🏷️ 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 to manual for inspection/cleaning intervals (frequent checks in dusty conditions recommended). Spark Plug Replacement: Refer to manual for recommended interval (e.g., every 1-2 years or specific hours). Fluid Specifications Coolant Type: Refer to manual for specific antifreeze/coolant mixture (typically ethylene glycol based). Brake Fluid Type: Refer to manual for DOT specification (typically DOT 3 or DOT 4). Known Issues Common Wear Items: CVT belt wear, suspension bushings, wheel bearings, battery. Electrical Connections: Corrosion in connectors can sometimes cause intermittent electrical issues. Torque Specifications Importance: Manual emphasizes the need for a torque wrench to ensure fasteners are tightened to specification, crucial for safety and component longevity. 📚 Vehicle History Brand Heritage Manufacturer Legacy: Polaris is a long-standing manufacturer of powersports vehicles, known for innovation and a wide range of ATVs. Model Evolution Sportsman Lineage: The Sportsman line is Polaris's flagship utility ATV series, known for comfort, capability, and versatility. Production Manufacturing Location: Typically manufactured in the USA (e.g., Spirit Lake, Iowa). 🏆 Awards & Recognition Recognitions Brand Awards:...