2006 Polaris Sportsman 500 EFI ATV Owner's Manual (P/N 9920012)

This Polaris owner's manual covers the 2006 Sportsman 500 EFI and its EH50PLE13 engine. P/N 9920012, Rev 02, copyright 2005, documents safe operation, routine maintenance, and owner-level troubleshooting.

Text search and navigation: The main text is searchable; the front and rear cover pages are not. There are no embedded PDF bookmarks. The printed table of contents and index provide section references.

• Engine lubrication and cooling: Oil and filter changes, oil pump priming, air and breather filter service, coolant checks, and spark plug inspection.

• PVT and AWD: Polaris Variable Transmission (PVT) operation, PVT drying, transmission and front gearcase oil changes, and drive-belt troubleshooting.

• EFI and instrument diagnostics: Electronic Fuel Injection (EFI) blink codes, Rider Information Center diagnostic screens, and troubleshooting charts for starting problems, misfires, power loss, and overheating.

• Brakes and chassis: Hydraulic disc and auxiliary brake checks, toe-alignment measurement, wheel removal and installation, and tire-pressure and fastener specifications.

• Battery and lighting: Conventional and sealed battery maintenance, charging reference data, headlight adjustment, and headlamp, taillight, brakelight, and worklight replacement.

• Operation and scheduled service: Pre-ride inspection, break-in, cargo and towing guidance, severe-use maintenance schedules, spark arrestor purging, storage, and transport.

Written for owners performing minor maintenance, this manual directs major repair work to Factory Certified Master Service Dealer (MSD) technicians using the separate Polaris Service Manual.

Engine Oil, Filters and Cooling

The oil-change section covers the dry-sump tank, crankcase drain, oil filter, and tank screen fitting. Its Oil Pump Priming illustration identifies the hose connections involved, and the procedure applies whenever the hose between the oil tank and pump inlet has been disconnected.

Air-filter and breather-filter service includes access and inspection instructions. The air-filter section warns that overtightening its clamp can damage the filter.

Cooling coverage explains the radiator, recovery bottle, pressure cap, and coolant-level checks. It distinguishes Polaris Premium 60/40 premix from an aluminum-compatible 50/50 coolant-and-distilled-water alternative. Follow the manual's precautions for hot coolant, exhaust components, and rotating PVT parts.

PVT, AWD and Clutching References

The PVT section explains how range selection affects belt slip and operating temperature. It links excessive slip to heat damage in the belt and outer clutch cover, while the Drive Belt and Cover Problems chart relates symptoms to operating conditions and clutch faults.

All-Wheel Drive (AWD) coverage explains front gearcase engagement and reverse-override operation. An altitude-based Clutching Chart identifies shift weights, drive and driven clutch springs, and the EBS helix by part number. It also notes that EBS models require no helix or spring adjustment.

EFI Fault Codes and Electrical Checks

The Special EFI Diagnostic Mode section explains how to retrieve stored blink codes through the instrument cluster without a separate scanner. Its failure-description table identifies sensor, injector, pump-relay, and ECU-related faults, helping an owner describe a reported problem accurately before discussing a repair with a dealer.

Other diagnostic screens show battery voltage, engine speed, AWD coil status, and gear-switch input. The controls and adjustment sections explain the Electronic Throttle Control (ETC) safety function and throttle cable freeplay adjustment.

Battery coverage distinguishes conventional batteries from YUASA activated sealed batteries. The sealed-battery charging table relates measured voltage to state of charge and charging guidance; a voltmeter or multimeter is specified for checking condition.

Brakes, Steering and Maintenance Limits

The Toe Alignment illustration supports checking wheel alignment; tie-rod adjustment is assigned to an authorized Polaris dealer. Valve-clearance inspection and adjustment appear in the maintenance schedule as dealer service, without a valve-adjustment procedure.

Chassis references include MacPherson strut front suspension, rear spring preload adjustment, and separate wheel-fastener requirements for cast aluminum and steel wheels. Brake coverage addresses fluid level, pad wear, disc condition, and the auxiliary system; a spongy brake lever calls for dealer diagnosis and repair.

The Periodic Maintenance Chart identifies severe-use and emission-related service, alongside tasks reserved for a dealer. Noise, crankcase, and exhaust emission controls are explained in their own section.

English PDF and Included Pages

One printable 126-page PDF contains 123 numbered pages, two cover pages, and one unnumbered warning page. The numbered section includes one otherwise blank page, six warranty pages, two maintenance-log pages, and a two-page index; all are already included in the total.