Polaris 2006 Sportsman 500 EFI Owner'S Manual Download

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Summary of Contents for 2006 Sportsman 500 EFI

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Page 3: ...hed 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 known to cause cancer birth defects or other reproductive harm WARNING ...

Page 4: ...d 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 about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and ...

Page 5: ...inor 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 liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2006 S...

Page 6: ...ATION NUMBERS 5 SAFETY 6 CONTROLS 31 FEATURES 39 OPERATION 46 EMISSION CONTROL SYSTEMS 63 MAINTENANCE AND LUBRICATION 64 ADJUSTMENTS 105 POLARIS PRODUCTS 107 TROUBLESHOOTING 108 SPECIFICATIONS 112 WARRANTY 114 MAINTENANCE LOG 120 INDEX 122 ...

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Page 8: ...paces 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 switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number 2 Key Number 3 2 1 3 31XX ...

Page 9: ...instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS ...

Page 10: ...ible and firmly secured to the racks With dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information 7172748 WARNING ATTENTION S Operation of this vehicle without the air filter element will severely damage...

Page 11: ...ve engine RPM which can result in serious injury or death NO STEP 7172563 WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172559 WARNING S 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 S Max Rack Loads Front ...

Page 12: ...much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual 7170911 TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 120 LBS 55KG MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS 7171492 CE VÉHICULE EST UN VÉHICULE TOU...

Page 13: ...nstitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings Z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4...

Page 14: ...nt Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this...

Page 15: ...n your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE ...

Page 16: ... including a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating an ATV S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating condition...

Page 17: ...ver attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for bra...

Page 18: ...FETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for th...

Page 19: ...se and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may...

Page 20: ... allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control ac...

Page 21: ... POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating 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 AVOI...

Page 22: ...efore or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always op...

Page 23: ...er 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 an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures...

Page 24: ... into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or ...

Page 25: ...te on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for ...

Page 26: ...oper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly w...

Page 27: ...ures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 57 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the...

Page 28: ...pt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 58 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weigh...

Page 29: ...ll Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV...

Page 30: ...anual 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 could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPP...

Page 31: ...ents 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 leaving water If necessary apply them several times to let friction dry out the pads WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HA...

Page 32: ...ore information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulli...

Page 33: ...ing systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious bur...

Page 34: ...ngine 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 slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Both the main switch and the emergency engine...

Page 35: ...ally 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 released This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position w...

Page 36: ...s 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 hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any ...

Page 37: ...When 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 107 for the part numbers of Polaris products WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moistu...

Page 38: ...brake 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 The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill An...

Page 39: ...laris ATV has an auxiliary brake 1 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 if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brak...

Page 40: ...ither leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter The in line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris Do not attempt to clean the fuel filter 1 ...

Page 41: ...ngine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the ATV is 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 42: ... no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not...

Page 43: ...eed to approximately 7 9 mph Refer to page 31 for additional information 1 Rider Information Center 2 Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that s...

Page 44: ... 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 the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 6 Odometer Tachometer T...

Page 45: ... 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 override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter ...

Page 46: ... Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery volta...

Page 47: ...lash 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 increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down...

Page 48: ...d 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 Circuit High Input 55 Diag Lamp Open Load 22 TPS Open or Short Circuit to Ground 55 Diag Lamp Short Circuit to Ground 22 TPS Short Circuit to Battery 55 Diag Lamp Short Circuit to Battery 23 RAM Error Def...

Page 49: ...ed 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 immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time WARNING The engine exhaust from this product contai...

Page 50: ...he oil reservoir level on the dipstick See page 71 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 yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride ...

Page 51: ... Inspect condition and pressure 84 Wheels fasteners Inspect ensure fastener tightness 85 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 71 Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 32 106 Indicator lights switches Ensure operation 33 Engine stop switch Ensure proper operation...

Page 52: ...e 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 Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round c...

Page 53: ...he specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Belt Life Use low forward gear when hauling or tow...

Page 54: ...stable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when a...

Page 55: ...t to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 56: ... the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp angles...

Page 57: ...rning the 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 wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire ...

Page 58: ...hrottle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operating on hills and follow prope...

Page 59: ... can be the most dangerous type of driving encountered 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 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins ...

Page 60: ...your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill ...

Page 61: ...icle is pointing straight uphill 4 Staying uphill 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 hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with th...

Page 62: ... front gearcase and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep o...

Page 63: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 64: ...es or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not ...

Page 65: ...ing on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in PARK 3 Set the parking brake 4 Always block the rear wheels on the downhill side as shown in the illustration 5 Shut off the fuel supply ...

Page 66: ...e viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delive...

Page 67: ... adjustment 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 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition S Frequent immersion in mud water or sand S Racing or race style high RPM us...

Page 68: ...sion related 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 the procedures marked with a J could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 69: ... E Air filter pre filter Daily Inspect clean often replace as needed E Air box sediment tube Daily Drain deposits when visible Coolant Daily Check level daily change coolant every 2 years Headlamp tail lamp worklight Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drain water as needed check often if operat...

Page 70: ... change Oil 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 cap lines filter pump replace lines every two years Radiator if applicable 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling hoses if applicable 100 H 12 M 1000 1600 Inspect for l...

Page 71: ...ngs 100 H 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 periodically adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Related Service J Have an authori...

Page 72: ...er severe use L Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease 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 Add to proper level on dip stick Brake Fluid DOT 3 Only Maintain level between fil...

Page 73: ...l breakdown 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 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not ...

Page 74: ...re collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Position the ATV on a level surface 2 Start the engine and let it idle for 20 30 seconds Stop the engine 3 Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick completely 5 Remove the dipstick and check the oil level Maintain the oil level in the normal or safe range 2...

Page 75: ...oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain plug and torque to 14 17 ft lbs 19 23 Nm 6 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 7 Reinstall the scre...

Page 76: ...rain remove 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 13 Reinstall the drain plug and torque to 14 ft lbs 19 Nm 14 Remove the dipstick 2 and add two quarts 1 9 l of the recommended oil Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 15...

Page 77: ...ine 1 approximately 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 bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation If you do not hear air the line has not bled and you ll need to repeat the pri...

Page 78: ...arcase Lubricant See page 107 for the part numbers of Polaris products Oil Check On the Sportsman 400 and 500 the transmission fill plug 1 is located on the left side of the ATV under the rear fender behind the wheel 1 Position the ATV on a level surface and remove the fill plug 2 Add the recommended oil as needed to bring the level to the bottom of the fill plug hole threads 3 Reinstall the fill ...

Page 79: ...d the wheel well 1 Remove the fill plug and the transmission drain plug 2 Drain the oil into a drain pan and dispose of properly 3 Clean and reinstall the drain plug Torque to 22 ft lbs 30 Nm 4 Add 32 oz 948 ml of the recommended transmission oil to bring the level to the bottom of the fill plug 5 Reinstall the fill plug Torque to 22 ft lbs 30 Nm 6 Check for leaks 2 2 ...

Page 80: ...n the ATV on a level surface 2 Remove the fill plug 2 and 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 ft lbs 11 14 Nm Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug 3 located on ...

Page 81: ...ons for the 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 should be inspected Add coolant as needed WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removin...

Page 82: ...ry system 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 forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the p...

Page 83: ...can lead 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 34 WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE Und...

Page 84: ...TE Pads should 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 activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only it will not be as effecti...

Page 85: ...1 8 to 1 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 the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the sid...

Page 86: ...e the side 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 four screws 1 on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets 2 securing the footwell to the fenders 3 Remove the footwell 3 1 2 3 1 2 ...

Page 87: ...stalled 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 Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine pl...

Page 88: ...nd lock the 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 tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts to specification Cast Aluminum Steel Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve be...

Page 89: ...ose 1 To access the breather filter 3 remove the left side panel as outlined on page 83 The breather filter is on the hose that runs between the engine and air box 2 Remove the clamps and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine 3 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging...

Page 90: ...s to skin 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 slightly while depressing the tabs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure ...

Page 91: ... and turn the headlight 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 weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclock...

Page 92: ...he wiring 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 from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the headlamp parting lin...

Page 93: ... the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the headlamp Taillight Brakelight Worklight Lamp Replacement 1 Remove the harness connector 1 from the back of the light assembly 2 Turn the lamp 2 counterclockwise to remove it 3 Apply dielectric grease to the socket and install the new lamp 4 Reinstall the harness conne...

Page 94: ...e normal 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 The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel 2 Wet Fouled The wet fouled insulator tip is black A damp oi...

Page 95: ... water below 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 using the electric start 5 Dry the spark plug and reinstall or replace it with a new plug 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the ATV to your dealer ...

Page 96: ...under the 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 and start the engine 3 Purge carbon from the system by momentarily revving the engine several times 4 If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times 5 If partic...

Page 97: ...l above the 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 at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switc...

Page 98: ...ended maintenance 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 housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before opera...

Page 99: ...clean shop 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 contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of ma...

Page 100: ...ery holder 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 could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte which can cause severe burns 3 First connect...

Page 101: ...necting 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 always connect the negative black cable last Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a YUASA activated sealed battery Read a...

Page 102: ...plode causing 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 condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts Non...

Page 103: ...water spots Avoid the use of harsh cleaners which can scratch the finish NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement CAUTION High water pressure may damage ATV components Polaris recommends washing the ATV by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage plastic surfaces Do not ...

Page 104: ...l tank Add 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 in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box ...

Page 105: ...illed with 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 leak 3 Reinstall the spark plug Torque to 18 ft lbs 24 Nm 4 Apply dielectric grease to the inside of the spark plug cap and reinstall the cap onto the plug 5 Turn the engine over several times...

Page 106: ...sily by using 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 automatically charge the battery if the voltage drops below a pre determined point Check the fluid level monthly Battery Maintenance Sealed Remove the battery and recharge it as outlined on page 98 S...

Page 107: ...engine and remove the key to prevent loss during transporting 2 Place the transmission in PARK and lock the parking brake 3 Securely install the fuel cap oil cap and seat 4 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets ...

Page 108: ...adjuster 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 exactly or see your Polaris dealer for service 1 Locate handlebar bolts 1 by removing the upper headlight pod 2 Loosen the four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars ...

Page 109: ... freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster...

Page 110: ...e 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 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt 2872073 Chain Lube 6 25 oz aerosol 2872348 Chain Lub...

Page 111: ...e 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 of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WA...

Page 112: ...lug 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 Low battery voltage Recharge battery to 12 5 VDC Mechanical failure See your Polaris dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug...

Page 113: ...ery 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 your Polaris dealer Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel ...

Page 114: ...2 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 See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause...

Page 115: ...ht 48 in 122 cm Wheelbase 50 5 in 128 3 cm Ground Clearance 11 25 in 28 6 cm Dry Weight 715 lbs 324 kg HO 722 lbs 327 kg New Break Up Minimum Turning Radius 65 in 165 cm Fuel Capacity 4 25 gal 16 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 25 qts 2 13 l Engine EH50PLE13 Displacement 499 Bore x Stroke 92 x 75 Alternator Output 350 w Compression Ratio 10 2 Full Stroke Ignition System Electr...

Page 116: ...wheel Front Suspension MacPherson Strut with 8 2 20 8 cm of travel Rear Suspension Progressive Rate with 9 5 24 1 cm of travel Shock Adjustment Rear Spring Preload Adjust Headlight 1 Single Beam on Headlight Pod 50 w 2 Single Beam on Bumper 27 w Taillights 8 26 w Brakelight 26 9 w Instrument Cluster LCD Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Fee...

Page 117: ...egistration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registratio...

Page 118: ...rrosion 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 that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE ...

Page 119: ...se 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 any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the ...

Page 120: ...eling 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 Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 121: ...ed 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 Vehicles registered to Government officials or mili tary personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 122: ... 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 LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE AL...

Page 123: ...120 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 124: ...121 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 125: ... in Reverse 61 Driving on Slippery Surfaces 54 Driving Over Obstacles 60 Driving Procedures 52 Driving Safely 50 62 Driving Through Water 59 Driving Uphill 55 E Electrical Switches 31 Emission Control Systems 63 Emissions Warranty 119 Engaging Front Gearcase 39 Engine Break in 47 Engine Cooling System 78 Engine Stop Switch 31 Equipment Modifications 15 Exhaust Emission Control System 63 F Features...

Page 126: ...als and Locations 6 9 Safety Training 11 Setting the Parking Brake 35 Severe Use 64 Side Panel Removal 83 Sidehilling 56 S Spark Arrestor 93 Spark Plugs 91 Specifications 112 113 Starting the Engine 49 Steering Assembly 82 Stop Switch 31 Storage 100 103 Storage Tips 101 103 Switches 31 33 T Tachometer 42 Taillight 90 Throttle Body 106 Throttle Cable Freeplay 106 Throttle Lever 32 Tires 84 Toe Alig...

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Polaris 2006 Sportsman 500 EFI, Owner'S Manual

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