Looking for 06 450 motor compatibility - Polaris ATV Forum
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post #1 of 20 (permalink) Unread 03-27-2019, 06:08 AM Thread Starter
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Looking for 06 450 motor compatibility

Hello, I have acquired an 06 Sportsman 450 that was my step-son's dad's 4-wheeler. His dad passed away on March 1st and we came into possession of his 4-wheeler.

I do not know anything about this wheeler except the motor is locked up. It was previously at a shop and the guy said it took in water and mud. He also said the motor was not worth fixing.

The wheeler is of sentimental to my step-son and I would like to try to put another motor in it as cheaply as possible.

What years of other Polaris 4-wheelers could be donors to the 06 Sportsman 450? I found this link for an exhaust system, but I didn't know if the other internal parts of the motor would be compatible with the 06.

Any help would be appreciated,

Casey Manning in Arkansas
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post #2 of 20 (permalink) Unread 03-27-2019, 07:28 AM
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The crankcase is the same for the following models - both the 450 and 500 motors will interchange

ASSEMBLIES WHERE THE 3089240 CRANKCASE IS USED
2004 A04BG50AA SCRAMBLER 500 4X4 (A04BG50AA/FA) - Crankcase
2004 A04CH42AQ SPORTSMAN 400 (A04CH42AQ/AR/AS/AT/AV) - Crankcase
2004 A04CH50AQ SPORTSMAN 500 (A04CH50AO/AQ/AR/AS/AT/AV/AW/AX) - Crankcase
2004 A04JD50AA ATP 500 4X4 (A04JD50AA/AB/CA) - Crankcase
2004 RANGER 2X4,4X4,6X6 (A04RB42AA) - Crankcase /A04rd50aa/Ab/Ac/A04rf50aa
2004 SPORTSMAN 6X6 (A04CL50AA) - Crankcase
2005 ATP 500 4X4 (A05JD50AA) - Crankcase /Ab/Ac
2005 RANGER 2X4,4X4,6X6 (R05RB50AA/RD50AA/AB/AC/AD/RF50AA/AB) - Crankcase
2005 SCRAMBLER 500 4X4 (A05BG50AA) - Crankcase /Fa
2005 SPORTSMAN 400 (A05MH42AB) - Crankcase /Ag/Ah
2005 SPORTSMAN 500 HO/INTL (A05MH50AB) - Crankcase /Ac/Ag/Ah/Al/At/Fb
2005 SPORTSMAN 6X6 (A05CL50AA) - Crankcase
2006 RANGER 500 2X4/4X4 (R06RB50AA) - Crankcase /Rd50aa
2006 RANGER 500 4X4 EFI (R06RD50AC) - Crankcase R06rd50ab/Ac
2006 SCRAMBLER 500 4X4 (A06BG50AA) - Crankcase /Fa
2006 SPORTSMAN 450 (A06MH46AA) - Crankcase A06mh46 All Options
2006 SPORTSMAN 500 EFI (A06MH50AQ) - Crankcase /Ax/Ay/Az/Al/At
2006 SPORTSMAN 500 EFI INTL (A06MH50FC) - Crankcase
2006 SPORTSMAN 500 HO (A06MH50AA) - Crankcase /Ab/Ad/Af
2006 SPORTSMAN 500 HO INTL (A06MH50FB) - Crankcase
2006 SPORTSMAN 6X6 (A06CL50AA) - Crankcase
2006 SPORTSMAN X2 (A06MN50AU) - Crankcase /Aw
2007 RANGER 500 2X4/4X4 (R07RB50AA/RH50AA) - Engine, Crankcase
2007 RANGER 500 EFI 4X4 (R07RH50AF/AR/AT) - Engine, Crankcase
2007 SCRAMBLER 500 2X4 INTL (A07BA50FA) - Engine, Crankcase
2007 SCRAMBLER 500 4X4 (A07BG50AA/FA) - Engine, Crankcase
2007 SPORTSMAN 450 (A07MH46AA/AZ) - Engine, Crankcase
2007 SPORTSMAN 500 EFI (A07MH50AB/AL/AQ/AX/AY/AZ/MN50AF/AN/AT/AY) - Engine, Crankcase
2007 SPORTSMAN 500 EFI INTL (A07MH50FC) - Engine, Crankcase
2007 SPORTSMAN 6X6 (A07CL50AA) - Engine, Crankcase
2007 SPORTSMAN X2 500 EFI (A07TH50AL/AQ/AU/AZ/TN50AF/AS/AU) - Engine, Crankcase
2007 SPORTSMAN X2 500 EFI QUAD (A07TH50EA) - Engine, Crankcase
2008 RANGER 4X4 500 EFI (R08RH50AF/AR/AT) - Engine, Crankcase
2008 RANGER 500 2X4 (R08RB50AA) - Engine, Crankcase
2008 SCRAMBLER 2X4 INTL (A08BA50FA) - Engine, Crankcase
2008 SCRAMBLER 500 4X4 (A08BG50AA) - Engine, Crankcase
2008 SCRAMBLER 500 4X4 INTL (A08BG50FA) - Engine, Crankcase
2008 SPORTSMAN 500 EFI SCANDINAVIAN (A08MH50SS/SQ) - Engine, Crankcase
2008 SPORTSMAN 500 HO (A08MH50AX/AZ) - Engine, Crankcase
2008 SPORTSMAN 500 HO EFI (A08MN50AF/AN/AQ/AR/AS/AT/AW/AX) - Engine, Crankcase
2008 SPORTSMAN 6X6 (A08CL50AA) - Engine, Crankcase
2008 SPORTSMAN TOURING 500 EFI (A08DN50AF/AS/AW/AZ) - Engine, Crankcase
2008 SPORTSMAN TOURING 500 EFI QUAD (A08DN50EA) - Engine, Crankcase
2008 SPORTSMAN X2 500 EFI (A08TN50AT/AX/AZ) - Engine, Crankcase
2008 SPORTSMAN X2 500 EFI QUAD (A08TN50EA) - Engine, Crankcase
2009 RANGER 2X4 500 CARB (R09RB50AF) - Engine, Crankcase
2009 RANGER 4X4 500 EFI (R09HH50AG/AR) - Engine, Crankcase
2009 SCRAMBLER 2X4 INTL (A09BA50FA) - Engine, Crankcase
2009 SCRAMBLER 500 4X4 (A09BG50AA) - Engine, Crankcase
2009 SCRAMBLER 500 4X4 INTL (A09BG50FA) - Engine, Crankcase
2009 SPORTSMAN 500 EFI (A09MN50AN/AX) - Engine, Crankcase
2009 SPORTSMAN 500 EFI TRACTOR (A09MN50ET) - Engine, Crankcase
2009 SPORTSMAN 500 HO (A09MH50AS/AX/AZ) - Engine, Crankcase
2009 SPORTSMAN TOURING 500 EFI (A09DN50AB/AZ) - Engine, Crankcase
2009 SPORTSMAN TOURING 500 EFI QUAD (A09DN50EA) - Engine, Crankcase
2009 SPORTSMAN X2 500 EFI (A09TN50AX/AZ) - Engine, Crankcase
2009 SPORTSMAN X2 500 EFI QUAD (A09TN50EA) - Engine, Crankcase
2010 RANGER 4X4 400 HO (R10RH45AG/AH/AR) - Engine, Crankcase
2010 RANGER 4X4 500 EFI (R10TH50AG/AR) - Engine, Crankcase
2010 SCRAMBLER 500 4X4 (A10NG50AA) - Engine, Crankcase
2010 SCRAMBLER 500 4X4 INTL (A10NG50FA) - Engine, Crankcase
2010 SPORTSMAN 500 EFI TRACTOR (A10MN50ET) - Engine, Crankcase
2010 SPORTSMAN 500 HO (A10MH50AJ/AX/AZ) - Engine, Crankcase
2010 SPORTSMAN 500 HO INTL (A10MH50FX/FF) - Engine, Crankcase
2010 SPORTSMAN TOURING 500 HO (A10DH50AX/AZ) - Engine, Crankcase
2010 SPORTSMAN TOURING 500 HO INTL (A10DH50FX) - Engine, Crankcase
2011 HAWKEYE 400 HO 2X4 (A11MB46FZ) - Engine, Crankcase
2011 RANGER 400 HO (R11RH45AG/AH/AR) - Engine, Crankcase
2011 RANGER 4X4 500 CREW (R11WH50AG/AH/AR) - Engine, Crankcase
2011 RANGER 4X4 500 EFI (R11RH50AG/AH/AR) - Engine, Crankcase
2011 SCRAMBLER 500 4X4 (A11NG50AA) - Engine, Crankcase
2011 SCRAMBLER 500 4X4 INTL (A11NG50FA) - Engine, Crankcase
2011 SPORTSMAN 400 HO 4X4 (A11MH46AX/AZ) - Engine, Crankcase
2011 SPORTSMAN 500 HO (A11MH50AX/AZ) - Engine, Crankcase
2011 SPORTSMAN FOREST 500 (A11MH50FF) - Engine, Crankcase
2011 SPORTSMAN FOREST TRACTOR 500 EFI (A11MN50ET) - Engine, Crankcase
2011 SPORTSMAN TOURING 500 HO (A11DH50AX/AZ) - Engine, Crankcase
2011 SPORTSMAN TOURING 500 HO INTL (A11DH50FX) - Engine, Crankcase
2012 HAWKEYE 400 HO 2X4 (A12MB46FZ) - Engine, Crankcase
2012 RANGER 400 4X4 (R12RH45AG/AH/AR) - Engine, Crankcase
2012 RANGER 500 4X4 (R12RH50AG/AH/AM/AR/AZ) - Engine, Crankcase
2012 RANGER 500 4X4 CREW (R12WH50AG/AH/AK/AR) - Engine, Crankcase
2012 SCRAMBLER 500 4X4 (A12NG50AA) - Engine, Crankcase
2012 SCRAMBLER 500 4X4 INTL (A12NG50FA) - Engine, Crankcase
2012 SPORTSMAN 400 HO 4X4 (A12MH46AF/AX/AZ) - Engine, Crankcase
2012 SPORTSMAN 500 HO (A12MH50AD/AO/AQ/AX/AZ) - Engine, Crankcase
2012 SPORTSMAN FOREST 500 (A12MH50FF/FX/FY) - Engine, Crankcase
2012 SPORTSMAN FOREST TRACTOR 500 (A12MN50ET/EX) - Engine, Crankcase
2012 SPORTSMAN TOURING 500 HO (A12DH50AX/AZ) - Engine, Crankcase
2013 HAWKEYE 400 HO 2X4 (A13MB46FZ) - Engine, Crankcase
2013 HAWKEYE 400 HO 2X4 HD (A13MB46TH) - Engine, Crankcase
2013 RANGER 400 MIDSIZE (R13RH45AG) - Engine, Crankcase
2013 RANGER 500 CREW MIDSIZE (R13WH50AG/AH/AR/AX) - Engine, Crankcase
2013 RANGER 500 MIDSIZE (R13RH50AG/AH/AM/AR) - Engine, Crankcase
2013 SPORTSMAN 400 HO 4X4 (A13MH46AF/AX/MS46AX) - Engine, Crankcase
2013 SPORTSMAN 500 HD (A13MH50TD) - Engine, Crankcase
2013 SPORTSMAN 500 HO (A13MH50AJ/AQ/AX/AZ) - Engine, Crankcase
2013 SPORTSMAN FOREST 500 (A13MH50FF/FJ/FU) - Engine, Crankcase
2013 SPORTSMAN FOREST TRACTOR 500 (A13MN50ET/EX) - Engine, Crankcase
2013 SPORTSMAN TOURING 500 HO (A13DH50AX/AZ) - Engine, Crankcase
2014 HAWKEYE 400 HO 2X4 HD (A14MB46TH) - Engine, Crankcase
2014 RANGER 4X4 400 (R14RH45AA) - Engine, Crankcase
2014 SPORTSMAN 400 HO 4X4/SE (A14MH46AA/AH/MS46AA) - Engine, Crankcase
2014 SPORTSMAN FOREST TRACTOR 500 (A14MN50EM/EA) - Engine, Crankcase

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #3 of 20 (permalink) Unread 03-27-2019, 10:10 AM Thread Starter
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Holy Cow latebird. Thank you for all of those models. I kind of figured the some of the 500 parts would work with a quick trip to eBay. But the info here will surely get me started!

Again, Thank you!
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post #4 of 20 (permalink) Unread 03-30-2019, 07:11 PM Thread Starter
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Looking for 06 450 motor compatibility

Long story short, the motor is not locked-up as previously stated by a shop. All the guy did, from what I can tell, was remove the cover with the pull start and remove the cover of the clutch drive system.

Two questions:

1. I need the secondary clutch. One did not come with the four-wheeler when we got it. I couldn't find one, new or used, on the net. What years/engine size would be compatible with the 06 Sportsman 450? I found this one on ebay, https://www.ebay.com/itm/Polaris-Tra...n/293025811920


2. I'm trying to remove the carb and I have been unsuccessful in getting the choke cable removed so I can clean the carb. I'm having trouble removing the big bolt/adapter the goes directly into the carb. What is the secret?



I've ordered a starter(bad), bendix(missing), and a temp sensor (wires broken off). I was having trouble with the doing anything, but the "off/run/off" switch has bad contacts and I did get that working. I get a click out of the starter solenoid when I turn the key all the way over, so I'm hopeful.

I just need some more advice.

Thanks again,

Casey

1984 Honda TRX200 Running
1984 Honda TRX200 (non running)
1984 Honda TRX200 (parts rig)
2006 Polaris Sportsman 450 (non running)

Last edited by kcmng; 03-30-2019 at 07:36 PM. Reason: added web address
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post #5 of 20 (permalink) Unread 03-31-2019, 05:21 AM
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The clutch you are looking for is part # 1321848 - it's $480 new and there is one used one on Ebay here https://www.ebay.com/itm/Polaris-Tra...YAAOSwootcnUnq

The same clutch was used on the following models:

ASSEMBLIES WHERE 1321848 IS USED
2000 TRAIL BOSS (A00AA32AA) - Driven Clutch
2000 TRAIL BOSS (A00AA32AB) - Driven Clutch
2000 TRAIL BOSS (A00AA32CA) - Driven Clutch A00aa32aa
2001 TRAIL BOSS (A01AA32AA) - Driven Clutch
2001 TRAIL BOSS (A01AA32AB) - Driven Clutch A01aa32aa
2001 TRAIL BOSS 325 SE (A01AA32AC) - Driven Clutch A01aa32aa
2002 TRAIL BOSS (A02CA32AA/AB) - Driven Clutch
2003 TRAIL BOSS 330 (A03CA32AA) - Driven Clutch
2004 A04CA32AA TRAIL BOSS 330 (A04CA32AA/AB/FA) - Driven Clutch
2004 RANGER 2X4,4X4,6X6 (A04RB42AA) - Driven Clutch /A04rd50aa/Ab/Ac/A04rf50aa
2005 RANGER 2X4,4X4,6X6 (R05RB50AA/RD50AA/AB/AC/AD/RF50AA/AB) - Driven Clutch
2005 SPORTSMAN 400 (A05MH42AB) - Driven Clutch /Ag/Ah
2005 TRAIL BOSS 330 (A05CA32AA) - Driven Clutch /Ab/Ac/Fa
2005 TRAIL BOSS 330 QUADRICYCLE (A05CA32EA) - Driven Clutch
2006 RANGER 500 2X4/4X4 (R06RB50AA) - Driven Clutch /Rd50aa
2006 RANGER 500 4X4 EFI (R06RD50AC) - Driven Clutch R06rd50ab/Ac
2006 SPORTSMAN 450 (A06MH46AA) - Driven Clutch A06mh46 All Options
2006 TRAIL BOSS 330 (A06CA32AA) - Driven Clutch /Ab
2007 RANGER 500 2X4/4X4 (R07RB50AA/RH50AA) - Clutch, Driven
2007 RANGER 500 EFI 4X4 (R07RH50AF/AR/AT) - Clutch, Driven
2007 SPORTSMAN 450 (A07MH46AA/AZ) - Clutch, Driven
2007 TRAIL BOSS 330 (A07CA32AA) - Clutch, Driven
2008 RANGER 4X4 500 EFI (R08RH50AF/AR/AT) - Drive Train, Secondary Clutch
2008 RANGER 500 2X4 (R08RB50AA) - Drive Train, Secondary Clutch
2008 TRAIL BLAZER 330 (A08BA32AA) - Drive Train, Secondary Clutch
2008 TRAIL BOSS 330 (A08CA32AA) - Drive Train, Secondary Clutch
2009 RANGER 2X4 500 CARB (R09RB50AF) - Drive Train, Secondary Clutch
2009 RANGER 4X4 500 EFI (R09HH50AG/AR) - Drive Train, Secondary Clutch
2009 TRAIL BLAZER 330 (A09BA32AA) - Drive Train, Secondary Clutch
2009 TRAIL BOSS 330 (A09CA32AA) - Drive Train, Secondary Clutch
SERIES 10 RANGER (A10RD50AA) - Driven Clutch
SERIES 10 UTV 4X4 (C10RD50AA) - Driven Clutch
SERIES 11 RANGER (A11RB42AA/A11RD50AA/AB/A11RF50AA) - Driven Clutch

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #6 of 20 (permalink) Unread 03-31-2019, 05:31 AM
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As to the enrichener nut, they are the un-handiest thing to deal with. I have in my arsenal of tools; a 12 & 14 mm box end wrenches that have been ground down on the outside for clearance and the box cut open to be able to slip over the cable and a pair of deep well sockets that I milled one side out of to allow the socket to clear the cable and can get on the nut - the socket allows more force to loosen the nut than the box end wrench does.

Yamaha and Kawasaki use similar carbs and enrichener locations, but some use 12mm adapters and others use 14mm

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #7 of 20 (permalink) Unread 03-31-2019, 11:35 AM Thread Starter
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Thanks latebird.

I had a 12mm box end already shaved down as a speciality wrench for a small engine shop I used to work for, but I did have to grind a slit for the cable to pass through. It worked like a charm. Now I need to clean the carb.

I also ordered the secondary clutch off of eBay. I should have the starter parts, temp sensor, clutch, and a bolt lot (for the bolts missing on the pull start cover and starter) in later this week. I hope to get everything on the four-wheeler and check to see if it will turn over with the key switch.


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1984 Honda TRX200 Running
1984 Honda TRX200 (non running)
1984 Honda TRX200 (parts rig)
2006 Polaris Sportsman 450 (non running)
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post #8 of 20 (permalink) Unread 04-03-2019, 11:23 AM Thread Starter
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The thermistor/ temp sensor came in 2 days ago and now the fan doesnít run when you switch the key on. My bolt lot should be here today and the starter, bendix, and carb parts by Friday. Hopefully Iíll see if the motor turns on itís on power by then.


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1984 Honda TRX200 Running
1984 Honda TRX200 (non running)
1984 Honda TRX200 (parts rig)
2006 Polaris Sportsman 450 (non running)
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post #9 of 20 (permalink) Unread 04-03-2019, 11:42 AM
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Thanks for the update

2006 Trailboss 330
2002 Sportsman 90
2005 TRX400EX (FOR SALE)
2003 LT-Z400 (needs engine work & is for sale)
2004 CRF250X
1971 Triumph 650 Bonneville (has 5 original miles)
1972 Triumph 650 Bonneville (undergoing restoration)
1979 Honda CBX (6 cylinder)
1970 Kawasaki G3SS 90cc Bushmaster
1976 Suzuki RE5 Rotary (not running & FOR SALE)
1981 Kawasaki KZ305-A
1981 Suzuki GS450T (undergoing repair & will be for sale when done)
1982 Kawasaki KZ750-H (FOR SALE)
1989 Honda VT1100C
2007 Vectrix VCTX Electric Scooter
1965 Montgomery Ward 3 1/2 HP Tecumseh Mini Bike
1970 Triumph T25 250cc Trailblazer
1968 Triumph 250cc Flat Tracker

Shop Owner and Mechanic with over 50 years experience
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post #10 of 20 (permalink) Unread 04-06-2019, 01:22 PM Thread Starter
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Looking for 06 450 motor compatibility

I have the starter and bendix now and I began looking through the bolts I ordered. I noticed some of the bolts are fine pitch, 1.00mm (I think) and others are 1.25mm. My next question is what is the correct pitch of bolt that bolts the starter on. The one bolt that was "holding" the starter in place wasn't threaded in all the way, so I'm thinking it was the wrong bolt or the threads in the case a boogered up, so I wanted to know the correct bolt pitch to make sure I don't mess anything up more.



I think " 3082038 " is the correct part number, but the descriptions don't have the thread pitch.

1984 Honda TRX200 Running
1984 Honda TRX200 (non running)
1984 Honda TRX200 (parts rig)
2006 Polaris Sportsman 450 (non running)

Last edited by kcmng; 04-06-2019 at 01:25 PM.
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