Polaris Offroad Vehicle Sportsman 6x6 User Manual

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WARNING

Indicates a potential hazard that could result in serious

injury or death.

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S Technical tips

S New product introductions

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www.polarisindustries.com/owner

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WELCOME

Thank you for choosing Polaris, and welcome to our world-wide

family of Polaris enthusiasts. Polaris proudly produces an exciting line

of recreational products, including snowmobiles, all-terrain vehicles,

personal watercraft, utility vehicles, and Victory motorcycles.

We believe Polaris sets the standard of excellence for all recreational

vehicles manufactured in the world today. Many years of experience in

engineering, design, and development have gone into making your

Polaris vehicle the finest machine we’ve ever produced.

Follow the instructions and recommendations in this Owner’s Manual

for safe and enjoyable operation of your vehicle. Your Owner’s Manual

contains instructions for minor maintenance. Major repairs are covered

in the Polaris Service Manual and should be performed by a Factory

Certified MSD (Master Service Dealer) Technician.

Your Polaris dealer knows your vehicle best and is interested in your

complete satisfaction. Return to your dealership for all of your service

needs during, and after, the warranty period.

Polaris also takes great pride in our PAA (Parts Apparel and

Accessories) which are available on our online store

www.purepolaris.com. Have your accessories and clothing delivered

right to your door!

Polaris and Polaris The Way Out are registered trademarks of Polaris

Industries Inc.

Polaris Industries Inc.

Printed in the U.S.A.

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ATTENTION!

This is an ADULT VEHICLE ONLY; not a toy. Operation is

prohibited for anyone under 16 years of age. READ AND

UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE

OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!

Read this manual thoroughly referring to the various areas which are

being discussed on your machine. Operating this vehicle carries with it

responsibilities for your personal safety, the safety of others, and the

protection of our environment.

SAFETY TRAINING

When you purchased this vehicle your dealer offered a hands-on safety

training course covering all aspects of vehicle safety. In addition, you

were provided with certain printed material which instructs you on safe

operating procedures.

You should review this information on a regular basis. In the event

you purchased a used Polaris vehicle from a party other than a Polaris

dealer, you can obtain this safety training at no charge from any

authorized Polaris dealer.

Failure to follow the warnings contained in this manual can result in

SEVERE INJURY OR DEATH.

NOTE: Illustrations used in this manual are for general representation

only. Your model may differ.

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TABLE OF CONTENTS

Vehicle Identification Numbers . . . . . . . . . . . . . . 6

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20

Understanding Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 7

Key Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Decals and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Controls and Features . . . . . . . . . . . . . . . . . 37 - 49

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 - 56

Pre Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Vehicle Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . 51

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Carrying Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Noise Emission Control System . . . . . . . . . . . . 57

Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 - 72

Pre Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Riding Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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TABLE OF CONTENTS

Maintenance and Lubrication . . . . . . . . . . 73 - 117

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . 74

Lubrication Recommendations . . . . . . . . . . . . . . . . . . . 77

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

PVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Specifications . . . . . . . . . . . . . . . . . . . . . . . 118 - 119

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Trouble Shooting . . . . . . . . . . . . . . . . . . . . 121 - 123

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 - 125

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VEHICLE IDENTIFICATION NUMBERS

Important: Record these numbers from your vehicle in the spaces

provided.

1. Frame VIN

2. Engine Serial Number (Right front side of engine crankcase)

Remove the spare key and store in a safe place. Your key can be

duplicated only by obtaining a key blank from Polaris and having it

cut by mating it with your existing key.

The vehicle frame and engine serial numbers are important for model

identification when registering your vehicle, obtaining insurance or

whenever replacement parts are required. In the event your vehicle

were stolen these numbers are essential to the recovery and

identification of your vehicle.

Dealer Imprint

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SAFETY

Understanding Warnings

The following two pages identify signal words and symbols that appear

in this manual. Your safety is involved when these words and symbols

are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol, on your vehicle or in this manual,

alerts you to the potential for personal injury.

WARNING

Indicates a potential hazard that could result in serious injury or

death.

CAUTION

Indicates a potential hazard that may result in minor personal

injury or damage to the machine.

CAUTION

Indicates a situation that may result in damage to the machine.

NOTE

“NOTE:” will alert you to important information or instructions.

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SAFETY

Key Safety Issues

Protect Your Sport

Know all local, state/province riding laws;

Respect your vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance

program as outlined. This preventive maintenance program is designed

to ensure that all critical components on this vehicle are thoroughly

inspected at various intervals.

All information in this manual is based upon the latest product data and

specifications available at the time of printing. Polaris Industries Inc.

reserves the right to make product changes and improvements which

may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written

permission of Polaris Industries Inc.

Illustrations included in this manual are general representations of

parts having a similar function. Your model may differ.

THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS

TO OPERATE. This Vehicle handles differently from other vehicles

including motorcycles and cars. A collision or rollover can occur

quickly, even during routine maneuvers such as turning and driving on

hills or over obstacles, if you fail to take proper precautions.

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SAFETY

Key Safety Issues

SERIOUS INJURY OR DEATH can result if you do not

follow these instructions:

Read this manual and all labels carefully and follow the operating

procedures described.

Never operate this vehicle without proper instruction. Take a

training course. Beginners should receive training from a certi-

fied instructor. Contact an authorized Polaris dealer or call Polaris

at 1-800-342-3764 to find out about the training courses nearest

you.

Never allow anyone under 16 years of age to operate this vehicle.

Never permit a guest to operate this vehicle unless the guest has

read this manual and all product labels, and has completed a certi-

fied training course.

Always avoid operating this vehicle on any paved surfaces, includ-

ing sidewalks, driveways, parking lots and streets.

Never operate this vehicle on any public street, road or highway,

even a dirt or gravel one.

Never operate this vehicle without wearing an approved helmet that

fits properly. You should also wear eye protection (goggles or face

shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

Never consume alcohol or drugs before or while operating this ve-

hicle.

Never operate at excessive speeds. Always travel at a speed which

is proper for the terrain, visibility and operating conditions, and

your experience.

Never attempt wheelies, jumps or other stunts.

Always inspect your vehicle each time you use it to make sure it is

in safe operating condition. Always follow the inspection and

maintenance procedures and schedules described in this manual.

Always keep both hands on the handlebars and both feet on the

footrests of the vehicle during operation.

Always go slowly and be extra careful when operating on unfamil-

iar terrain. Always be alert to changing terrain conditions when

operating the vehicle.

Never operate on excessively rough, slippery or loose terrain.

Always follow proper procedures for turning as described in this

manual. Practice turning at low speeds before attempting to turn at

faster speeds. Do not turn at excessive speed.

Always have the vehicle checked by an authorized Polaris dealer if

it has been involved in an accident.

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SAFETY

Key Safety Issues

Never operate the vehicle on hills too steep for the vehicle or for

your abilities. Practice on smaller hills before attempting larger

hills.

Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before you start up any

hill. Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward. Never open the throttle suddenly or

make sudden gear changes. Never go over the top of any hill at

high speed.

Always follow proper procedures for going down hills and for brak-

ing on hills as described in this manual. Check the terrain careful-

ly before you start down any hill. Shift your weight backward.

Never go down a hill at high speed. Avoid going down a hill at an

angle which would cause the vehicle to lean sharply to one side.

Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as

described in this manual. Avoid hills with excessively slippery or

loose surfaces. Shift your weight to the uphill side of the vehicle.

Never attempt to turn the vehicle around on any hill until you have

mastered the turning technique described in this manual on level

ground. Avoid crossing the side of a steep hill if possible.

Always use proper procedures if you stall or roll backwards when

climbing a hill. To avoid stalling, maintain a steady speed when

climbing a hill. If you stall or roll backwards, follow the special

procedure for braking described in this manual. Dismount on the

uphill side or to either side if pointed straight uphill. Turn the ve-

hicle around and remount, following the procedure described in

this manual.

Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as large rocks or fallen

trees. Always follow proper procedures when operating over ob-

stacles as described in this manual.

Always be careful of skidding or sliding. On slippery surfaces,

such as ice, go slowly and be very cautious in order to reduce the

chance of skidding or sliding out of control.

Avoid operating the vehicle through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maxi-

mum depth (pg. 68), go slowly, balance your weight carefully

avoiding sudden movements, maintain a slow and steady forward

motion, do not make sudden turns or stops, and do not make sud-

den throttle changes.

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SAFETY

Key Safety Issues

Wet brakes may have reduced stopping ability. Test your brakes

after leaving water. If necessary apply them lightly several times

to let friction dry out the pads.

Always be sure there are no obstacles or people behind you when

you operate in reverse. When it is safe to proceed in reverse, go

slowly. Avoid turning at sharp angles in reverse.

Always use the size and type tires specified in this manual. Always

maintain proper tire pressure as described in this manual.

Never modify this vehicle through improper installation or use of

accessories.

Never exceed the stated load capacity for this vehicle. Cargo

should be properly distributed and securely attached. Reduce

speed and follow instructions in this manual for carrying cargo or

pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT vehicle SAFETY, call the

Consumer Product Safety Commission at 1-800-638-2772, or Polaris

at 1-800-342-3764.

Additional Important Information...

Due to our concern for the safety of our customers and the general

public, Polaris hereby strongly recommends and requests that

consumers not have installed on a Polaris 6x6 any equipment which is

intended to increase the speed or power of the vehicle; or make any

other modifications to the vehicle for these purposes. Any

modifications to the original equipment of the vehicle substantially

increase the risk of bodily injury. Please be aware that these

modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on your vehicle is

terminated if any such equipment has been added to the vehicle or any

modifications have been made to the vehicle which increase its speed

or power.

We also advise you to strictly follow the recommended maintenance

program outlined in this manual. This preventive maintenance

program is designed to ensure that all critical components on the

vehicle are thoroughly inspected by your dealer at various mileage

intervals.

NOTE: The addition of certain accessories including (but not limited

to) mowers, blades, tires, sprayers, or large racks may change the

handling characteristics of the vehicle. Be certain any accessories

added to this vehicle have been approved by Polaris. Familiarize

yourself with their function and affect on the vehicle.

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SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding you are doing.

Riding this vehicle requires special protective clothing which will

make you feel more comfortable and reduce chances of injury.

1. Helmet

Your helmet is the most important

piece of protective gear for safe

riding. A helmet can prevent a

serious head injury.

Select an approved helmet which

meets or exceeds your state’s

safety standards and bears either

the Department of Transportation

(DOT) label, the American

National Standards Institute label

(ANSI Z90.1), or the Snell

Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for

proper eye protection. A pair of

goggles or helmet face shield offer

the best protection for your eyes.

They should be kept clean and be

of shatterproof design (bearing the

markings Z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and

protection.

4. Boots

The best footwear is a pair of strong over the calf type boots with heels

such as moto cross boots.

5. Clothing

To protect your body, long sleeves and pants should always be worn.

Riding pants with kneepads, a jersey and shoulder pads provide the

best protection.

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SAFETY

Safety Decals and Locations

NOTE:

Warning decals have been placed on the vehicle for your protection.

Read and follow the instructions on each decal carefully. In the event

any decal becomes illegible or comes off, contact your Polaris dealer

for a replacement. Any safety decal needing replacement will be

provided by Polaris at no charge. The part number is printed on the

decal.

The addition of certain accessories including, but not limited to:

mowers, blades, tires, sprayers, or large racks may change the handling

characteristics of this vehicle. Be certain any accessories added to this

vehicle have been approved by Polaris. Familiarize yourself with their

function and affect on the vehicle.

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SAFETY

Safety Decals and Locations

WARNING

DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may result causing severe

injury or death. Tow only from tow hooks or hitch

Maximum Front Rack Load 75 lbs.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause

loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT 5 CENTER 5 REAR 5

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight

INCLUDING MACHINE, DRIVER AND CARGO IS 1965 LBS.)

Reduce speed and allow greater distance for braking when carrying

cargo. Overloading or carrying tall, off-center, or unsecured loads

will increase your risk of losing control. Loads should be centered,

carried as low as possible in box, and firmly secured to the rack.

For stability on rough or hilly terrain, reduce speed and cargo. Do

not block headlight. Be careful if load extends over the side of the

rack or box.

Read Owner’s Manual for more detailed loading information.

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SAFETY

Safety Decals and Locations

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SAFETY

Safety Decals and Locations

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

D Operate on public roads. A collision can occur with another vehicle.

Carry passengers. Passengers affect balance and steering and in-

crease risk of losing control.

USE ALCOHOL or DRUGS before or while operating this vehicle.

Operate at speeds too fast for your skills or the conditions.

Operate this vehicle on HILLS steeper than 15 degrees

15°.

D To prevent flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

Use an approved HELMET AND PROTECTIVE GEAR.

D Avoid paved surfaces. Pavement may seriously affect handling and

control.

D Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills

and rough terrain and in turns.

Use OVERRIDE for reverse speed limiter with caution. To prevent

loss of control, never activate override button with open throttle.

D REVERSE operation can be dangerous, even at low speeds. Steer-

ing becomes difficult. To prevent flipover, avoid sharp turns.

PARKING BRAKE may relax when used for more than 5 minutes.

When parking on grades, leave shift in forward.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL

INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS

MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT.

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SAFETY

Safety Decals and Locations

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SAFETY

Safety Decals and Locations

ETC

This vehicle is equipped with

Polaris Electronic Throttle Control

(ETC) to reduce the risk of a stuck or

“frozen” throttle. Please refer to your

Owner’s Manual for details.

Operating this vehicle if you are under the

age of 16 increases your chance of severe

injury or death.

NEVER operate this vehicle if you are under

age 16.

7078254

Passengers can be thrown off.

This can cause serious injury

or death.

Never carry passengers.

Maximum Box Load 800 lbs.

Remove flammable containers from box before refueling.

WARNING

Pushing reverse

override button

may cause

ALL WHEEL

DRIVE

SWITCH

sudden in-

creases in pow-

er and traction if

too much

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

throttle is ap-

plied. Loss of

control or for-

ward flipover

may result, es-

pecially in

See your Owner’s

Manual.

AWD. See Own-

er’s Manual.

7079780

7079604

AWD Models

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SAFETY

Safety Decals and Locations

WARNING

Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle with

guard removed.

Do not modify engine or clutch. Doing so can cause part

failure, possible imbalance, and excessive engine RPM

which can result in serious injury or death.

NO STEP

7078689

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SAFETY

Safety Decals and Locations

TRAILER MAX WEIGHT:

1225 LBS. (557 KG) ON LEVEL GROUND

850 LBS. (368 KG) UP TO 15 GRADE

HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16 KG)

7078261

(On Hitch)

ATTENTION

Specific

carburetor jetting and

Operation of this vehicle without

the filter element will severely

damage the engine.

adjustments are required depending on

temperature and altitude. See your

Owner’s Manual.

Clean air filter often, more

frequent cleaning required in

dusty conditions

Factory setting:

Operation of this vehicle without

engine breather filter(s) can

cause engine damage. Consult

owner’s manual for details.

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7079902

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does

not know how to operate the vehicle properly in different

situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the

certified training course offered by Polaris Industries Inc. They

should then regularly practice the skills learned in the course

and the operating techniques described in the Owner’s Manual.

For more information about the training course, contact an

authorized Polaris dealer or call Polaris at 1-800-342-3764.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this vehicle.

WHAT CAN HAPPEN

Use by children of vehicles that are not recommended for their

age can lead to severe injury or death of the child.

Even though a child may be within the age group for which some

vehicles are recommended, he or she may not have the skills,

abilities, or judgment needed to operate the vehicle safely and

may be involved in a serious accident.

HOW TO AVOID THE HAZARD

No one under 16 should operate a Polaris wheeled vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on this vehicle.

WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this vehicle.

Could cause an accident, resulting in harm to you and/or your

passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The operator requires the space of

the entire seat to shift position as needed during operation. The

seat is not for carrying passengers.

WARNING

POTENTIAL HAZARD

Operating this vehicle on paved surfaces.

WHAT CAN HAPPEN

This vehicle’s tires are designed for off-road use only; not for

use on pavement. Paved surfaces may seriously affect

handling and control of the vehicle, and may cause the vehicle

to go out of control.

HOW TO AVOID THE HAZARD

Always avoid paved surfaces, including sidewalks, driveways,

parking lots and streets.

WARNING

Safe operation of this rider active vehicle requires good

judgement and physical skills. Persons with cognitive or

physical disabilities who operate this vehicle have an

increased risk of overturns and loss of control which could

result in serious injury or death.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle on public streets, roads or

highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this vehicle on any public street, road or

highway, even a dirt or gravel one.

In many states it is illegal to operate vehicles of this type

on public streets, roads and highways.

WARNING

POTENTIAL HAZARD

Operating this vehicle without wearing an approved helmet, eye

protection and protective clothing.

WHAT CAN HAPPEN

Operating without an approved helmet increases your chances

of a severe head injury or death in the event of an accident.

Operating without eye protection can result in an accident and

increases your chances of a severe injury in the event of an

accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet which fits properly.

You should also wear:

eye protection (goggles or face shield);

gloves;

boots;

long-sleeved shirt or jacket; and

long pants.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while

climbing a hill.

WHAT CAN HAPPEN

Could result in vehicle overturning.

HOW TO AVOID THE HAZARD

Maintain steady speed when climbing a hill.

If you lose all forward speed:

Keep weight uphill.

Apply the brakes.

Lock parking brake after you are stopped.

If you begin rolling backwards:

Keep weight uphill; never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the service brake, gradually.

When fully stopped, apply auxiliary brake as well, and then lock

parking brake.

Dismount on uphill side, or to either side if pointed straight uphill.

Turn the vehicle around and remount, following the procedure

described in the Owner’s Manual. See page 67. In the event of

an accident, have a qualified service dealer check the complete

machine including, but not limited to brakes, throttle and steering

for possible damage.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle at excessive speeds.

WHAT CAN HAPPEN

Increases your chances of losing control of the vehicle, which can

result in an accident.

HOW TO AVOID THE HAZARD

Always travel at a speed which is proper for the terrain, visibility

and operating conditions; and your experience.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or person behind you, resulting in

serious injury.

HOW TO AVOID THE HAZARD

When you select reverse gear, make sure there are no

obstacles or people behind you. When it is safe to proceed, go

slowly.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the vehicle before operating.

Failure to properly maintain the vehicle.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your 6x6 each time you use it to make sure it is in

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

WARNING

POTENTIAL HAZARD

Removing hands from handlebars or feet from footrests during

operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce your ability to

control the vehicle or could cause you to lose your balance and

fall off the vehicle. If you remove a foot from the footrest, your

foot or leg may come into contact with the rear wheels, which

could injure you or cause an accident.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on

the footrests of your 6x6 during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

You may lose control of the vehicle.

You may also regain traction unexpectedly, which may cause the

vehicle to overturn.

HOW TO AVOID THE HAZARD

On slippery surfaces, such as ice, go slowly and be very

cautious in order to reduce the chance of skidding or sliding out

of control.

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating this vehicle on unfamiliar

terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or holes, without

enough time to react.

Could result in the vehicle overturning or going out of control.

HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar

terrain.

Always be alert to changing terrain conditions when operating the

vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating on excessively

rough, slippery or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or vehicle control, which could

result in an accident, including an overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose

terrain until you have learned and practiced the skills

necessary to control the vehicle on such terrain.

Always be especially cautious on these kinds of terrain.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Vehicle could go out of control, causing a collision or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in

the Owner’s Manual. See page 61.

Practice turning at low speeds before attempting to turn at

faster speeds.

Do not turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle can overturn more easily on extremely steep hills

than on level surfaces or small hills.

HOW TO AVOID THE HAZARD

Never operate the 6x6 on hills too steep for the vehicle or for

your abilities.

Practice on smaller hills before attempting large hills.

Never operate vehicle on hills steeper than 15_.

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SAFETY

Operator Safety

WARNING

15° Maximum

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause vehicle to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as

described in the Owner’s Manual. See pages 62 through

67.

Always check the terrain carefully before you start up any

hill.

Never climb hills with excessively slippery or loose

surfaces.

Shift your weight forward.

Never open the throttle suddenly. The vehicle could flip

over backwards.

Never go over the top of any hill at high speed. An

obstacle, a sharp drop, or another vehicle or person could

be on the other side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause vehicle to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for going down hills as described

in the Owner’s Manual. See page 65. NOTE: A special

technique is required when braking as you go downhill.

Always check the terrain carefully before you start down any hill.

Shift your weight backward.

Never go down a hill at high speed.

Avoid going down a hill at an angle which would cause the vehicle

to lean sharply to one side. Go straight down the hill where

possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause vehicle to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the vehicle around on any hill until you have

mastered the turning technique as described in the Owner’s

Manual on level ground. See pages 62 and 67. Be very careful

when turning on any hill.

Avoid crossing the side of a steep hill if possible.

When crossing the side of a hill:

Always follow proper procedures as described in the Owner’s

Manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision. Could cause vehicle

to overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Use extreme caution when riding over large obstacles, such as

large rocks or fallen trees.

If you cannot avoid obstacles, always follow proper procedures

as described in the Owner’s Manual on page 71.

WARNING

POTENTIAL HAZARD

Overloading this vehicle or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which could lead to an

accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this vehicle.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow

greater distance for braking.

Always follow the instructions in the Owner’s Manual for carrying

cargo or pulling a trailer. See pages 54 and 59.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle 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.

HOW TO AVOID THE HAZARD

Never operate this vehicle in fast flowing water or in water

deeper than that specified in your Owner’s Manual. See

page 68.

Remember that wet brakes may have reduced stopping

ability. Test your brakes after leaving water. If necessary,

apply them several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Attempting jumps and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt stunts such as jumps. Don’t try to show off.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle with improper tires, or with improper or

uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this vehicle, or operation of this vehicle

with improper or uneven tire pressure, may cause loss of control,

and increases the risk of an accident.

HOW TO AVOID THE HAZARD

Always use the size and type tires specified in the Owner’s Manual

for this vehicle. See page 96.

Always maintain proper tire pressure as described in the Owner’s

Manual. See page 96.

WARNING

POTENTIAL HAZARD

Operating this vehicle with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle

may cause changes in handling which in some situations could

lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this vehicle through improper installation or use of

accessories. All parts and accessories added to this vehicle

should be genuine Polaris Industries Inc. or equivalent components

designed for use on this vehicle; and should be installed and used

according to instructions. If you have questions, consult an

authorized Polaris dealer.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Riding on frozen lakes and rivers.

WHAT CAN HAPPEN

Severe injury or death can result if the vehicle and/or the

operator break through the ice.

HOW TO AVOID THE HAZARD

Never ride your 6x6 on a frozen body of water before you are

sure the ice is thick enough and sound enough to support the

machine and its operator, as well as the force that is created by

a moving vehicle.

WARNING

POTENTIAL HAZARD

Operating this vehicle after consuming alcohol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while driving this

vehicle.

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CONTROLS AND FEATURES

Controls

Sportsman 6x6 Vehicle Nomenclature

6. Floor Boards

1. Service Brake Lever

2. Middle Axle Auxiliary Brake

3. Throttle Lever

4. Bed Dump Latch Release(s)

5. Gearbox Shift Lever

7. Back Rest

8. Bed

9. Front Rack

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CONTROLS AND FEATURES

Controls

Engine Electrical Switches

OFF

RUN

WARNING

Activating the override button while throttle is open can cause loss

of control resulting in severe injury or death.

1. Override Switch (Reverse Speed Limiter)

This vehicle is equipped with a reverse speed limiter system. To obtain

additional power while backing up, depress the override button.

NOTE: The override switch also allows activation of All Wheel Drive

(AWD) in reverse, if AWD switch is on.

2. Main Switch

To start the engine, slide the stop switch (3) to the center “run” position

and turn the main key switch clockwise past the “on” position. Release

the key when the engine starts.

This switch must be turned clockwise to the “on” position to start the

engine.

3. Engine Stop Switch

The engine will not start or run when the switch is in its “off” position.

Its purpose is to provide the operator with a quick means of engine

shutdown in case of stuck throttle or other emergency. NOTE: Both

the main switch and the emergency engine stop switch shut off all

electrical power to the entire vehicle including lights. To stop the

engine, slide the stop switch right or left to the “off” position.

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CONTROLS AND FEATURES

Controls

Throttle Lever

Engine speed and vehicle

movement are controlled by

pressing the throttle lever.

The throttle lever (1) is

spring loaded and engine

speed returns to idle when

the lever is released. This

vehicle is equipped with a

Polaris Electronic Throttle

Control (ETC) which is

designed to reduce the risk of

a frozen or stuck throttle. In the event the throttle should stick in an

open position, engine RPM will diminish and power to the rear wheels

will cease.

Choke Knob (2)

Refer to the engine starting procedure on pages 52 - 53 for correct

choke and throttle settings during starting.

WARNING

The Electronic Throttle Control (ETC) limits engine power in the

event of a throttle system malfunction and is provided for your

safety. Do not attempt to modify the ETC system or replace it with

any after market throttle mechanisms.

WARNING

Do not start or operate this vehicle with sticking or improperly

operating throttle controls. A stuck or improperly operating throttle

could cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle

problems arise.

Failure to check or maintain proper operation of the throttle system

can result in the throttle lever sticking during riding and cause an

accident.

Always check the lever for free movement and return before

starting the engine and occasionally during riding.

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CONTROLS AND FEATURES

Controls

Front and Rear Brakes

The master cylinders, which are

located on the left and right

handlebars, should be checked

before each ride. The fluid level can

be seen through an indicator window

(3) on the top of the master cylinder.

This “eye” will appear dark when

the fluid level is full. When fluid

needs to be added, the eye will be

clear. NOTE: When checking the

fluid level, the handle bars should be

turned so until the top of the reservoir is level. If the fluid level is low

add DOT 3 (PN 2870990) only.

WARNING

Once a bottle of brake fluid is opened, use what is necessary and

discard the rest. Do not store or use a partial bottle of brake fluid.

Brake fluid is hygroscopic, meaning it rapidly absorbs moisture

from the air. This causes the boiling temperature of the brake fluid

to drop, which can lead to early brake fade and the possibility of

serious injury.

The service brakes are applied by squeezing the left side brake lever

toward the handlebar. These brakes are hydraulically activated disc

type brakes which are activated by one lever only.

Always test brake lever travel and reservoir fluid level before riding.

When squeezed, the lever should feel firm. Any sponginess would

indicate a possible fluid leak or low master cylinder fluid level which

must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

WARNING

Improperly operating the vehicle with a spongy brake lever can

result in loss of braking. Loss of braking could cause an accident.

Never operate the vehicle with a spongy feeling brake lever.

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CONTROLS AND FEATURES

Controls

Brakes/Rear Auxiliary Brake

The braking system is controlled by two levers located on the

handlebars directly in front of the handgrips.

1. Service Brakes (front wheel and transmission) - Left Handlebar

Lever

This lever controls braking action to all six wheels. It is the normal

service brake system to use for braking.

2. Auxiliary Brakes - Right Handlebar Lever

This lever controls the auxiliary brake for the rear axles. It is to be

used for additional braking effect, or in the event of failure of the

normal service brake

system.

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CONTROLS AND FEATURES

Controls

Parking Brake

Setting the Parking Brake

1. Squeeze the left hand brake

lever two or three times and

hold it.

2. Rotate the park brake lock (3)

into the notches on the master

cylinder body. Release the

brake lever.

3. To release the parking brake

lock, squeeze the brake lever.

It will return to its released

position.

The parking brake will slowly

relax or lose holding power if left

unattended for more than five

minutes. Do not depend on

parking brake to hold vehicle for

more than five minutes.

WARNING

Always check to be sure that the parking brake has been

disengaged before operating the vehicle. An accident could

result if the parking brake is left on while the vehicle is operated.

The parking brake may relax when left on for a long period of

time. This could cause an accident.

Do not leave the vehicle on a hill depending on the parking

brake for more than five minutes.

Always block the downhill side of the wheels if leaving the vehicle

on a hill or park the vehicle in a side hill position.

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CONTROLS AND FEATURES

Controls

Engine Fuel and Oil System

The fuel tank filler cap (1) is located directly behind the handlebar. Its

capacity is 4.25 U.S. gallons (16 l) with 1/2 gallon (1.9 l) in reserve.

Use either leaded or unleaded gasoline with a minimum pump octane

number of 87 (R+ M)/2 octane.

The fuel tank supply valve (2) located on the left side of the vehicle has

three positions:

OFF: For vehicle storage and

whenever transporting.

ON: For normal operation.

RES

RES: For reserve supply in the

event of main supply exhaustion.

NOTE: There is about a 7 to 10

mile (11.2 to 16 km) range on

reserve gas. Always refill the gas

tank as soon as possible after

having used the reserve supply.

OFF

Always remember to take the fuel

valve off “RES” after refueling

your machine.

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CONTROLS AND FEATURES

Controls

Engine Fuel and Oil System

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

D Always exercise extreme caution whenever handling gasoline.

D Always refuel with the engine stopped and outdoors or in a well

ventilated area.

Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

Do not over fill the tank. Do not fill the tank neck.

D If you should get gasoline on your skin or clothing, immediately

wash it off with soap and water and change clothing.

D Never start the engine or let it run in an enclosed area. Gaso-

line powered engine exhaust fumes are poisonous and can

cause loss of consciousness and death in a short time.

Shut off fuel valve whenever the vehicle is stored or parked.

NOTE: The taillight is on whenever the main switch (key) is in the on

position. Turn the key off to prevent battery drain.

WARNING

The engine exhaust from this

product contains chemicals

known to cause cancer, birth de-

fects or other reproductive harm.

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CONTROLS AND FEATURES

Controls

Transmission Gear Selector Operation

The transmission gear

selector is located on the

right side of the vehicle

Shift Patterns

directly above and forward

of the engine recoil starter.

The transmission selector

lever has four positions:

high forward; reverse;

neutral; and low forward.

Use of low forward gear is

recommended in heavy

pulling situations to extend

belt life.

To change gears, stop the

vehicle and with the engine

idling, move the lever to the desired gear. Do not attempt to shift gears

with engine speed above idle or while the vehicle is moving.

Always place the transmission in gear with the parking brake locked

whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper

transmission function. Should you experience any shifting problem

see your dealer.

WARNING

1. Do not attempt to shift the transmission while the vehicle is mov-

ing or while operating on hilly terrain.

2. Always place the transmission in gear with the parking brake ap-

plied whenever the vehicle is left unattended.

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CONTROLS AND FEATURES

Controls

Recoil Starter

If the battery is weak and

cannot start the engine, use of

the recoil starter located on

the right side of the machine

will allow vehicle operation

until repairs can be made.

Recoil Starter

1. Be certain the parking brake

is set. See page 42.

2. Grasp the recoil starter

tightly and pull slightly un-

til the starter mechanism

engages.

3. Pull the rope abruptly to

start the engine.

CAUTION

Do not extend the starter rope so far that it stops This will cause

damage to the recoil assembly.

Make sure the manual start handle is fully seated on the recoil

housing, especially when travelling in wet areas. If it is not sealed

properly, water may enter the recoil housing and damage

components.

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CONTROLS AND FEATURES

Features

Light Switches and Indicator Lights

1. Main switch

2. Handlebar light switch and headlight Hi-Lo beam control NOTE:

Will not light unless main switch is on.

3. Headlight Hi beam indicator (Blue)

4. Transmission reverse indicator (Yellow)

5. Transmission neutral indicator (Green)

6. All Wheel Drive indicator (Red)

7. Engine hi temp warning indicator (Red) NOTE: Will light only if

engine overheats.

With engine running, verify function of indicator lights each time

vehicle is used.

WARNING

This vehicle is not equipped with highway approved lighting. This

vehicle is designed for off-road use only and must not be ridden

on streets or highways. Use caution and drive at reduced speeds

in conditions of reduced visibility such as fog, rain and darkness.

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CONTROLS AND FEATURES

Features

All Wheel Drive System

AWD Button

Reverse Speed Limiter

Override Button

The Polaris 6x6 is equipped with a unique Polaris exclusive AWD (All

Wheel Drive) system which is activated by a switch on the right

handlebar. When the switch is “off” the 6x6 is in rear wheel drive at

all times. When the switch is “on” the 6x6 is in AWD and the front

wheels will automatically engage anytime the rear wheels lose traction.

When the rear wheels regain traction, the front wheels will

automatically disengage. NOTE: The override switch also allows

activation of AWD in reverse, if AWD switch is on.

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CONTROLS AND FEATURES

Features

A red AWD light on the switch indicates when the vehicle is in AWD.

There is no limit to the length of time the vehicle may remain in AWD.

The AWD switch may be turned on or off while the vehicle is moving.

If the switch is turned off when the front hubs are driving they will not

release until the rear wheels regain traction.

CAUTION

Do not switch on AWD if the rear wheels are spinning. This may

cause severe drive shaft and clutch damage. Engage the AWD

switch before getting into conditions where front wheel drive may

be needed. If the rear wheels are spinning, release the throttle

before turning the AWD switch on.

Disengaging Wheel Hubs

When backing uphill while in AWD and then going forward downhill,

one or both hubs may remain engaged. If one or both hubs remain

engaged they can be disengaged by stopping, shifting to and moving in

reverse. Then proceed in forward again.

WARNING

If both hubs were engaged and only one released during

operation, loss of control could result. If you experience hub

engaging symptoms, use the above disengaging technique

before proceeding. Failure to disengage front hubs as directed

above could result in severe injury or death.

If the hubs remain engaged after following these instructions

return the vehicle to your dealer for service.

You can tell if only one front hub is engaged if the handlebars pull to

one side. If both front wheel hubs are engaged, steering effort

increases but remains balanced from left to right, and vehicle speed is

somewhat restricted.

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OPERATION

Vehicle Break-in Period

The break-in period for your new Polaris 6x6 is defined as the first ten

hours of operation or the time it takes to use the first two tanks of

gasoline. No single action on your part is as important as a proper

break-in period. Careful treatment of a new engine will result in more

efficient performance and longer life for the engine. Perform the

following procedures carefully.

CAUTION

Use only Polaris Premium 4 All Season synthetic oil, or API certified

“SH” oil. Never substitute or mix oil brands. Serious engine

damage and voiding of warranty can result.

1. Fill fuel tank with either unleaded or leaded fuel which has a mini-

mum pump octane number of 87= (R+ M)/2.

2. Check oil reservoir lev-

el indicated on dipstick.

ADD 8 OZ.

NORMAL

FULL

Add oil if necessary.

3. Drive slowly at first.

Select an area which is

Maintain Oil Level In Normal Range

open and will give you room to familiarize yourself with vehicle

operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

CAUTION

Do not operate at full throttle or high speeds for extended periods

during the first three hours of use. Excessive heat can build up and

cause damage to close fitted engine parts.

5. Perform regular checks on fluid levels, controls and all important

areas on the vehicle as outlined earlier on the daily pre-ride inspec-

tion checklist found on page 12.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 200 miles.

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OPERATION

Daily Pre-Ride Inspection

Inspect your 6x6 each time before riding to ensure it is in proper

working order. If proper inspection is not done, severe injury or death

could result.

WARNING

If a proper inspection is not performed serious injury or death

can result.

Always inspect your 6x6 before riding following the checklist

carefully.

Before riding your vehicle, inspect all operating controls and

parts.

Item/Inspection Procedure

Tires - check condition and pressures

Fuel and oil tanks - fill both tanks to their proper levels

All brakes - check operation, adjustment and fluid level (in-

cludes auxiliary brake)

Throttle - check for free operation and closing

Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches

Engine stop switch - check for proper function

D Wheels - check for tightness of wheel nuts and axle nuts; check

that axle nuts are secured by cotter pins

Drive chain - condition and slack; refer to drive chain adjust-

ment

Air cleaner element - check for dirt; clean or replace

Steering - check for free operation noting any unusual loose-

ness in any area

D Loose parts - visually inspect vehicle for any damaged or loose

nuts/bolts or fasteners

Operators helmet, goggles and clothing

Engine coolant - check for proper level at the recovery bottle.

Check condition and operation of the dump box/bed latch

mechanism.

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OPERATION

Starting a Cold Engine

1. Placethetransmission in neutral and

reset the parking brake.

2. Turn the fuel tank valve to ON.

3. Sit on the vehicle.

4. Pull the choke button (A)all theway

out.

5. Set the engine stop switch to “run”.

6. Turn the ignition key past the “ON”

position to engage the starter.

NOTE: the choke is on “FULL” when the knob is pulled out all the

way. The choke is “OFF” when the knob is pushed in. This is a

variable choke and can be adjusted gradually, depending on how much

choke is needed for starting.

7. Do not press the throttle while starting the engine.

8. Activate the starter for a maximum of five seconds, releasing the key

or button when the vehicle starts. If engine does not start, release the

starter and wait five seconds; then activate the starter for another five

seconds. Repeat this procedure until engine starts.

NOTE: Do not press the throttle while starting the engine.

After the Engine Starts

1. If the engine slows or stops, pushing the choke button in half way will

allow proper engine warm up.

2. Vary the engine RPM slightly with the throttle to aid in warm up until

the engine idles smoothly. Then push the choke button all the way in.

CAUTION

Proper engine warm up is essential each time before driving to

avoid engine damage.

WARNING

Carbon monoxide exhaust gas is poisonous!

Always start the vehicle outdoors.

Never run the engine in an enclosed area.

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OPERATION

Starting a Warm Engine

Warm engines do not normally require the use of the choke since the

spark plug can easily become wet fouled.

1. Place the transmission in neutral and push the vehicle to a level sur-

face.

2. Lock the parking brake.

3. Turn the fuel tank valve to ON.

4. Sit on the vehicle.

5. If the engine has cooled to a point where it does not readily start, inter-

mittent use of the choke button pulled half way out is permitted.

6. If the engine is over-choked by mistake when warm, depress the

throttle lever fully while cranking to aid in starting.

7. Release the throttle lever immediately after the engine starts. If the en-

gine does not start and all conditions are favorable, change the spark

plug.

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OPERATION

Carrying Loads

Your 6x6 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. Never exceed the following weights.

Maximum Capacities

(Level Ground)

Front Rack

Cargo

Cargo Bed

Sportsman 6x6 - 875

lbs. (397 kg)

75 lbs. (34 kg)

800 lbs. (363 kg)

Improper loading of the front rack can obstruct the headlight beam,

reducing night visibility. Do not obstruct the headlight beam with

cargo.

Maximum Towing Capacities (Level Ground)

Maximum towed load weight - 1250 lbs. (568 kg) on level ground

only; 850 lbs. (386 kg) up to 15° grade. Maximum vertical hitch

weight - 30 lbs (14 kg).

Use of low forward is recommended in heavy pulling situations to

extend belt life.

Maximum grade while trailer towing - 15°; do not tow any trailer on a

grade steeper than 15°.

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OPERATION

Carrying Loads

WARNING

Overloading the vehicle or carrying or towing cargo improperly

can be dangerous.

Improper loading can drastically alter 6x6 handling and braking

stability.

Never exceed the stated load capacity for this vehicle.

Do not obstruct the headlight when loading the front rack.

Cargo should be properly distributed and carried as low and

forward in the cargo bed as possible.

Reduce speed and allow greater distance for braking.

Heavy loads can cause braking and control problems.

Use extreme caution when applying brakes with a loaded ve-

hicle. Generally avoid terrain or situations which may require

backing downhill.

D Always attach the tow load to the hitch point designated for your

vehicle.

Vehicle should never exceed 10 mph (16 kph) while towing a

load on a level grass surface. Vehicle speed should never ex-

ceed 5 mph (8 kph) when towing loads in rough terrain, while

cornering, or while ascending or descending a hill.

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OPERATION

Carrying Loads

Dumping the Cargo Bed

1. Select a level site to dump the cargo bed. Do not attempt to dump or

unload the vehicle while parked on an incline.

2. Set the parking brake.

3. Dismount the vehicle.

4. Pull the cargo bed release mechanism lever forward and lift the front

of the cargo bed to dump.

WARNING

Never carry passengers on the bed.

If the weight distribution on the bed is located toward the rear of

the bed and the release lever is pulled forward, the bed will

want to dump on its own. Never operate the dump lever

without checking the position of the load. This will prevent

unexpected dumping of the cargo bed.

WARNING

In the event of an accident have a qualified service dealer check

the complete machine including, but not limited to, brakes,

throttle, and steering for possible damage.

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NOISE EMISSION CONTROL SYSTEM

REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

U.S. Federal law prohibits the following acts or the causing thereof:

(1) The removal or rendering inoperative by any person other than for

purposes of maintenance, repair, or replacement of any device or

element of design incorporated into any new vehicle for the purpose of

noise control prior to its sale or delivery to the ultimate purchaser or

while it is in use or

(2) the use of the vehicle after such device or element of design has

been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE

TAMPERING ARE THE ACTS LISTED BELOW.”

1. Removal or alteration or the puncturing of the muffler or any engine

component which conducts removal of engine exhaust gases.

2. Removal or alteration or the puncturing of any part of the engine air

induction system.

3. Replacement of any vehicle parts with parts not in compliance with

federal regulations.

4. Lack of proper maintenance.

CAUTION

Remember, exhaust system components are very hot during and

after use of the vehicle.

Do not touch hot exhaust system components. Serious burns

can result.

D Be especially careful when traveling through tall grass. The po-

tential for fire exists.

USFS Approved Spark Arrestor

The muffler on this vehicle was tested and approved in accordance with

the USFS Forest Service Standard 5100-1A.

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RIDING

Daily Pre-Ride Inspection

Inspect your 6x6 each time before riding to ensure it is in proper

working order. If proper inspection is not done, severe injury or death

could result.

WARNING

If a proper inspection is not performed serious injury or death

can result.

Always inspect your 6x6 before riding following the checklist

carefully.

Before riding your vehicle, inspect all operating controls and

parts.

Item/Inspection Procedure

Tires - check condition and pressures

Fuel and oil tanks - fill both tanks to their proper levels

All brakes - check operation, adjustment and fluid level (in-

cludes auxiliary brake)

Throttle - check for free operation and closing

Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches

Engine stop switch - check for proper function

D Wheels - check for tightness of wheel nuts and axle nuts; check

that axle nuts are secured by cotter pins

Drive chain - condition and slack; refer to drive chain adjust-

ment

Air cleaner element - check for dirt; clean or replace

Steering - check for free operation noting any unusual loose-

ness in any area

D Loose parts - visually inspect vehicle for any damaged or loose

nuts/bolts or fasteners

Operators helmet, goggles and clothing

Engine coolant - check for proper level at the recovery bottle.

Check condition and operation of the dump box/bed latch

mechanism.

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RIDING

Riding Safely

Load Distribution

Maximum Cargo Bed

Sportsman 6x6 800 lbs.

(363 kg)

Maximum Front Rack

75 lbs. (34 kg)

1. Always load the cargo bed placing the load as far forward as possible.

2. Always operate the vehicle with extreme care whenever hauling or

towing loads as balance, handling, and control may be affected.

3. Slow down and drive in low range only.

4. The cargo bed dump latch must be securely latched before loading and

operating. Unintentional bed tilting will result if weight is placed in

the rear of the bed and the latch is not secured.

WARNING

Never operate this vehicle with the cargo bed in the raised position.

The cargo bed could close unexpectedly while driving, severely

injuring the driver. The rear tires will catch the rear of the bed,

damaging the vehicle and creating hazardous driving conditions.

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RIDING

Riding Safely

1. Sit upright with both feet on thefootrests and both handson thehandle-

bars.

2. Afterstarting theengineand allowing it to warm up, shift thetransmis-

sion into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driving.

Vehicle speed is controlled by the amount of throttle opening and PVT

shifting is done automatically.

6. Drive slowly, practice maneuvering and using the throttle and brakes

on level surfaces.

WARNING

Indicates a potential hazard which could result in serious injury

or death.

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RIDING

Riding Safely

Making Turns

Practice making turns at slow speeds.

Polaris 6x6s are equipped with solid rear axles which drives all rear

wheels equally at all times. This means that the wheel on the outside

of the turn must travel a greater distance than the inside wheel when

turning and the inside tire must slip traction slightly. To turn, steer in

the direction of the turn leaning your upper body to the inside of the

turn while supporting your weight on the outer footrest. This

technique alters the balance of traction between the rear wheels

allowing the turn to be made smoothly. The same learning technique

should be used for turning in reverse.

WARNING

Avoid turning at sharp angles in reverse as tipover and serious

injury may result.

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RIDING

Riding Safely

Sidehilling

Sidehilling your 6x6 is one of the most dangerous types of riding

and should be avoided if possible. In the event you do enter into a

situation where sidehilling is necessary, always:

1. Slow down.

2. Lean into the hill transferring your upper body weight toward the hill

while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

If vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

WARNING

Improperly crossing hills or turning on hills can be dangerous!

Loss of vehicle control or overturning of the vehicle could occur.

Avoid crossing the side of a steep hill if possible.

Use extreme care when operating your 6x6 in hilly terrain.

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RIDING

Riding Safely

Riding On Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose

gravel, or during cold freezing weather, special attention must be

paid to prevent vehicle turnover. Always:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding quick,

sharp turns which can cause skids.

3. Correct a skid by turning the handlebars in thedirection ofthe skid and

shifting your body weight forward.

4. Driving with Demand 6 Drive (All Wheel Drive) engaged can assist

in controlling the vehicle in slippery areas.

Before riding your vehicle on a frozen body of water be sure that the

ice is thick enough to support the machine and its operator, as well as

the force that is created by a moving vehicle. Severe injury or death

can result if the vehicle and/or its operator break through the ice.

CAUTION

Never engage Demand Drive while wheels are spinning as severe

damage to drive train may occur.

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RIDING

Riding Safely

Riding On Slippery Surfaces

WARNING

Failure to exercise care when operating on slippery surfaces can

be dangerous.

Loss of tire traction and vehicle control can result in an accident,

including an overturn.

Never apply brakes during a skid. Complete loss of control

can result.

Do not operate on excessively slippery surfaces if possible.

Always reduce speed and use additional caution.

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RIDING

Riding Safely

Traveling Downhill

Whenever descending a hill always:

1. Drive directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

WARNING

Loss of vehicle control due to excessive speed can occur. Loss

of control may result in serious injury or death.

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RIDING

Riding Safely

Traveling Uphill

15_ Maximum

Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills.

2. Keep both feet on the footrests.

3. Transfer your weight forward.

4. Proceed at a steady rate of speed and throttle opening.

5. Remain alert and be prepared to take emergency action. This may in-

clude quick dismounting of the vehicle.

WARNING

Braking and handling are greatly affected whenever operating in

hilly terrain.

Loss of vehicle control or overturning of the vehicle could occur.

Avoid climbing steep hills (15_ maximum).

Use extreme care when operating your vehicle in hilly terrain.

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RIDING

Riding Safely

Turning Around On A Hill

8’

Uphill

If the vehicle stalls while climbing a hill, never back it down the

hill! One maneuver which can be used when it is necessary to turn

around while climbing a hill is the K-turn.

1. Stop and lock theparking brakewhile maintaining body weight uphill.

2. Leave transmission in forward and shut off engine.

3. Dismount on left or uphill side of vehicle.

4. Staying uphill of vehicle, turn handlebars full right (facing front of ve-

hicle).

5. While holding service brake, release parking brake lock and slowly al-

low vehicle to roll around to your right until it is pointing across the

hill or slightly downward.

6. Lock the parking brake and remount vehicle from the uphill side,

maintaining body weight uphill.

7. Restart engine with transmission still in forward, and proceed slowly,

controlling speed with the service brake, until vehicle is on reasonably

level ground.

WARNING

Avoid climbing steep hills.

Loss of vehicle control or overturning of vehicle could occur.

Use extreme care when operating your 6x6 in hilly terrain.

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RIDING

Riding Safely

Crossing Streams

Your Polaris 6X6 can operate through water up to maximum

recommended depths reaching the footrests. Before fording

streams always:

1. Determine water depths and current.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the lever

until braking action is normal.

Avoid operating the 6X6 through deep or fast flowing water. If you

cannot avoid water which exceeds the recommended maximum

depth, go slowly, balance your weight carefully, avoid sudden

movements, maintain a slow and steady forward motion. Do not

make sudden turns or stops and do not make sudden throttle

changes.

CAUTION

If your 6X6 becomes immersed, take it to your dealer before

starting the engine. Major engine damage can result if the machine

is not thoroughly inspected.

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RIDING

Riding Safely

Backing Up

1. When backing up, always avoid backing downhill.

2. Back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

6. Never activate override button while throttle is open. Loss of control

may result.

NOTE: This vehicle 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. Only open

the throttle enough to maintain a desired speed. Opening the throttle

more than required may cause excessive fuel to build in the exhaust,

resulting in engine popping and/or engine damage.

WARNING

Indicates a potential hazard which could result in serious injury

or death.

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RIDING

Riding Safely

Backing Up

WARNING

Backing your 6x6 can be dangerous!

You could hit an obstacle or person behind you; or the vehicle

could tip over on a steep incline causing severe injury or death.

Always back slowly avoiding excessive speed and do not use

the reverse speed override switch system unless additional

power is required for vehicle movement.

Avoid backing on steep inclines.

Avoid turning at sharp angles in reverse.

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RIDING

Riding Safely

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you ride. Stay on the right

side of the trail, if possible, and be constantly alert for hazards such as

logs, rocks and low hanging branches.

WARNING

Hidden or unseen hazards on the trail can be dangerous.

Personal injury or the vehicle overturning can occur from unseen

obstacles.

Keep alert and constantly look for obstacles on the trail.

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RIDING

Riding Safely

Parking On An Incline

Whenever the Vehicle is Parked

1. Place the transmission in gear.

2. Set the parking brake.

3. Avoid parking on an incline. If it is necessary to park on an incline,

always block the rear wheels on the down hill side as shown above.

4. Shut off fuel supply.

WARNING

Always check to be sure that the parking brake has been

disengaged before operating the vehicle. An accident could result

if the parking brake is left on while the vehicle is operated.

The parking brake may relax when left on for a long period of

time. This could cause an accident.

Do not leave the vehicle on a hill depending on the park

brake for more than five minutes.

Always block the downhill side of the wheels if leaving the vehicle

on a hill or park the vehicle in a side hill position.

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MAINTENANCE AND LUBRICATION

Tool Kit

To help you perform routine maintenance, a tool kit is provided in the

storage compartment under the seat. Items included in the kit are:

screwdriver

open end wrench (8-10 mm)

open end wrench (12-14 mm)

box end wrench

tire pressure gauge

spark plug wrench and handle

torx wrench (rack removal)

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication

intervals of important components are explained in the following chart

Maintenance intervals are based upon average riding conditions and a

vehicle speed of approximately 10 miles per hour. Vehicles subjected

to severe use, such as operation in wet or dusty areas, should be

inspected and serviced more frequently. If you are not familiar with

safe service and adjustment procedures, have a qualified dealer perform

these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE:

Inspection may reveal the need for replacement parts. Always use

genuine Polaris parts.

CAUTION

Due to the nature of the adjustments marked with a J, it is

recommended that service be performed by an authorized Polaris

dealer.

More often under severe use, such as dirty or wet conditions

NOTE: Inspection may reveal the need for replacement parts. Always

use genuine Polaris parts available from your Polaris dealer.

Item

Hours or

Odometer

Frequency

Remarks

Headlamp Inspection

Pre-ride

Check operation daily; apply Polaris di-

electric grease to connector when re-

placed

Tail lamp inspection

Pre-ride

Check operation daily; apply Polaris di-

electric grease to socket when replaced

Tires - Air Pressure

Brake System

Pre-ride

Daily

Pre-ride

Daily

Inspect daily, pre-ride inspection item

Pre-ride inspection item

Fill to proper level

Wheels

Frame nuts, bolts, fasteners

Fuel and Oil Tanks

Air Box Sediment Tube

Air Filter - Pre-Cleaner

Coolant/Level Inspection

Drain deposits whenever visible

Inspect-Clean

Daily

Replace engine coolant every two

years

Air Filter - Main Element

Weekly

Inspect-Replace if necessary

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule (Cont.)

CAUTION

Due to the nature of the adjustments marked with a J, it is

recommended that service be performed by an authorized Polaris

dealer.

More often under severe use, such as dirty or wet conditions

NOTE: Inspection may reveal the need for replacement parts. Always

use genuine Polaris parts available from your Polaris dealer.

Item

Hours or

Odometer

Frequency

Remarks

Brake pad wear

Engine breather filter

10 hrs/100

miles

Monthly

Inspect periodically

20 hrs

Monthly

Inspect--replace annually and as need-

Battery

20 hrs

25 hrs

50 hrs

Monthly

3 months

6 months

Check Terminals/clean/check fluid level

Inspect monthly; change annually

Transmission Oil Level

General Lubrication

Throttle Cable/ETC Switch

Lubricate all fittings, pivots, cables, etc.

Inspect--adjust, lubricate, replace if nec-

essary; pre-ride inspection item

Choke (Enricher) Cable

Carburetor Float Bowl

Engine Oil - Level/Change

50 hrs

6 months

Inspect--adjust, lubricate, replace if nec-

essary

Drain bowl periodically and prior

to storage

100 hrs/1000 6 months

miles

Check Level Daily; Break in Service at

1 month. Change oil more often in cold

weather use

Oil Filter

100 hrs/1000 6 months

miles

Replace with oil change

Coolant strength/pressure test

system

100 hrs

6 months

Inspect strength seasonally; pressure

test system annually

Engine breather hose

Rear Suspension

Drive Chains

100 hrs

50 hrs

6 months

Inspect

Inspect, tighten fasteners

Inspect daily, adjust and lubricate if

needed

Drive Belt

50 hrs

6 months

Inspect--adjust, replace if necessary

Check monthly

Front hubs/fluid check

Shift linkage

Inspect, lubricate, adjust

Inspect daily, lubricate

Steering

Rear Axle/Center Axle

Front Suspension

Inspect bearings

Inspect--lubricate, tighten fasteners

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours or

Odometer

Frequency

Remarks

Valve Clearance

Fuel System

100 hrs

12 months

Inspect/Adjust

100 hours

Check for leaks at tank cap, lines, fuel

valve, filter, pump and carburetor. Re-

place lines every two years.

Fuel Filter

100 hrs

200 hrs

As required

12 months

24 months

As required

Replace annually

Inspect/clean external surface

Inspect

Radiator

Cooling System hoses

Engine Mounts

Spark arrestor

Inspect

Clean out

Spark Plug

Inspect--replace if necessary

Front hubs/fluid change

Clutches (drive and driven)

Shift selector box

Brake fluid

Inspect, clean

Change lubricant every two years

Change every two years

Adjust if necessary

Headlight Aim

Toe adjustment

Periodic inspection, adjust when parts

are replaced

Recoil housing

Idle Speed

As required

As Required

As required

As Required

Drain moisture out after riding in water

Adjust

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item

Lube Rec.

DOT 3 Only

Method

Frequency*

Brake Fluid

Maintain proper level.

See page 40.

As required;

change every

two years or 200

hours

Drive Chains

Gear Selector

O-Ring chain lube

or SAE 80/90

Lubricate as often as re-

quired (before each ride in

wet conditions).

As required

10 W

Non-detergent Oil

Maintain oil level at the

Change every 2

center of the shift rail. Do years or 200

not overfill.

hours.

Transmission Oil Polaris Premium

Fill to bottom of the filler

hole.

Change annually

or at 100 hours

Synthetic gearcase

lube

Front Prop Shaft Grease+

U-joints

Locate Fittings and

Grease

Every 3 months

or 50 hours

Front Drive Axle

(U Joint) (AWD

Models)

Grease+

Locate grease fitting and

grease with grease gun.

Every 3 months

or 50 hours

Front Prop Shaft

(U-Joint)

Fill plug

Transmission

plug

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Inner Tie Rod End

Steering Post

Bushings

Demand 6 Hubs

Upper

Front A-Arm

Pivot Shaft

Ball Joint

4:00 position

Demand 6

Premium

Hub Lube

Remove set screw in hubs. Ro-

Annually or at

Hubs - All

tate wheels to 4:00 position. If lu- 100 hrs

bricant is not visible add more.

Reinstall set screw.

Wheel Drive

Ball Joint

Grease**

Locate zerk on back side of struts Every 3 months

and grease with grease gun.

or at 50 hrs

Front A Arm

Pivot Shaft

Locate zerk on pivot shaft and

grease with grease gun.

Every 3 months

or at 50 hrs

Steering Post

Bushings

Locate fitting on steering post and Every 3 months

grease with grease gun. or at 50 hrs

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Middle Axle Bearings

U Joint

Swing Arm

Bushings

Center Swing Arm

Housing

Rear Axle

Bearing

Rear Strut

Front Drive

Axle U Joints

Rear Axle

Bearing

Grease +

Grease**

Locate grease fitting and grease

with grease gun.

Locate fitting on eccentric and

grease with grease gun.

Every 3 months

or 50 hrs

Every 3 months

or 50 hrs

Swing Arm

Bushings

Grease**

Grease*

Locate fitting on swing arm and

grease with grease gun.

Monthly or at 20

hrs

Middle Axle

Bearings

Locate fitting on eccentric and

grease with grease gun.

Every 3 months

or 50 hrs

Center

Locate fitting on swing arm

housing and grease with

grease gun.

Every 3 months

or 50 hrs

Swing Arm

Housing

Rear Strut

Grease*

Locate fitting on rear strut

and grease with grease gun.

Every 3 months

or 50 hrs

More often under severe use, such as wet or dusty conditions

** Grease conforming to NLGI No. 2, such as Conoco Superlube M or

Mobilegrease Special

+ Use Polaris Premium U-Joint Lube

NOTE: Hours are based on 10 mph average.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Lubrication

The transmission fill plug (1) is located on the right side of the

machine behind the propshaft shield or footwell.

The transmission lubricant level should be checked every six months or

1000 miles (1600 km), whichever comes first. Transmission oil should

be changed annually. With the 6X6 on a level surface, remove fill plug

(2) and check the lubricant level. Lubricant level is correct when it

reaches the bottom of the filler hole. The correct transmission

lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN

2871478).

Transmission Oil Changing Procedure

1. Remove propshaft shield from the right side of the vehicle.

2. Remove fill plug.

3. Remove transmission drain plug located on the bottom left hand side

and drain the oil. Catch and discard used oil properly.

4. Clean and reinstall the drain plug.

5. Add Polaris Premium Synthetic Gearcase Lubricant (PN2871478 -12

oz. bottle) until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall propshaft shield or footwell and screws removed in step 1.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Lubrication

The front gearcase fill plug (3) is

located as shown.

The front gearcase lubricant level

should be checked every six

months or 1000 miles (1600 km),

whichever comes first. Front

gearcase oil should be changed

annually. With the 6X6 on a level

surface, remove fill plug and

check the lubricant level.

Lubricant should be kept at the

bottom of fill plug thread. The

correct gearcase lubricant to use is

GL5 80-90 Weight Gear Lube.

Gearcase Oil Changing Procedure

1. Remove fill plug.

2. Remove gearcase drain plug located on the bottom right hand side and

drain the oil.

3. Clean and reinstall the drain plug and tighten securely (14 ft. lbs/1.93

kgm).

4. Add GL 80-90 Weight Gear Lube to the bottom thread on the fill hole.

5. Reinstall filler plug.

6. Check for leaks.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially

formulated for use in Polaris 4 cycle engines. It is a fully synthetic,

high performance, multi-viscosity oil designed to provide the ultimate

in lubrication performance and protection.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

breakdown in ambient temperatures from -40° F to 120° F. 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. Oil may

need to be changed more frequently if Polaris Premium 4 is not used.

You will also need to follow the manufacturers recommendations for

ambient temperature operation.

Oil System

The oil tank is located on

the left side of the vehicle.

To check the oil:

ADD 8 OZ.

NORMAL

FULL

1. Set machine on a level

surface.

Maintain Oil Level In Normal Range

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine, remove dipstick and wipe dry with a clean cloth.

4. Screw in the dipstick completely, remove it and read the oil level.

NOTE: The dipstick must be screwed in to keep the angle and depth

of stick consistent.

5. Remove dipstick and check to see that the oil level is between the full

and add marks. Add oil as indicated by the level on the dipstick. Do

not overfill. If oil level rises above the full mark, water and/or fuel

may be collecting in the tank and oil should be changed.

CAUTION

Use only Polaris Premium 4 All Season synthetic oil, or API certified

“SH” oil. Never substitute or mix oil brands. Serious engine

damage and voiding of warranty can result.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

CAUTION

Oil may be hot. Do not allow hot oil to come into contact with skin

as serious burns may result.

The recommended oil change interval is 100 hours, 1000 miles, or

every six months, whichever comes first. Suggested break in oil

change is at 20 hours, 200 miles, or one month, whichever comes first.

Severe use requires more frequent service. Severe use includes

continuous duty in dusty or wet conditions and cold weather riding.

Severe use cold weather riding is all riding below 10°F, and riding

between 10°F and 30° F when most trips are slow speed. Be sure to

change the oil filter whenever changing oil (Polaris PN 3084963)

1. Place vehicle on a level surface.

2. Clean area around drain plug at the bottom of the oil tank.

3. Place a drain pan beneath the oil tank and remove the drain plug.

4. Allow oil to drain completely.

5. Install a new sealing washer (PN 5850135) on oil drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank

should be clean and free of burrs, nicks or scratches.

6. Reinstall drain plug and

torque to 14-17 ft. lbs.

(1.93-2.35 kg/m)

7. Disconnect the lower

oil delivery hose.

Remove the fitting (C)

from the oil tank.

Clean the fitting screen.

Reinstall the fitting

screen, torquing to

14-17 ft. lbs. Reattach

oil line. If banjo fitting

(D) is used, torque to

14-17 ft. lbs. If hose

clamp (E) is used,

tighten securely.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

8. Place shop towels beneath oil filter. Using an oil filter wrench, turn

filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface on crankcase.

10. Lubricate the O-Ring on the new filter with a film of new engine oil.

Check to make sure the O-Ring is in good condition. Also make sure

the O-ring from the old filter is not still on the engine.

11. Install new filter and tighten by hand 1/2 to 3/4 turn after gasket

contact.

12. Approximately 1 cup of engine oil will remain in the crankcase. To

drain, remove drain plug found on lower right side of crankcase.

NOTE: The sealing surfaces on the drain plug and crankcase should

be clean and free of burrs, nicks or scratches.

13. Reinstall drain plug.

14. Remove dipstick and add 2 quarts (1.9 l) of Polaris Premium 4

synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add

about 1 3/4 quarts initially.

15. Place gear selector in neutral and set parking brake.

16. Start engine and let it idle for one to two minutes. Stop engine and

inspect for leaks.

17. Re-check oil level on the dipstick and add oil as necessary to bring the

level to the upper mark on the dipstick.

18. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance work:

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs.

50 Hrs.

75 Hrs.

100 Hrs.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level In-

spection

Front

Cover

NOTE: This procedure is only

required if the cooling system

has been drained for

Rack

maintenance and/or repair.

However, if the recovery bottle

has run dry, the level in the

radiator should be inspected and

coolant added if necessary.

WARNING

Never remove the pressure cap when the engine is warm or hot.

Escaping steam can cause severe burns. The engine must be

cool before removing the pressure cap.

To access the radiator pressure cap:

Remove the four screw securing front rack. Remove front cover by

placing your fingers under the front of the cover and pulling upward.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. If the cap should need

replacement contact your dealer for the correct replacement part.

To insure that the coolant maintains its ability to protect the engine, it

is recommended that the system be completely drained every two years

and a fresh mixture of antifreeze and water be added. Polaris

recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a

50/50 mixture of high quality aluminum compatible anti-freeze/coolant

and distilled water.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

Using a funnel, slowly add coolant as necessary through the radiator

filler neck.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle, located on

the left side of the machine,

must be maintained between the

minimum and maximum levels

indicated on the recovery bottle.

The engine coolant level is

Recovery

Bottle

controlled or maintained by the

recovery system. The recovery

system components are the

recovery bottle, radiator filler

neck, radiator pressure cap and

connecting hose.

As coolant operating

temperature increases, the

expanding (heated) excess

coolant is forced out of the engine past the pressure cap and into the

recovery bottle. As engine coolant temperature decreases the

contracting (cooled) coolant is drawn back up from the bottle past the

pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the

system is purging itself of trapped air. Observe coolant levels and

maintain as recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40

anti-freeze/coolant or a 50/50 mixture of high quality aluminum

compatible anti-freeze/coolant and distilled water.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

To access the recovery bottle on Gen IV machines it is necessary to

remove the left side panel as described on page 102.

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

It is recommended that the air filter be replaced yearly. When riding in

extremely dusty conditions replacement will be required more often.

1. Remove seat.

2. Remove spring clamps securing the airbox lid and remove lid.

3. Loosen clamp and remove filter.

4. Removefabrictypepre-filterfrom main filter. Wash pre-filterinsoapy

water and dry it.

5. Reinstall pre-filter over main filter. Replace main filter as required.

6. Reinstall filter into air box and tighten clamp. Do not over tighten

clamp or filter damage may occur.

CAUTION

Operation of your 6X6 without a breather filter can cause engine

damage.

Pre--filter

Main Filter

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Box Drain

Periodically check the air box drain tube located on the bottom rear of

the air box and empty if necessary.

Breather Filter and Hoses:

Operation of your vehicle without a breather filter can cause engine damage.

1. Remove the clamps and pull the

filter out of the hoses. NOTE:

It will not be necessary to

remove the lower hose from the

engine.

2. Inspect filter for debris. Blow

through gently in direction of

arrow on filter to check for

clogging. Replace as needed.

Breather

filter

3. Check hoses for cracks,

deterioration, abrasion, or leaks.

Replace as needed.

4. Reinstall filter and clamps with

arrow pointing toward engine. NOTE: The breather filter is

intended to be used with airbox pre-filter in place. Without the

pre-filter, the breather filter can clog quickly. Never operate your

vehicle without the pre-filter. NOTE: Inspect the filter monthly

or every 20 hours of operation, whichever comes first. Replace

filter as needed.

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MAINTENANCE AND LUBRICATION

Adjustments

WARNING

Do not attempt to adjust the tie rod for toe alignment. Severe injury

or death can result from improper adjustment. Contact your Polaris

dealer. He/she has the training and tools to make these

adjustments.

Toe Alignment

You can check the toe alignment of the

vehicle using the following method.

The recommended toe alignment is

1/8″ to 1/4″ toe out. If you discover

improper adjustment have your dealer

correct it.

1. Set handlebars in a straight ahead

position and hold them in this posi-

tion. NOTE: The steering frog can

be used as an indicator of whether

the handlebars are straight. The

frog should always point straight

back from the steering post.

2. Place stands in front of the ma-

chine, perpendicular to the rear

tires.

3. Tie an elastic string around the

stands, making sure string just

touches side surface of the rear tires

on each side of machine and goes

around the stands in front of the

machine.

4. Measure from string to rim at front and rear of front rim. Rear rim mea-

surement should be 1/16″ - 1/8″ (.2 to .3 cm) more than front rim mea-

surement.

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MAINTENANCE AND LUBRICATION

Adjustments

Steering Inspection

The steering assembly of the machine should be checked periodically

for loose nuts and bolts. If loose nuts and bolts are found, have your

dealer tighten them before riding your vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Handlebar Adjustment

Your 6x6 has handlebars

which can be adjusted for your

personal fit.

1. Remove handlebar cover

and loosen the four bolts.

2. Adjust handlebar to desired

height. Be sure handlebars

do not hit gas tank or any

other part of machine when

turned fully to left or right.

3. Torque handlebar adjuster block bolts to 10 to 12 ft. lbs.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the

adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death.

Optional Suspension Springs

Although your Polaris 6x6 suspension has the capability of providing

you with the best ride possible, the following accessory springs are

available to better suit your individual riding preference. NOTE:

Optional springs may be a different color than standard springs.

Owner may paint springs to desired color using Polaris touch up paint,

available through your dealer.

SOFT

FIRM

Sportsman 6x6 -

7041375-067

OPTION

64/113 lb/in

7041450-195

N/A

Front Strut Spring

STANDARD

101 lb/in

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MAINTENANCE AND LUBRICATION

Adjustments

Front Brake

Front Wheel and Middle Axle

Brake

The front and middle axle

brakes are hydraulic disc type

brakes which are activated by

the brake lever being moved

toward the handlebar. These

brakes are self-adjusting and

require no adjustment.

The following checks are

recommended to keep the

brake system in good

3/64″

(.1cm)

operating condition. How

often they need checking

depends upon the type of

driving that has been done.

Always keep brake fluid at

an adequate level (see

page 40). Normal func-

tioning of the diaphragm

is to extend into the reser-

voir as fluid level drops.

If the fluid level is low

and the diaphragm is not

extended, a leak is indi-

cated and the diaphragm

should be replaced. Al-

ways fill the reservoir as

indicated whenever the

cover is loosened or re-

moved to insure proper

diaphragm operation. Use

Polaris DOT 3 brake fluid

(PN 2870990).

Middle Axle Brake

Check brake system for fluid leaks.

Check brake for excessive travel or spongy feel.

Check friction pads for wear, damage and looseness.

Check security and surface condition of the disc.

Pads should be changed when worn to 3/64″ (.1 cm), or about the

thickness of a dime.

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Brake

The transmission brake is a

hydraulic disc type brake

which is activated by the same

lever which activates the front

brake system. The

transmission brake system is

self adjusting and requires no

maintenance other than

periodic checks of the pads for

wear.

3/64″ (.1 cm)

Wear Line

Pads should be changed

when worn to 3/64″ (.1

cm) which is about the

thickness of a dime.

Inspect the brake disc

spline and pad wear sur-

face for excessive wear.

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MAINTENANCE AND LUBRICATION

Adjustments

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the handlebar.

1. Slide the bolts off inline cable adjuster sleeve. Loosen adjuster

locknut.

2. Turn adjuster until 1/16″ to 1/8″ freeplay is achieved at thumb lever.

Flip throttle lever several times to confirm adjustment.

3. Tighten locknut and slide boots over cable adjuster until they touch at

the middle point of adjuster.

Adjuster

Sleeve

Boot

Locknut

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MAINTENANCE AND LUBRICATION

Adjustments

Wheel Removal Procedure

1. Stop the engine, place the transmission in gear and lock the parking

brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the

footrest frame.

4. Remove the wheel nuts and remove the wheel.

Wheel Installation

1. With the transmission in gear

and the parking brake locked,

place the wheel in the correct

position on the wheel hub. Be

sure the valve stem is toward

the outside and rotation ar-

rows on the tire point toward

forward rotation.

2. Attach the wheel nuts and fin-

Tapered side

of nut goes in

ger tighten them.

3. Lower the vehicle to the

ground.

Rear Wheel Assembly

4. Securely tighten the wheel

nuts to the following torque:

Torque center and rear wheel nuts to 50 ft. lbs. (6.9 kg/m).

Torque front wheel nuts to 20 ft. lbs. (2.1 kg/m).

CAUTION

If wheels are improperly installed it could affect vehicle handling and

tire wear. Make sure the tapered end of the rear wheel nut goes into

the taper on the wheel.

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MAINTENANCE AND LUBRICATION

Adjustments

Tire Inspection

CAUTION

Maintain proper tire pressure according to charts below. Improper

tire inflation may affect vehicle maneuverability.

When replacing a tire always use original equipment size and type.

The use of non-standard size or type tires may affect vehicle

handling.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less.

Tread

Depth 1/8I

(.3 cm)

WARNING

Operating your 6x6 with worn tires will increase the possibility of

the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

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MAINTENANCE AND LUBRICATION

Adjustments

Tire Specifications

Sportsman 6x6

Front - 25 x 8.00 -12

Inflation Pressure - 5 PSI

Center - 25 x 11.00 - 10

Inflation Pressure - 5 PSI

Rear - 25 x 11.00 - 10

Inflation Pressure - 5 PSI

Cargo Bed Load Capacity

800 lbs. (363 kg)

Front Rack Load Capacity

75 lbs. (34 kg)

Gross Vehicle Weight 1970 lbs.

(894 kg) including vehicle, driver and cargo. Vehicle weighs

895 lbs. (406 kg).

The following items should be checked occasionally for tightness; or if

they have been loosened for maintenance service.

Axle and Wheel Nut Torque Specifications

Item

Specification

100 In. Lbs.

20 Ft. Lbs.

80 Ft. Lbs.

50 Ft. Lbs.

Front Spindle Nut(s)

Front Wheel Nuts

Center and Rear Axle Nut(s)

Center and Rear Wheel Nuts

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. Service work must be performed by your

authorized Polaris dealer.

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MAINTENANCE AND LUBRICATION

Adjustments

Front Drive Chain Adjustment

CAUTION

Never adjust or operate the vehicle with the drive chain slack out

of the 3/16″-3/8″ (.48 cm - .95 cm) specification. Severe damage

to the transmission and drive components can result.

Check the amount of chain

slack by moving the vehicle

slightly forward to gain slack at

the top side of the front chain.

Then pull up and down on the

chain. At this point the chain

should have 3/16″-3/8″ (.48 cm

Proper

- .95 cm) deflection. If the

Splicelink Clip

chain needs adjustment, use the

following procedure.

Opening

Position

Adjustment Procedure

1. Loosen chain guide.

2. Loosen two eccentric locking

bolts.

Front Drive Chain Adjustment

3. Loosen caliper mount bolts.

4. Insert a pin punch through the

sprocket hub and into the ec-

centric axle housing.

5. Roll the vehicle ahead or back

to adjust chain slack to the

proper dimension.

6. Tighten caliper mount bolts 10-12 ft. lbs. (1.4 - 1.7 kg/m).

7. Tighten the eccentric locking bolts to 45 ft. lbs. (6.2 kg/m).

8. Confirm correct tension by rolling the 6x6 forward, checking chain

tension in several places around the chain.

9. Reinstall chain guard.

NOTE: Reposition chain guide to allow 1/8″ (.3 cm) clearance

between sprocket and guide.

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Axle Drive Chain Adjustment

All procedures used in adjusting the front chain apply to the rear chain

adjustment. Total slack for the rear chain, however, should be adjusted

to 1/4″-1/2″ (.6-1.3 cm).

3/16″-3/8″

(.48 cm - .95 cm)

1/4″-1/2″ (.6-1.3 cm)

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MAINTENANCE AND LUBRICATION

Adjustments

Carburetor/Engine Idle RPM Adjustment

Recommended engine idle RPM is 1200

+/- 200. If the engine idle speed is not

satisfactory, and all other conditions are

favorable, the carburetor can be adjusted

as follows:

If the engine idle speed is not satisfactory,

and all other conditions are favorable, the

carburetor can be adjusted as follows:

1. Warm up the engine by running the ve-

hicle approximately five minutes.

Idle Screw

2. Place the transmission in gear with the parking brake applied.

3. Adjust the carburetor idle screw in or out until the desired idle RPM

is reached. Turning the screw in (clockwise) will raise RPM. Turning

the screw out (counterclockwise) will lower RPM.

100

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MAINTENANCE AND LUBRICATION

Adjustments

Carburetor Adjustments

If the vehicle is to be operated at various altitudes and temperatures,

certain adjustments can be made to improve its operation and

driveability. Above 6000 feet (1800 m) the engine air/fuel mixture

becomes overly rich. An engine loses approximately 3% of its power

for each 1000 foot (304.8 m) increase in elevation. Although this

power cannot be regained, changes to the carburetor and drive system

can be made to allow efficient operation. These changes include:

1. Carburetor re-jetting to compensate for atmospheric pressure and oxy-

gen loss.

2. Transmission convertor modification to adjust for engine horsepower

loss. Contact your dealer.

Contact your dealer for altitude adjustments. They have the training

and special tools required to perform all necessary modifications for

you.

Pilot screws are sealed with metal plugs and are serviceable only by

dealers.

Jetting Chart

AMBIENT TEMPERATURE

2002 Sportsman 6x6

Below 40_F

Below 5_C

Above 40_F

Above 5_C

0-1800

147.5

142.5

Altitude

Meters

(Feet)

(0-6000)

Over 1800

(Over 6000)

140

135

101

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MAINTENANCE AND LUBRICATION

Adjustments

Side Panel Removal

1. Side panel removal may

be difficult until the

locking tabs and

Step 1.

receivers have been

snapped and unsnapped

a few times.

2. Remove seat. Grasp

rear of side panel near

rear cab. With a quick

and firm motion, pull

the panel forward and

outward to disengage

the two rear tabs.

Pull forward and out to disengage

two rear tabs.

Step 2.

3. Place hand on top of

side panel behind the

fuel tank. With a quick

and firm motion, push

down on the side panel

to disengage the top

rear two tabs. Then

pull up on side panel to

disengage front upper

and lower tab.

Push down to disengage top rear

two tabs.

Step 3.

4. To reinstall side panel,

align panel tabs with

slots on front cab. Push

panel upward and

To reinstall, align panel tabs with

slots. Push upward and forward un-

til tabs lock.

forward until tabs lock.

Bend rear of side panel

and insert the two tabs into

the rear cab.

102

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MAINTENANCE AND LUBRICATION

Spark Plugs

Use NGK BKR5ES spark plugs.

Proper electrode gap is .025″ (.06 cm).

Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11

ft. lbs (1.52 kg/m) for a new spark plug.

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine is warmed up and

the vehicle is driven at higher speeds. Immediately check the spark

plug for correct color.

1. Normal

The insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect

carburetion adjustments.

2. Wet Fouled

The insulator tip is black. A damp oil film covers the firing end.

There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes are excessive oil, use of

non-recommended injection oil, improper use of the choke, or incorrect

carburetion adjustments.

Spark Plug Removal and Replacement

WARNING

Never attempt to remove a spark plug while the engine is warm.

The exhaust system or engine could burn you causing severe

injury.

The spark plug is removed by using the special wrench provided in the

tool pouch under the seat. Reach under the right hand fender and then

back for access. Remove the spark plug cap and then the spark plug by

rotating counterclockwise.

Reverse the procedure for spark plug installation. Torque to 17 ft. lbs.

(2.3 kg/m). Never deviate from the recommended spark plug as engine

damage can occur.

103

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MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Because exhaust system temperatures can reach 1000°F, do

not perform this operation immediately after the engine has

been run because the exhaust system becomes very hot.

Because of the increased fire hazard, make sure that there are

no combustible materials in the area when purging the spark

arrestor.

Wear eye protection.

Do not stand behind or in front of the vehicle while purging

the carbon from the spark arrestor.

Never run the engine in an enclosed area. The exhaust con-

tains poisonous carbon monoxide gas.

Do not go under the machine while it is inclined.

Failure to heed these warnings could result in serious personal injury

or death.

104

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MAINTENANCE AND LUBRICATION

Spark Arrestor (Cont.)

The exhaust pipe must be periodically purged of accumulated carbon as

follows:

1. Remove the cleanout

plug (A) located on the

bottom of the muffler as

shown above.

2. Place the transmission in

neutral and start the en-

gine. Purge accumulated

carbon from the system

by momentarily revving

the engine several times.

3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe

around the cleanout plug while revving the engine several more times.

4. If particles are still suspected to be in the muffler, back the machine

onto an incline so the rear of the machine is one foot higher than the

front. Set the parking brake and block the wheels. Make sure the ma-

chine is in neutral and repeat steps 2 and 3.

5. If particles are still suspected to be in the muffler, drive the machine

onto the incline so the front of the machine is one foot higher than the

rear. Set the parking brake and block the wheels. Make sure the ma-

chine is in neutral and repeat steps 2 and 3.

6. Repeat steps 2 through 5 until no more particles are expelled when the

engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the arrestor plug.

105

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MAINTENANCE AND LUBRICATION

Recoil Housing

Drain the recoil housing

after operating the vehicle

in very wet conditions.

This should also be done

before storing the vehicle.

The drain screw is located

at the bottom of the recoil

housing. Remove the screw

with a 10mm wrench.

Crankcase Drain

Reinstall screw once

housing has been drained.

Water will enter the recoil

housing if the starter handle

is disengaged from the rope

guide when under water.

Recoil Drain (above front

propshaft on shaft drive models)

After travelling in wet areas the recoil housing and starter should

always be drained completely by removing the recoil.

Do not open the crankcase drain unless the engine has ingested water.

On 4-cycle engines, some engine oil will be lost if crankcase drain is

opened.

106

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MAINTENANCE AND LUBRICATION

PVT System

WARNING

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

testing has been conducted to insure the safety of this product.

However, as the owner you have the following responsibilities to

make sure this system remains safe:

D Do not modify any component of the PVT system. Doing so may

reduce its strength so that a failure may occur at high speeds.

This system has been precision balanced. Any modification will

cause the system to be out of balance, creating vibration and

additional loads on components.

D Routine maintenance is the responsibility of the owner. Always

follow recommended maintenance procedures. See your deal-

er!

This PVT system is intended for use on Polaris products only.

The PVT housing must be securely in place during operation.

Failure to comply with this warning can result in severe injury

or death.

107

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MAINTENANCE AND LUBRICATION

WARNING

Battery

Whenever removing the battery, disconnect the negative (black)

cable first. When reinstalling the battery, connect the negative

(black) cable last or an explosive situation could result causing

serious injury or death.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious

burns can result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk

of magnesia, beaten egg, or vegetable oil. Call physician

immediately.

Eyes: Flush with water for 15 minutes and get prompt medical

attention.

Batteries produce explosive gases. Keep sparks, flame,

cigarettes, etc. away. Ventilate when charging or using in an

enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

Replenishing the Battery Fluid

A poorly maintained battery will

deteriorate rapidly. Check the

battery fluid level often. The fluid

level should be kept between the

upper and lower level marks.

Maintain

between

upper and

lower level

marks

To refill use only distilled water.

Tap water contains minerals which

are harmful to a battery.

108

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MAINTENANCE AND LUBRICATION

Battery

Battery Removal

1. Disconnect hold down straps holding the electrical box and battery in

position and remove battery cover.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable next.

5. Lift the battery out of the ATV, being careful not to tip it sideways and

spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to

the ATV.

Battery Installation and Connections

WARNING

To avoid the possibility of explosion, always connect battery cables

in the order specified. Red (positive) cable first; black (negative)

cable last. An exploding battery can cause serious injury or death.

Battery terminals and connections should be kept free of corrosion.

If cleaning is necessary, remove the corrosion with a stiff wire brush.

Wash with a solution of one tablespoon baking soda and one cup water.

Rinse well with tap water and dry off with clean rags. Coat the

terminals with dielectric grease or petroleum jelly.

Be careful not to allow cleaning solution or tap water into the battery.

109

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MAINTENANCE AND LUBRICATION

Battery

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions and se-

curely installed. If not, battery gases could accumulate and cause an

explosion. The tube should be routed away from the frame and body

to prevent corrosion. Avoid skin contact with electrolyte, severeburns

could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall battery cover and attach the hold down strap.

6. Verify that cables are properly routed.

NOTE:

When your ATV is placed in storage for three months or more, the

battery should be removed, charged to proper level, and stored in a

cool dry place.

Before reusing, take the battery to your dealer for testing and re-

charging.

Power plug leads may need to be bent down so that the battery cov-

er may be installed.

When installing a new battery, make certain it is fully charged prior

to it’s initial use. Using a new battery that has not been fully

charged can damage the battery resulting in a shorter life of the

battery. It can also hinder vehicle performance.

WARNING

Indicates a potential hazard that could result in serious injury or

death.

110

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MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement

Headlight Lamp Replacement

WARNING

Due to the nature of these vehicles and where they are ridden,

headlight and taillight lenses become dirty. Frequent washing is

necessary to maintain lighting quality. Poor lighting while riding

can result in severe injury or death

Snap pins

into tabs

Position

Slip O-Ring

over pin

knob in

slot and

Route plug

secure in

over

Adjustment

Knob Stop

locking

tabs

handlebar

1. Using a small flat blade screwdriver, push in on the lock tab

through the two small openings at the front of the headlight pod.

2. Lift the pod lightly while depressing the tabs.

3. Remove the screw in the back of the headlight pod

4. Lift pod cover up. Disconnect speedometer harnesses from

speedometer. Unplug indicator light harness and remove pod

cover.

5. Unplug headlamp from wiring harness.

6. Remove boot and locking collar from back of lamp housing.

7. Grasp base of lamp and lift it out.

8. Reverse previous steps to replace lamp and reassemble pod. Make

sure tab on lamp locates properly in housing.

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MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement

High Beam Headlight Adjustment

The headlight beam can be adjusted to any position desired by turning

the adjusting knob located on the bottom right side of the headlight

pod.

1. Place the vehicle on a level surface with the headlight approximately

25’ (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and

make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight beam

should be aimed 2″ (5.1 cm) below the mark placed on the wall in step

2. NOTE: Rider weight must be included on the seat.

5. Adjust beam to desired position by turning the adjustment knob.

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MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement

Headlight Housing Replacement

1. Remove Phillips screws from bottom of headlight pod at each front

corner. NOTE: To aid in accessing these screws, it may be helpful

to turn handlebars to left or right and use a short, stubby screwdriver.

Removal of the front rack and cover may also allow easier access.

2. Remove three Phillips screws at

back of headlight pod.

O-Ring

3. Lift pod cover up. Disconnect

speedometer harnesses from

speedometer. Unplug indicator

light harness and remove pod cov-

er.

4. Unplug headlamp from wiring har-

ness.

5. Remove O-Ring from headlight

pivot pins.

6. Pull headlight housing up to re-

lease from locking tabs.

7. Lift adjusting knob up to remove

from locking tabs.

5 1/8″

(13 cm)

8. Carefully pull assembly up and out

Distance from headlamp parting

of pod.

line to end of adjustment knob stop

is 5 1/8″ (13 cm).

9. Reverse steps to install new hous-

ing and reassemble pod.

10.Adjust headlight aim by turning

adjusting knob.

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MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement

Taillight/Brakelight Lamp Replacement

If the taillight/brakelight does not

work the lamp may need to be

replaced.

Lens

1. Remove the taillight assembly by

removing the two screws securing

Lamp

it to the vehicle.

Lamp

Harness

2. Twist the lamp harness 1/4 turn to

release the lock. Pull the lamp har-

ness out of the back of the assem-

bly.

3. Remove the lamp from the harness

and replace it with the recom-

mended lamp.

4. Test the taillight/brakelight to see

that it’s working.

Taillight Assembly

5. Replace the lamp harness into the

back of the taillight assembly, twist-

ing 1/4 turn to lock in place.

6. Reinstall the taillight assembly to

the vehicle.

Indicator Lamp Replacement

1. Follow steps 1 - 3 of Headlight

Housing Replacement on pre-

vious page.

2. Unplug light from harness.

3. Using a screwdriver, turn the light

1/4 turn counter clockwise.

4. Install new light and use a screw-

driver to seat it into place, 1/4 turn

clockwise.

5. Reassemble pod.

114

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Cleaning the 6x6

Keeping your 6x6 clean will not only improve its appearance but it can

also extend the life of various components. With a few precautions,

your 6x6 can be cleaned much like an automobile.

Washing the 6x6

If a high pressure type car wash system is used, extreme care must be

taken to avoid water damage to the drive chain, wheel bearings,

transmission seals, body panels, brakes and warning labels. Many

expensive repair bills can result from using high pressure detergent

systems.

The best and safest way to clean your 6x6 is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots.

Waxing the 6x6

Your 6x6 can be waxed with any quality brand automotive paste wax.

Avoid the use of harsh cleaners since they can scratch the body finish.

115

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage of the 6x6

If your 6x6 is to be placed in

extended or off season storage,

the following steps should be

taken to preserve its condition.

1. Perform all necessary repairs

and thoroughly clean the ve-

hicle.

Drain tube

attached

here

2. Turn the fuel valve to “off” and

drain the carburetor.

3. Remove the spark plug and

pour approximately one ounce

of Premium 4 oil into the cylin-

der. Operatethestarter for a few

seconds and reinstall the spark

plug.

Drain Screw

4. Remove the battery. Store it in a cool, dry place out of the sun.

5. Lubricatesuspension pivot points, lowersteering post and rearaxlefit-

tings.

6. Drain the recoil housing.

7. Block the vehicle so all tires are suspended off the ground.

8. Cover the vehicle with a canvas cover. Do not use plastic or coated

materials since they do not allow ventilation of the vehicle.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Transporting the 6x6

Whenever the 6x6 is to be transported the following measures should

be taken.

1. Turn the fuel valve to “off.”

2. Be certain the fuel cap and oil cap are installed correctly.

3. Always tie the vehicle to the transporting unit securely using suitable

straps and/or rope.

4. Always place the transmission in gear and lock the parking brake.

Accessories

Polaris has a wide variety of accessories for your 6x6. Contact your

Polaris dealer for a complete list.

117

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SPECIFICATIONS

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48″

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46″

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105″

Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.5″

Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35″

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5″

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 895 lbs.

Front Susp. - MacPherson Strut . . . . . . . . . . . . . . . . . . . . . . 6.7″ Travel

Rear Susp. - (Swing Arm with Scissor Stabilizer) . . . . . . . 7.5″ Travel

Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 x 8 - 12

Center Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 x 11 - 10

Rear Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 x 11 - 10

Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Disc Hydraulic

Floating Caliper

Rear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Disc Hydraulic

Floating Caliper

Auxiliary Brake . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Disc Hydraulic

Floating Caliper

Fuel Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 U.S. Gal.

Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 U.S. Qts.

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 60W

Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USFS Approved

Front Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard

Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard

Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard

Gross Vehicle Weight . . . . . . . . . . . . . . . . . . . . . . . 1970 lbs., including

machine, driver & cargo

Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Lbs. Front

800 Lbs. Cargo Bed

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVT

Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hi/Lo-R-N

Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520 - O Ring

Turn Radius (Unloaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98″

Final Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . 12/38 - 80 Pitch

Axle to Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30/30 - 116 Pitch

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SPECIFICATIONS

Engine Specifications

2002 Sportsman 6x6

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EH50PLE-06

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499 cc

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cylinder

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid

Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 x 75 mm

Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Sump

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric/Manual

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BKR5E (NGK)

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250W

Comp. Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2:1 Full Stroke

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° @ 3500

Carburetion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/BST34 (CV Type)

Main Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.5

Pilot Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4HB41-3

Needle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-4(829)

Pilot Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Polaris Industries Inc. reserves the right to make changes in design and

specifications and/or to make additions or improvements to its products

without notice.

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WIRING DIAGRAM

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TROUBLESHOOTING

Clutch Drive Belt & Cover Related Issues: Diagnosis

Possible Causes

Solutions/What to do

Loading the 6x6 into a pick- Shift transmission to low range during

up or tall trailer when in high loading of the 6x6 to prevent belt burn-

range.

ing.

Starting out going up a

steep incline.

When starting out on an incline, use

low range, or dismount the 6x6 after

first applying the park brake and per-

form the “K” turn as described on page

67 of this manual.

Driving at low RPM or low

ground speed (at approxi-

mately 3--7 MPH).

Drive at higher speed or use Low

Range. The use of Low Range is high-

ly recommended for cooler PVT oper-

ating temperatures and longer compo-

nent life.

Insufficient warm--up of

6x6s exposed to low ambi-

ent temperatures.

Warm engine at least 5 min., then with

transmission in neutral, advance

throttle to approx. 1/8 throttle in short

bursts, 5 to 7 times. The belt will be-

come more flexible and prevent belt

burning.

Slow and easy clutch en-

gagement.

Fast, effective use of the throttle for

efficient engagement.

Towing/Pushing at low

RPM/low ground speed.

Use Low Range only.

Plowing snow, dirt, etc./util- Use Low Range only.

ity use.

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TROUBLESHOOTING

Possible Causes

Solutions/What to do

Stuck in mud or snow.

Shift the transmission to Low Range,

carefully use fast, aggressive throttle

application to engage clutch. WARN-

ING: Excessive throttle may cause

loss of control and vehicle overturn.

Climbing over large objects Shift the transmission to Low Range,

carefully use fast, brief, aggressive

throttle application to engage clutch.

WARNING: Excessive throttle may

cause loss of control and vehicle over-

turn.

from a stopped position.

Belt slippage from water or Shift the transmission to neutral. Using

snow ingestion into the PVT the throttle, vary the engine rpm from

system.

idle to full throttle. Repeat several

times as required. During this proce-

dure, the throttle should not be held at

the full position for more than 10 sec-

onds. Clutch seals should be inspected

for damage if repeated leaking occurs.

Clutch malfunction.

For inspection of clutch components,

please contact your Polaris dealer.

Poor engine performance.

Fouled plugs, foreign material in gas

tank, fuel lines, or carburetor. Contact

you dealer for further service informa-

tion.

GENERAL RANGE OPERATION GUIDELINES:

Low Range

Heavy pulling, basic operational

speeds less than 7 MPH, riding

through rough terrain (swamps, moun-

tains, etc.), low ground speeds.

High Range

High ground speeds, speeds above 7

MPH.

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TROUBLESHOOTING

The following information is provided to help you identify probable

causes for questions you may have about the operation of your vehicle.

See your Polaris dealer with any additional questions you may have.

ENGINE CRANKS BUT FAILS TO START

Stop Switch Off

No Fuel

Water in Fuel

Drain System

Spark Plug

No Spark to

Spark Plug

Fuel Valve Off

Clogged Fuel

Valve

Contact Your

Dealer

ENGINE STOPS OR LOSES POWER

Overuse of

Choke

Spark Plug

Fouled

Engine

Overheated

No Fuel

Turn Fuel Valve

to “Res”

Air Filter

Clogged

Clean Radiator

screen

Fuel Vent Line

Kinked or

Reverse Speed

Limiter

Malfunction

Clean Engine

Exterior

Plugged

Contact Your

Dealer

Water in Fuel

Electronic

Throttle Control

Malfunction

Contact Your

Dealer

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WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 1225 Highway 169 North, Minneapolis,

Minnesota 55441-5078, gives a SIX MONTH LIMITED WARRANTY

on all components of the Polaris Light Utility Vehicle 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. This warranty

begins on the date of purchase. This warranty is transferrable to

another consumer during the warranty period through a Polaris dealer.

There is a charge of $35.00 payable to Polaris Industries Inc.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed

by your dealer and submitted to Polaris within ten days. Upon receipt

of this registration, Polaris will record the registration for warranty.

THE PURCHASER MUST COMPLETE A SAFETY TRAINING

COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE

VALID WARRANTY ON THE VEHICLE. No verification of

registration will be sent to the purchaser as the copy of the Warranty

Registration Form will be the warranty entitlement. If you have not

signed the original registration and received the “customer copy”,

please contact your dealer immediately. NO WARRANTY

COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS

REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in

ensuring trouble-free operation. Purchasing a machine in the crate or

without proper dealer set-up will void your warranty coverage.

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.

This warranty also does not cover any vehicle that has been altered

structurally, neglected, improperly maintained, used for racing, or used

for purposes other than for which it was manufactured, or for any

damages which occur during trailer transit or as a result of

unauthorized service or the use of unauthorized parts. In addition, this

warranty does not cover physical damage to paint or finish, stress

cracks, tearing or puncturing of upholstery material, corrosion, or

defects in parts, components or the vehicle due to fire, explosions or

any other cause beyond Polaris’ control.

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WARRANTY

This warranty does not cover the use of unauthorized lubricants,

chemicals, or fuels that are not compatible with the vehicle. The

exclusive remedy for breach of this warranty shall be, at Polaris’

exclusive option, repair or replacement of any defective materials, or

components or products. THE REMEDIES SET FORTH IN THIS

WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY

PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR

IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR

OTHER TORT OR OTHERWISE. Some states do not permit the

exclusion or limitation of incidental or consequential damages or

implied warranties, so the above limitations or exclusions may not

apply to you if inconsistent with controlling state law.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED

TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN

DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD.

POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow

limitations on how long an implied warranty lasts, so the above

limitation may not apply to you if inconsistent with controlling state

law.

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a Polaris

Servicing Dealer. When requesting warranty service you must present

your copy of the Warranty Registration form to the dealer. (THE

COST OF TRANSPORTATION TO AND FROM THE DEALER IS

YOUR RESPONSIBILITY). Polaris suggests that you use your

original selling dealer; however, you may use any Polaris Servicing

Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should

your dealer require any additional assistance they will contact the

appropriate person at Polaris.

This warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all

other warranty terms will remain in effect.

Engine Oil

1. Always use Polaris engine oil.

2. Never substitute or mix oil brands as serious engine damage and

voiding of warranty can result.

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . . . . . 117

Adjustments . . . . . . . . . . . . . . . . . . . 90-102

Air Box Drain . . . . . . . . . . . . . . . . . . . . . 89

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . 88

All Wheel Drive . . . . . . . . . . . . . . . . . . . 48

Backing Up . . . . . . . . . . . . . . . . . . . . . 69-70

Battery Fluid . . . . . . . . . . . . . . . . . . . . . 108

Battery Installation . . . . . . . . . . . . . . . . 109

Battery Maintenance . . . . . . . . . . . . 108-110

Battery Removal . . . . . . . . . . . . . . . . . . 109

Brake, Auxiliary . . . . . . . . . . . . . . . . . . . 41

Brake, Front . . . . . . . . . . . . . . . . . . . . . . 92

Brake, Parking . . . . . . . . . . . . . . . . . . . . 42

Brake, Rear . . . . . . . . . . . . . . . . . . . . . . . 93

Brakelight Lamp Replacement . . . . . . . . 114

Brakes, Front . . . . . . . . . . . . . . . . . . . . . 40

Brakes, Rear . . . . . . . . . . . . . . . . . . . . . . 40

Breather Filter . . . . . . . . . . . . . . . . . . . . . 89

Camber And Caster . . . . . . . . . . . . . . . . 91

Carburetor Adjustment . . . . . . . . . . . . . 100

Carburetor Adjustments . . . . . . . . . . . . 101

Carrying Loads . . . . . . . . . . . . . . . . . . 54-56

Choke Adjustment . . . . . . . . . . . . . . . . . 94

Choke Lever . . . . . . . . . . . . . . . . . . . . . . 39

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 115

Controls . . . . . . . . . . . . . . . . . . . . . . . 37-46

Controls And Features . . . . . . . . . . . . 37-49

Coolant Level . . . . . . . . . . . . . . . . . . . . . 87

Coolant Level Inspection . . . . . . . . . . . . 86

Crossing Streams . . . . . . . . . . . . . . . . . . 68

Daily Pre -ride Inspection . . . . . . . . . . 51, 58

Disengaging Wheel Hubs . . . . . . . . . . . . 49

Drive Chain Adjustment . . . . . . . . . . . 98-99

Dumping Cargo Bed . . . . . . . . . . . . . . . . 56

Engine Cooling System . . . . . . . . . . . 86-87

Engine Electrical Switches . . . . . . . . . . . 38

Engine Idle Rpm Adjustment . . . . . . . . 100

Engine Specifications . . . . . . . . . . . . . . . 119

Features . . . . . . . . . . . . . . . . . . . . . . . 47-49

Filter Systems . . . . . . . . . . . . . . . . . . . 88-89

Lubrication Recommendations . . . . . . 77-84

Main Switch . . . . . . . . . . . . . . . . . . . . . . 38

Maintenance And Lubrication . . . . . 73-117

Maintenance Record . . . . . . . . . . . . . . . . 85

Making Turns . . . . . . . . . . . . . . . . . . . . . 61

Noise Control System . . . . . . . . . . . . . . . 57

Oil Change . . . . . . . . . . . . . . . . . . . . . . . 83

Oil Filter Change . . . . . . . . . . . . . . . . . . 83

Oil System . . . . . . . . . . . . . . . . . . 43-44, 82

Operating Safety . . . . . . . . . . . . . . . . . . . 56

Operation . . . . . . . . . . . . . . . . . . . . . . 50-55

Operator Safety . . . . . . . . . . . . . . . . . . 21-36

Parking On An Incline . . . . . . . . . . . . . . 72

Periodic Maintenance Schedule . . . . . 74-76

Premium 4 Synthetic Lubricant . . . . . . . 82

Pvt System . . . . . . . . . . . . . . . . . . . . . . 107

Recoil Starter . . . . . . . . . . . . . . . . . . . . . 46

Riding . . . . . . . . . . . . . . . . . . . . . . . . . 58-72

Riding Gear . . . . . . . . . . . . . . . . . . . . . . 12

Riding On Slippery Surfaces . . . . . . . 63-64

Riding Safely . . . . . . . . . . . . . . . . . . . 59-72

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Safety Decals And Locations . . . . . . . 13-20

Safety Training . . . . . . . . . . . . . . . . . . . . .

Serial Number . . . . . . . . . . . . . . . . . . . . . .

Side Panel Removal . . . . . . . . . . . . . . . 102

Sidehilling . . . . . . . . . . . . . . . . . . . . . . . 62

Spark Arrestor . . . . . . . . . . . . . 57, 104-106

Spark Plug Removal103

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . 103

Specifications . . . . . . . . . . . . . . . . . 118-119

Starting A Cold Engine . . . . . . . . . . . . . . 52

Starting A Warm Engine . . . . . . . . . . . . . 53

Steering Inspection . . . . . . . . . . . . . . . . . 91

Stop Switch . . . . . . . . . . . . . . . . . . . . . . . 38

Storage Of The 6x6 . . . . . . . . . . . . . . . . . 116

Suspension Springs . . . . . . . . . . . . . . . . . 91

Table Of Contents . . . . . . . . . . . . . . . . . . 4-5

Taillight Lamp Replacement . . . . . . . . . . 114

Throttle Lever . . . . . . . . . . . . . . . . . . . . . 39

Tire Inspection . . . . . . . . . . . . . . . . . . . . 96

Tire Specifications . . . . . . . . . . . . . . . . . 97

Toe Alignment . . . . . . . . . . . . . . . . . . . . 90

Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Torque Specifications . . . . . . . . . . . . . . . 97

Towing Capacities . . . . . . . . . . . . . . . . . 54

Trail Obstacles . . . . . . . . . . . . . . . . . . . . 71

Transmission Gear Selector Operation . . 45

Transmission Lubrication . . . . . . . . . . . . 80

Transmission Oil Changing . . . . . . . . . . 80

Transporting The 6x6 . . . . . . . . . . . . . . . 117

Traveling Downhill . . . . . . . . . . . . . . . . . 65

Traveling Uphill . . . . . . . . . . . . . . . . . . . 66

Troubleshooting . . . . . . . . . . . . . . . 121-123

Turning Around On A Hill . . . . . . . . . . . 67

Frame VIN . . . . . . . . . . . . . . . . . . . . . . . .

Front Gearcase Lubrication . . . . . . . . . . 81

Front Wheel Hub Tightening . . . . . . . . . 97

Fuel System . . . . . . . . . . . . . . . . . . . . 43-44

Gearcase Oil Changing . . . . . . . . . . . . . 81

Handlebar Adjustment . . . . . . . . . . . . . . 91

Headlight Adjustment . . . . . . . . . . . . . . . 112

Headlight Housing Replacement . . . . . . 113

Headlight Lamp Replacement . . . . . . . . 111

Identification Numbers . . . . . . . . . . . . . . .

Indicator Lamp Replacement . . . . . . . . . 114

Indicator Lights . . . . . . . . . . . . . . . . . . . 47

Jetting Chart . . . . . . . . . . . . . . . . . . . . . 101

Light Switches . . . . . . . . . . . . . . . . . . . . 47

Lights-Adjustment-Replacement . . 111-114

Load Distribution . . . . . . . . . . . . . . . . . . 59

126

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INDEX

Welcome . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Break -in Period . . . . . . . . . . . . . 50

Vehicle Identification Numbers . . . . . . . .

Vehicle Nomenclature . . . . . . . . . . . . . . . 37

Warranty . . . . . . . . . . . . . . . . . . . . . 124-125

Wheel Installation . . . . . . . . . . . . . . . . . . 95

Wheel Removal . . . . . . . . . . . . . . . . . . . 95

Wiring Diagram . . . . . . . . . . . . . . . . . . 120

Understanding Warnings . . . . . . . . . . . . .

127

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