The Polaris Sportsman 450 is a versatile All-Terrain Vehicle (ATV) designed for a range of outdoor activities. Produced between 2006 and 2008, this model is recognized for its robust engineering and reliable performance, characteristic of its established reputation in the powersports industry. The Sportsman line is known for its comfort, capability, and adaptability, making the 450 a capable machine for work and recreation. Its design prioritizes user experience and durability, ensuring it can handle demanding terrain and tasks. This comprehensive workshop service manual provides detailed guidance for the maintenance and repair of the Polaris Sportsman 450 ATVs from the 2006, 2007, and 2008 model years. It covers essential areas including engine service, fuel and ignition systems, lubrication, exhaust, electrical components, and transmission. The manual offers step-by-step procedures for routine maintenance, diagnostic processes, component removal and installation, and troubleshooting, mirroring the information found in authorized dealer service departments. Its purpose is to empower owners and technicians to perform repairs accurately and efficiently, ensuring optimal vehicle performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 450 Model Year Range: 2006-2008 Vehicle Type: ATV (All-Terrain Vehicle) Codes Product Identifier: Polaris 450 Sportsman 2006-2008 Workshop Service Manual PDF Download 👋 Introduction Market Position Positioning: Essential resource for maintaining and repairing Polaris Sportsman 450 ATVs from 2006-2008. Competitive Analysis Analogy To Dealer Resources: Contains specifications and procedures equivalent to those found in authorized Polaris dealer service departments. Key Features Value Proposition: Enables owners and technicians to perform repairs professionally, save money on labor, and get the best value from their vehicle. Safety Emphasis: Highlights the importance of safety equipment (e.g., torque wrench) and precautions. Special Tool Identification: Identifies and illustrates recommended or required special tools with Polaris part numbers. 📋 Manual Details Coverage Areas Applicable Models: Polaris Sportsman 450 Applicable Years: 2006, 2007, 2008 Page Count Estimated Page Count: Comprehensive (specific count not provided, typical for workshop manuals of this era) Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Yes (including tune-ups, overhaul, disassembly, assemblies) Fuel System: Yes Ignition System: Yes Lubrication System: Yes Exhaust System: Yes Electrical System: Yes Bodywork: Yes Transmission Service: Yes (including disassembly and assemblies) Procedures Included Routine Maintenance: Yes Diagnostic Procedures: Yes Repair Procedures: Yes Removal And Installation: Yes Troubleshooting: Yes Proprietary Component Repair: Yes (includes manufacturer instructions for proprietary parts) Technical Depth Depth Of Coverage: Comprehensive (from routine maintenance to full engine/transmission overhauls) Target Audience: Mechanical Technicians (familiar with BRP products and general automotive practices), Enthusiast Owners Diagnostic Focus: Emphasis on specific product aspects, troubleshooting when trouble occurs 📊 Manual Specifications File Format Format: PDF Deliverable Method: Electronic Delivery via Email Delivery Speed: Fast Print Quality: Printable Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Likely a 4-stroke, single-cylinder (common for this class of ATV) Engine Displacement: 450cc (as indicated by model name) Performance Horsepower Approximate: Approximately 20-25 HP (typical for this engine size and era) Torque Approximate: Approximately 25-30 lb-ft (typical for this engine size and era) Fuel System Fuel Delivery: Likely Carbureted (common for 2006-2008 models, though EFI was becoming more prevalent) Fuel Type: Unleaded Gasoline Lubrication System Oil Type: Refer to manual for specific SAE viscosity grade (e.g., SAE 10W-40, SAE 20W-50 synthetic blend or full synthetic recommended for ATV engines). Oil Capacity: Refer to manual for exact capacity (typically 2-3 quarts/liters). 🔧 Transmission Standard Transmission Type: Automatic (Polaris PVT - Polaris Variable Transmission) Drive System: 2WD/4WD Selectable Gearbox Features: High/Low Range, Neutral, Reverse Features Clutch Type: CVT (Continuously Variable Transmission) with primary and secondary drive clutches. Transmission Fluid: Refer to manual for specific Polaris PVT fluid or equivalent. 📐 Dimensions Exterior Overall Length Approximate: 81 inches (2057 mm) Overall Width Approximate: 46 inches (1168 mm) Overall Height Approximate: 48 inches (1219 mm) Weights Dry Weight Approximate: 650 lbs (295 kg) Payload Capacity Approximate: 200 lbs (91 kg) Towing Capacity Approximate: 1500 lbs (680 kg) Cargo Rack Capacity Front Approximate: 100 lbs (45 kg) Rack Capacity Rear Approximate: 200 lbs (91 kg) 🛡️ Safety Features Ratings Rollover Protection: Not applicable (ATVs are open vehicles, safety relies on rider skill and protective gear). Active Features Braking System: Hydraulic Disc Brakes (front and rear) 4Wd System: On-Demand AWD (All-Wheel Drive) Passive Features Lighting: Halogen headlights, taillight/brake light. Operator Safety Warnings: Manual includes WARNING, CAUTION, NOTE symbols for critical safety information. 💡 Technology Features Infotainment Features: Basic instrumentation panel (speedometer, odometer, fuel gauge, indicator lights). Driver Assistance Features: On-Demand AWD system for enhanced traction. Connectivity Features: Not applicable (no modern connectivity features like Bluetooth or Wi-Fi). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/hour intervals (typically every 100 hours or 6 months). Air Filter Maintenance: Refer...