2006 Polaris Sportsman 450/500/700 ATV Owner's Manual (P/N 9920228)

The 2006 Polaris Sportsman 450, 500, and 700 Owner’s Manual for Maintenance and Safety is publication P/N 9920228, Rev 02, copyright 2005. It covers operation and minor maintenance; major repairs belong to the separate Polaris Service Manual.

• Controls and instrumentation: All Wheel Drive (AWD), Electronic Throttle Control (ETC), Rider Information Center diagnostic displays, and programmable service-interval settings.

• Engine lubrication and cooling: Model-specific oil checks and changes, oil pump priming for the 450/500, filter service, and radiator and recovery-bottle checks.

• PVT and carburetion: Polaris Variable Transmission operation, clutch and belt break-in, PVT drying, idle adjustment, and model-specific Jetting and Clutching Charts.

• Brakes and chassis: Hydraulic and auxiliary brake checks, toe-alignment inspection, wheel removal and installation, wheel-fastener torque specifications, and rear spring adjustment.

• Electrical and minor component service: Battery removal, installation and charging; spark plug replacement; headlamp replacement and aiming; and taillight, brakelight and worklight service.

• Maintenance and troubleshooting: Periodic Maintenance Chart, Lubrication Guide, spark arrestor clean-out, storage preparation, and symptom-based engine and drive-belt troubleshooting.

Written for Sportsman owners, this manual explains operating fundamentals and minor maintenance while identifying services that require an authorized Polaris dealer.

Operation, AWD and Instrument Diagnostics

Rider guidance covers transmission shift patterns, engine and drivetrain break-in, cargo handling, hill climbing, sidehilling, and water crossings. Starting instructions distinguish cold and warm engines and address an over-choked engine.

The Rider Information Center section explains battery-voltage and tachometer displays, AWD coil-current indication, and gear-switch resistance readings. It also covers setting the maintenance reminder. The diagnostic mode is informational, rather than a substitute for the major-repair procedures in the service manual.

Oil Service, Filters and Cooling

Separate instructions distinguish the dry-sump 450/500 engines from the 700’s pressurized wet-sump system. They explain different oil-check conditions, filter replacement, drain-plug torques, and the oil pump priming required after disconnecting the 450/500 oil-tank-to-pump inlet hose.

On the 700, the dipstick’s entry angle produces a higher reading on its underside. The illustrated explanation helps owners avoid mistaking that reading for the actual oil level.

Transmission and gearcase sections distinguish Premium AGL Synthetic Gearcase Lubricant, Premium Demand Drive Hub Fluid, and the 700’s rear angle-drive lubricant. This model-specific guidance helps prevent applying the same fluid or level-check method to different housings.

Air-filter and breather-filter procedures sit alongside radiator and recovery-system checks. The breather-filter warning explains that leaving the filter out after service can damage the engine.

PVT, Jetting and Running Problems

The PVT section connects range selection and operating conditions with belt slip and heat damage to the belt and outer clutch cover. It includes a drying procedure for water entering the PVT; the separate vehicle-immersion section calls for dealer inspection before restarting a submerged ATV.

Model-specific Jetting Charts organize carburetor settings by altitude and temperature. Clutching Charts identify weights, springs, and helixes by part number, including an EBS-specific adjustment note for the 700. These are setup references, not clutch-overhaul instructions.

The Drive Belt and Cover Problems chart links operating conditions to belt symptoms. Engine troubleshooting tables address no-crank and no-start conditions, backfiring, irregular running, power loss, and overheating, with dealer referrals where further diagnosis or repair is needed.

Brake Checks, Chassis Service and Minor Repairs

Brake coverage includes fluid-level checks, pad inspection, and auxiliary-brake operation. The chassis reference identifies MacPherson struts and rear spring preload adjustment, while distinguishing wheel removal and installation from dealer-only front wheel hub service.

Illustrated procedures cover side-panel and footwell removal, lamp and headlight-housing replacement, and beam adjustment. Battery guidance separates conventional batteries from sealed types and includes a voltage-based charging table.

Follow the manual’s warnings for brake work, hot exhaust components, and the rotating PVT system. Consult a qualified technician when a service task exceeds your experience.

Tire and Alignment Checks: Selected Specifications

For the covered models, the toe-alignment inspection specifies 1/8–1/4 in. toe-out. Tie-rod adjustment is reserved for an authorized Polaris dealer.

The tire inspection section gives a replacement threshold of 1/8 in. (.3 cm) of remaining tread or less, alongside its wheel-removal instructions.

PDF Search, Navigation and Included Pages

Search and navigation: The manual’s main text is searchable; the two cover pages have no searchable text. There are no embedded PDF bookmarks. A printed contents page and alphabetical index provide section references.

Supplied as one printable, 134-page PDF in English, including 131 numbered pages, two cover pages, and one unnumbered safety page. The total includes the blank and notes pages, warranty section, maintenance log, and index.