2006 Polaris Sportsman 700 EFI / 800 EFI ATV Owner's Manual (P/N 9920028)

The 2006 Polaris Sportsman 700 EFI and 800 EFI Owner's Manual for Maintenance and Safety (P/N 9920028, Rev 02) details routine maintenance, operating procedures, and basic troubleshooting for these adult-only ATVs.

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• Engine maintenance: Engine oil and filter changes, dipstick checks, air-filter and pre-filter service, and spark-plug inspection and replacement.

• Driveline service: Transmission and front/rear gearcase oil changes, AWD engagement, PVT drying, clutch/belt break-in, and high/low range selection.

• EFI and instruments: Special EFI Diagnostic Mode, blink-code descriptions, Rider Information Center diagnostics, and programmable service interval adjustment.

• Brakes and chassis: Brake inspections and wear limits, toe-alignment checks, wheel removal and installation, rear spring adjustment, and throttle cable freeplay.

• Cooling and electrical upkeep: Radiator and recovery-bottle checks, headlight aim and lamp replacement, battery removal and installation, and sealed-battery charging.

• Operating and recovery guidance: Pre-ride checks, cargo and towing limits, water immersion recovery, exhaust spark arrestor purging, and storage preparation.

This manual is suited to owners familiar with safe basic maintenance procedures; its maintenance chart identifies work assigned to an authorized Polaris dealer.

Maintenance Schedules and Repair Scope

This manual breaks down the required lubrication and inspection schedules. Severe-use definitions address conditions such as mud or water immersion, prolonged low-speed loading, and short cold-weather trips.

The Periodic Maintenance Chart distinguishes emission-related items from work assigned to a dealer. Major repair procedures belong to the separate Polaris Service Manual, which is not included here; this owner's publication does not cover internal engine overhaul or transmission teardown.

Engine, Gearcase, and Cooling Maintenance

The Lubrication Guide distinguishes AGL transmission lubricant, front Demand Drive Hub Fluid, and rear ATV Angle Drive Fluid. Separate oil-check and change procedures include fill-point illustrations, fluid capacities, and component-specific torque specifications.

The air-filter section warns that overtightening the clamp can damage the filter. The Crankcase Emission Control System section explains how blow-by gases return through the intake.

Cooling-system coverage explains how the radiator pressure cap and recovery bottle work together, including the effect of using an incorrect pressure cap.

PVT, AWD, and Model Differences

The automatic transmission gear selector and All Wheel Drive (AWD) sections explain gear positions, front gearcase engagement, and reverse override operation.

The Polaris Variable Transmission (PVT) explanation and Drive Belt and Cover Problems chart connect low-speed loading with belt slip and heat damage. That helps owners recognize operating conditions behind repeat belt trouble before planning a repair.

Separate Clutching Charts list altitude-dependent shift weights, springs, and EBS helix part numbers for each model. The spark-arrestor instructions illustrate the 700 EFI muffler and distinguish the 800 EFI's two arrestors.

EFI Diagnostics and Battery Checks

Rider Information Center diagnostics display battery voltage, AWD coil status, and gear-switch resistance. The Electronic Fuel Injection (EFI) failure-code table covers engine temperature sensor circuits, injectors, the throttle position sensor, and fuel pump relay faults.

These diagnostic modes provide fault information; detailed circuit repair procedures and wiring diagrams are outside this manual's scope. The Engine Turns Over, Fails to Start chart organizes common fuel, ignition, and battery causes.

Sealed-battery guidance includes voltage-based state-of-charge references, charging limits, and charging-time tables.

Chassis Checks and Water Recovery

Toe alignment is a checking procedure; tie-rod adjustment is assigned to an authorized Polaris dealer.

The Vehicle Immersion section provides a contingency procedure when the ATV cannot be taken to a dealer before restarting, and calls for dealer follow-up.

Before turning a wrench, follow the manual's precautions for hot oil, pressurized coolant, and rotating PVT components.

Printable PDF and Included Pages

One printable English PDF with 124 pages total: 121 numbered pages (including blank page 4), two cover pages, and one unnumbered safety page. The warranty section, maintenance log, and index are already included in that total.