ...ing of the vehicle 7 If the vehicle stalls while climbing a hill never back it down the hill Apply the hand brake If a passenger is on board ask the passenger to dismount Use the K turn to turn around...

Page 65: ...ntered and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Do not cross a hillside with a passenger on board...

Page 66: ...nsmission in neutral 2 Slow down 3 Proceed directly downhill 4 Shift body weight uphill 5 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary brake in the...

Page 67: ...8 2 4 m 64 OPERATION Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around...

Page 68: ...of the vehicle turn the handlebars full left 5 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the...

Page 69: ...Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until brakin...

Page 70: ...ng the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sud...

Page 71: ...s injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is r...

Page 72: ...ore operating over an obstacle that could cause a fall from the vehicle or vehicle tipover WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obs...

Page 73: ...ATING Unsecured loads may shift and create unstable operating condi tions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before mov ing t...

Page 74: ...ward as possible 2 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down 4 Make sure the cargo box dump latch is sec...

Page 75: ...ways position the weight as far forward and as low as possible 6 Pull the cargo box release lever A upward 7 Lift the front of the cargo box and dump the cargo 8 Lower the cargo box and make sure the...

Page 76: ...CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankca...

Page 77: ...nt procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 mi...

Page 78: ...ted service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions J Have an authorized Polaris dealer perform these services WARNING Improperly performing t...

Page 79: ...Pre Ride E Air filter pre filter Daily Inspect clean often replace as needed Air box sediment tube Daily Drain deposits when visible Coolant Daily Check level daily change coolant every 2 years Headla...

Page 80: ...il tank vent hose if equipped 100 H 12 M 1000 1600 Inspect routing condition J E Valve clearance 100 H 12 M 1000 1600 Inspect adjust J E Fuel system filter 100 H 12 M 1000 1600 Check for leaks at tank...

Page 81: ...12 M 1000 1600 Inspect replace as needed J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed J Toe adjustment Inspect p...

Page 82: ...Special F Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging Item Lube Method Engine Oil Polaris Premium 4 Synthetic 0W40 See page...

Page 83: ...wn in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium...

Page 84: ...ng in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds Stop the engin...

Page 85: ...ain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 7 Disconnect the l...

Page 86: ...ve the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 14 Reinstall the drain plug To...

Page 87: ...roximately 2I from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If the line is...

Page 88: ...earcase Lubricant See page 117 for the part numbers of Polaris products Oil Check The transmission fill plug 1 is located on the left side of the ATV under the rear fender behind the wheel 1 Position...

Page 89: ...well 1 Remove the fill plug Remove the drain plug 2 Drain the oil into a drain pan Dispose of used oil properly 3 Clean and reinstall the drain plug Torque to 20 25 ft lbs 27 34 Nm 4 Add 32 oz 948 ml...

Page 90: ...el surface 2 Remove the fill plug 2 View the oil level 3 Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to 8 10 f...

Page 91: ...he freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator shoul...

Page 92: ...The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is...

Page 93: ...to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see page 39...

Page 94: ...hould be changed when worn to 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activa...

Page 95: ...4 toe out 1 Set the handlebars in a straight ahead position NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from th...

Page 96: ...panel from the grommet 3 Pull the panel downward and rearward to remove it from the ATV 4 Reinstall the side panel by reversing the removal procedure Footwell Removal 1 Remove the six screws 1 on the...

Page 97: ...properly Always replace tires when the tread depth measures 1 8 3 cm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration Front Wheel Hub Tighten...

Page 98: ...parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighte...

Page 99: ...access the breather filter 3 remove the left side panel as outlined on page 93 The breather filter is on the hose that runs between the engine and air box 2 Remove the clamps and pull the filter out o...

Page 100: ...Allow lamps to cool before servicing Headlight Lamp Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slig...

Page 101: ...adlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 1 cm below the mark on the wall NOTE Include rider and passenger...

Page 102: ...harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it...

Page 103: ...kwise to secure the headlamp Taillight Brakelight Worklight Lamp Replacement 1 Open the tailgate 2 Remove the two screws 1 near the tailgate latch 3 Grasp the entire taillight assembly and pull it awa...

Page 104: ...insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE...

Page 105: ...low the footrests 2 Check the air box for any water and dry it if water is present NOTE Filter replacement is required if water is present 3 Remove the spark plug 4 Turn the engine over several times...

Page 106: ...he vehicle while it s inclined 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in PARK Start the engine 3 Purge carbon from the system by momentarily rev...

Page 107: ...he engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running a...

Page 108: ...ntenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housi...

Page 109: ...p towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poisonous It con...

Page 110: ...er 2 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed If not battery gases coul...

Page 111: ...or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery al...

Page 112: ...sing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging NOTE Always verify battery condi...

Page 113: ...ots Avoid the use of harsh cleaners which can scratch the finish NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement CAUTION High water pressure may damage A...

Page 114: ...d Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth i...

Page 115: ...h the pre measured amount of oil NOTE Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil l...

Page 116: ...sing Polaris Battery Tendert charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tendert can be left connected during the storage period and will automati...

Page 117: ...and remove the key to prevent loss during transporting 2 Place the transmission in PARK Lock the parking brake 3 Securely install the fuel cap oil cap and seat 4 Always tie the frame of the ATV to the...

Page 118: ...djuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exa...

Page 119: ...ttle cable adjuster on the handlebar 2 Squeeze the end of the rubber boot 1 and slide it far enough to expose the end of the inline cable adjuster 2 3 Loosen the locknut 3 4 Rotate the boot to turn th...

Page 120: ...Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460...

Page 121: ...plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss o...

Page 122: ...ug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Clogged fuel filter Replace the filter...

Page 123: ...ry to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See y...

Page 124: ...5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction Se...

Page 125: ...2 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Dry Weight 798 lbs 362 kg Minimum Turning Radius 82 in 208 cm Fuel Capacity 6 gal 22 7 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 5 q...

Page 126: ...ll wheel Front Suspension MacPherson Strut with 8 2 20 8 cm of travel Rear Suspension Progressive Rate with 8 75 22 2 cm of travel Shock Adjustment Rear Spring Preload Adjust Headlight 1 Single Beam o...

Page 127: ...olaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will r...

Page 128: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels tha...

Page 129: ...use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require an...

Page 130: ...ling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Co...

Page 131: ...d outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Ve...

Page 132: ...of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABIL...

Page 133: ...130 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 134: ...131 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 135: ...n 53 Driving Downhill 63 Driving in Reverse 68 Driving on a Hillside 62 Driving on Slippery Surfaces 60 Driving Over Obstacles 69 Driving Procedures 56 Driving Through Water 66 67 D Driving Uphill 61...

Page 136: ...enter 47 51 Rider Safety 14 35 S Safe Riding Gear 13 Safety Decals and Locations 6 11 Safety Training 12 Seat Conversion 44 Setting the Parking Brake 40 Severe Use 74 Side Panel Removal 93 Sidehilling...

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Polaris 2006 Sportsman X2 500 EFI, Owner'S Manual

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