Polaris Sportsmabn X2 500 EFI Owner's Manual
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Polaris Sportsmabn X2 500 EFI Owner's Manual

Polaris 2006 atv owner's manual
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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached 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.
  • Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 5 Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Table Of Contents

    ......EMISSION CONTROL SYSTEMS MAINTENANCE ADJUSTMENTS POLARIS PRODUCTS TROUBLESHOOTING SPECIFICATIONS WARRANTY .

  • Page 8: Vehicle Identification Numbers

    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.

  • Page 9: Safety

    ATV, always read and follow the 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.

  • Page 10: Safety Decals And Locations

    S make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 WARNING NEVER USE NEVER CARRY...
  • Page 11 SAFETY Safety Decals and Locations IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, OPERATOR, PASSENGER AND CARGO IS 1500 LBS.
  • Page 12 Safety Decals and Locations Operating this vehicle 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. DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death.
  • Page 13 SAFETY Safety Decals and Locations To reduce the risk of SEVERE INJURY or DEATH. PASSENGER UNDER NEVER CARRY A PASSENGER UNDER AGE 12 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 helmet and protective gear S securely grasp hand holds and plant feet firmly...
  • Page 14 See your Owner’s Manual. 7079780 WARNING NO STEP MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55KG) SAFETY 7172563 7171492...

  • Page 15: Know Your Vehicle

    SAFETY Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV available to you and your eligible family members. RiderCourse This training is included in the purchase price of your ATV. Polaris...

  • Page 16: Safe Riding Gear

    Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
  • Page 17 Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
  • Page 18 S Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse S Never allow anyone under 16 years of age to operate this ATV.
  • Page 19 Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skid- ding or sliding out of control.
  • Page 20 Allow a greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-3764. SAFETY...

  • Page 21: 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 these purposes.
  • Page 22 HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner’s Manual.
  • Page 23 SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating with more than one passenger. WHAT CAN HAPPEN Passengers affect balance and steering and increase the risk of losing control, which can result in severe injury or death. HOW TO AVOID THE HAZARD Never operate the 2-up ATV with more than one passenger.
  • Page 24 SAFETY Rider Safety 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, accident, and/or injury.
  • Page 25 SAFETY Rider Safety WARNING POTENTIAL HAZARD Riding an ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Riding an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 26 SAFETY Rider Safety WARNING POTENTIAL HAZARD Riding the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator (and passenger) judgment. Reaction time may be slower. Balance and perception could be affected. Consuming alcohol and/or drugs before or while riding an ATV could result in an accident causing severe injury or death.
  • Page 27 SAFETY Rider Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
  • Page 28 SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water. WARNING POTENTIAL HAZARD Removing hands from the...
  • Page 29 SAFETY Rider Safety 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 overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 30 SAFETY Rider Safety 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 turning as described in the owner’s manual.
  • Page 31 SAFETY Rider Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper 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. See page 61. Always check the terrain carefully before ascending any hill.
  • Page 32 SAFETY Rider Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. See page 63. Always check the terrain carefully before descending a hill.
  • Page 33 SAFETY Rider Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt 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.
  • Page 34 SAFETY Rider Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Lean forward to keep body weight uphill.
  • Page 35 SAFETY Rider Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 36 SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 37 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
  • Page 38 SAFETY Rider Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

  • Page 39: Controls

    CONTROLS Engine Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system.

  • Page 40: Throttle Lever

    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 when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 41: Brake Lever

    CONTROLS Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position.

  • Page 42: Master Cylinder

    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 117 for the part numbers of Polaris products. WARNING After opening a bottle of brake fluid, always discard any unused portion.

  • Page 43: Parking Brake

    CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in PARK. 2.

  • Page 44: Auxiliary Brake

    The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Your Polaris 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.

  • Page 45: Fuel Tank

    CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

  • Page 46: Features

    All Wheel Drive (AWD) System The AWD system is activated by a switch (1) on the right handlebar. When the switch is on 2X4 (center position), the ATV is in two wheel drive at all times and the differential is locked. When the switch is on AWD (left position), the ATV is in AWD and the differential is locked.

  • Page 47: Engaging Front Gearcase

    FEATURES All Wheel Drive (AWD) System 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.
  • Page 48 Repeat the set-up procedure. NOTE: If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. 8. To return the vehicle to 1-up operation, reverse all steps. Be sure to lower the passenger backrest to the lowest position before folding it down into the cargo box.

  • Page 49: Instrument Cluster

    FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph.

  • Page 50: Rider Information Center

    If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As the shift lever is moved, this indicates the...
  • Page 51 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button.
  • Page 52 Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.
  • Page 53 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours.
  • Page 54 Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module: 1. Place the transmission in PARK. Turn the engine off and turn the key switch to the ON position.

  • Page 55: Operation

    OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Never fill a gas container while it’s in the cargo box. Static elec- tricity between the box and container could cause a spark.

  • Page 56: Break-In Period

    Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.

  • Page 57: Pre-Ride Inspection

    Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear helmet, goggles, protective...

  • Page 58: Starting The Engine

    Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. OPERATION...

  • Page 59: Driving Procedures

    OPERATION Driving Procedures 1. Wear appropriate riding gear. See page 13. 2. Perform the pre-ride inspection. See page 54. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the handlebars.

  • Page 60: Making Turns

    Making Turns Both rear wheels drive equally at all times, except when operating in TURF mode. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1.

  • Page 61: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard.
  • Page 62 Driving with a Passenger 10. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle. 11. Do not cross a hillside with a passenger on board. See page 62. 12.

  • Page 63: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction. 3.

  • Page 64: Driving Uphill

    Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15_ maximum). 3. Keep both feet on the footrests. 4. Shift body weight uphill. 5. Proceed at a steady rate of speed and throttle opening. 6.

  • Page 65: Driving On A Hillside

    OPERATION Driving on a Hillside WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Do not cross a hillside with a passenger on board.

  • Page 66: Driving Downhill

    Driving Downhill < 15_ Whenever descending a hill, follow these precautions: 1. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 2. Slow down. 3. Proceed directly downhill. 4. Shift body weight uphill. 5.

  • Page 67: Turning Around On A Hill

    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. 8’ (2.4 m)
  • Page 68 Turning Around on a Hill 1. Stop the vehicle and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.

  • Page 69: Driving Through Water

    OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines.
  • Page 70 Driving Through Water 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.

  • Page 71: Driving In Reverse

    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 operate at wide open throttle.

  • Page 72: Driving Over Obstacles

    Driving Over Obstacles 1. Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. 2. Avoid operating over large obstacles such as rocks and fallen trees when possible.

  • Page 73: Hauling Cargo

    OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: S Never exceed the stated load capacity for this vehicle. S Never carry cargo in the rear box when operating the ATV in the 2-up mode with a passenger.

  • Page 74: Load Distribution

    Hauling Cargo Load Distribution Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the specified weights. Cargo weight should be mounted as low as possible.

  • Page 75: Dumping Cargo

    OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Lock the parking brake. 4.

  • Page 76: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 77: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 130.

  • Page 78: Periodic Maintenance Chart

    Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death.
  • Page 79 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Hours Calendar Steering Front suspension " Rear suspension " Tires Brake fluid level " Brake lever travel " Brake system Passenger seat lock-out Wheels/fasteners Frame fasteners Engine oil level "...
  • Page 80 100 H Wiring 100 H " Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 500 (800) 500 (800)
  • Page 81 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M 1000 (1600) Inspect; clean; replace worn 12 M 1000 (1600) Inspect;...

  • Page 82: Lubrication Guide

    Lubrication Guide Key More often under severe use " Polaris Premium All Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.

  • Page 83: Premium 4 Synthetic Lubricant

    +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.

  • Page 84: Oil Level

    Oil Level The oil dipstick and fill tube (1) are located on the left side of the ATV. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.

  • Page 85: Oil And Filter Change

    MAINTENANCE Oil and Filter Change Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

  • Page 86: Oil Change

    Oil Change 10. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 11. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

  • Page 87: Oil Pump Priming

    MAINTENANCE Oil Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line (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).

  • Page 88: Transmission Oil

    Periodic Maintenance Chart beginning on page 74. We recommend the use of Polaris Premium AGL Synthetic Gearcase 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.
  • Page 89 MAINTENANCE Transmission Oil Oil Change The transmission drain plug (2) is located on the right side of the gearcase, on the right side of the ATV, behind the wheel well. 1. Remove the fill plug. Remove the drain plug. 2. Drain the oil into a drain pan. Dispose of used oil properly. 3.

  • Page 90: Front Gearcase Oil

    Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of components. See page 117 for the part numbers of Polaris products.

  • Page 91: Engine Cooling System

    Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 117 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations...

  • Page 92: Coolant Level

    Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).
  • Page 93 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill.
  • Page 94 Brakes 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″...

  • Page 95: Steering Assembly

    MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment.

  • Page 96: Side Panel Removal

    Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 3. Pull the panel downward and rearward to remove it from the ATV. 4.

  • Page 97: Wheel Removal

    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. Place the transmission in PARK. 2. Lock the parking brake.

  • Page 98: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in PARK. 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.

  • Page 99: Filter Systems

    MAINTENANCE Filter Systems Air Filter Service 1. Remove the seat, release the air box cover clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2).

  • Page 100: Headlight Lamp Replacement

    Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 101: High Beam Adjustment

    MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2.

  • Page 102: Headlight Housing Replacement

    Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
  • Page 103 MAINTENANCE Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly.

  • Page 104: Spark Plugs

    CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 105: Vehicle Immersion

    MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 106: Spark Arrestor

    Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 107: Pvt System

    MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

  • Page 108: Pvt Drying

    Always follow all recommended 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.
  • Page 109 MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion.

  • Page 110: Battery Removal

    Battery Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5.

  • Page 111: Battery Storage

    MAINTENANCE Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging.
  • Page 112 Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery. NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for recharging.

  • Page 113: Cleaning And Storage

    Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. See your Polaris dealer. Cleaning and Storage See page 117 for the part numbers of Polaris products.

  • Page 114: Storage Tips

    Use dish soap type cleaners only. High pressure washers may force water past seals. Stabilize the Fuel Fill the fuel 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...
  • Page 115 5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injector should be completely drained of gasoline.
  • Page 116 Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Battery Maintenance (Conventional) Remove the battery and add distilled water to the proper level. Do not use tap water, which may contain minerals that reduce battery life.

  • Page 117: Transporting The Atv

    MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine 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.

  • Page 118: Adjustments

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Locate handlebar bolts (1) by removing the upper headlight pod.

  • Page 119: Throttle Cable Freeplay

    ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Locate the throttle cable adjuster on the handlebar.

  • Page 120: Polaris Products

    60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid 2872893 Engine Degreaser 2871956 LOCTITE 565 Thread Sealant POLARIS PRODUCTS...

  • Page 121: Troubleshooting

    TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline...
  • Page 122 Drain the fuel system and refuel Replace with new fuel Inspect plug(s), replace if necessary Inspect plug(s), verify stop switch is on Immediately see your Polaris dealer Replace the filter Recharge battery to 12.5 VDC See your Polaris dealer Solution...
  • Page 123 Stopping/starting without adequate warm- Incorrect fuel Clogged air filter Solution Replace with recommended fuel See your Polaris dealer Set gap to specs or replace plug Solution Inspect, clean and/or replace spark plug See your Polaris dealer Set gap to specs or replace plug...

  • Page 124: Engine Overheating

    Solution Refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plug See your Polaris dealer Set gap to specs or replace plug Check all connections and tighten Recharge battery to 12.5 VDC Replace with recommended fuel...

  • Page 125: Specifications

    2.5 qts./2.4 l EH50PLE210 92 x 75 350 w 10.2:1 Full Stroke Electronic Ignition 10 +/- - 1 BTDC @ idle condition 1150 +/- - 50 RPM NGK BKR6E .035+0.0/- -0.004 in. (0.9+0.0/- -0.1 mm) Dry Sump Automatic PVT (Polaris Variable Transmission)

  • Page 126: Clutching Chart

    SPORTSMAN X2 500 EFI Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight...

  • Page 127: Warranty

    MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 128 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
  • Page 129 SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340.1(c) for 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations.
  • Page 130 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling 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.
  • Page 131 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
  • Page 132 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 133: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 134 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 135: Index

    INDEX Accessories ....Adjustments ....Age Restrictions ....Air Filter Service .
  • Page 136 Passenger Seat ....Periodic Maintenance Chart Polaris Products ....Pre-Ride Inspection ... . .

This manual is also suitable for:

2006 sportsman x2 500 efi

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