Polaris 2002 ATV Sportsman 6X6- Manuals

Page 2 - WARNING; The engine exhaust from this

WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm.

Page 3 - Indicates a potential hazard that could result in serious

Indicates a potential hazard that could result in serious injury or death. WARNING

Page 5 - WELCOME

2 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 se...

Page 6 - KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!; protection of our environment.; SAFETY TRAINING; dealer, you can obtain this safety training at no charge from any; SEVERE INJURY OR DEATH.

3 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 dis...

Page 7 - TABLE OF CONTENTS

4 TABLE OF CONTENTS Vehicle Identification Numbers 6 . . . . . . . . . . . . . . Safety 7 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding Warnings 7 . . . . . . . . . . . . . . . . . . . . . . . . . Key Safety Issues 8 . . . . . . . . . . . . . . . . . . . . . . ...

Page 8 - Maintenance and Lubrication

5 TABLE OF CONTENTS Maintenance and Lubrication 73 - 117 . . . . . . . . . . Tools 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic Maintenance Schedule 74 . . . . . . . . . . . . . . . . . . Lubrication Recommendations 77 . . . . . . . . . . . . . . . . ...

Page 9 - VEHICLE IDENTIFICATION NUMBERS; Record these numbers from your vehicle in the spaces; Engine Serial Number (Right front side of engine crankcase); were stolen these numbers are essential to the recovery and; Dealer Imprint; Remove the spare key and store in a safe place. Your key can be

6 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) The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obt...

Page 10 - SAFETY; Understanding Warnings; are used. Become familiar with their meanings before reading the

7 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 manu...

Page 11 - Key Safety Issues; Protect Your Sport; permission of Polaris Industries Inc.

8 SAFETY Key Safety Issues Protect Your Sport Know all local, state/province riding laws;Respect your vehicle;Respect the environment; andYou will gain the respect of others.We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is ...

Page 12 - SERIOUS INJURY OR DEATH can result if you do not; Take a

9 SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions: S Read this manual and all labels carefully and follow the operating procedures described. S Never operate this vehicle without proper instruction. Take a training course. Beginners should receive ...

Page 15 - Safe Riding Gear

12 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 r...

Page 16 - Safety Decals and Locations; for a replacement. Any safety decal needing replacement will be

13 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 rep...

Page 17 - MAXIMUM WEIGHT CAPACITY

14 SAFETY Safety Decals and Locations 1 2 DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitchMaximum Front Rack Load 75 lbs. IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR...

Page 22 - Moving parts hazard under belt-clutch guard. To; NO STEP

19 SAFETY Safety Decals and Locations 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 ...

Page 23 - ATTENTION

20 SAFETY Safety Decals and Locations (On Hitch) TRAILER MAX WEIGHT:1225 LBS. (557 KG) ON LEVEL GROUND850 LBS. (368 KG) UP TO 15 GRADE HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16 KG) 7078261 ATTENTION D Operation of this vehicle without the filter element will severely damage the engine. D Clean air fil...

Page 24 - Operator Safety; not know how to operate the vehicle properly in different

21 SAFETY Operator Safety POTENTIAL HAZARDOperating this vehicle without proper instruction.WHAT CAN HAPPENThe 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 HAZARDB...

Page 26 - increases your chances of a severe injury in the event of an

23 SAFETY Operator Safety POTENTIAL HAZARDOperating this vehicle on public streets, roads or highways.WHAT CAN HAPPENYou can collide with another vehicle.HOW TO AVOID THE HAZARDNever operate this vehicle on any public street, road or highway, even a dirt or gravel one.In many states it is illegal to...

Page 27 - described in the Owner’s Manual. See page 67. In the event of

24 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENCould result in vehicle overturning.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If you lose all forward speed:Keep weight uphill.Apply th...

Page 28 - and operating conditions and your experience.; obstacles or people behind you. When it is safe to proceed, go

25 SAFETY Operator Safety POTENTIAL HAZARDOperating this vehicle at excessive speeds.WHAT CAN HAPPENIncreases your chances of losing control of the vehicle, which can result in an accident.HOW TO AVOID THE HAZARDAlways travel at a speed which is proper for the terrain, visibility and operating condi...

Page 29 - schedules described in the Owner’s Manual.

26 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the vehicle before operating.Failure to properly maintain the vehicle.WHAT CAN HAPPENIncreases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your 6x6 each time you use it to make sure it is in saf...

Page 30 - cautious in order to reduce the chance of skidding or sliding out

27 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra care when operating this vehicle on unfamiliar terrain.WHAT CAN HAPPENYou 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 HAZARDGo...

Page 31 - terrain until you have learned and practiced the skills

28 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra care when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENCould cause loss of traction or vehicle control, which could result in an accident, including an overturn.HOW TO AVOID THE HAZARDDo not operate on excessi...

Page 33 - described in the Owner’s Manual. See pages 62 through

30 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control or cause vehicle to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 62 through 67.Always check the terrain c...

Page 34 - A special

31 SAFETY Operator Safety POTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause vehicle to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills as described in the Owner’s Manual. See page 65. NOTE: A special technique is req...

Page 35 - mastered the turning technique as described in the Owner’s

32 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause vehicle to overturn.HOW TO AVOID THE HAZARDNever attempt to turn the vehicle around on any hill until you have mastered the turning technique as described in th...

Page 36 - as described in the Owner’s Manual on page 71.; cargo or pulling a trailer. See pages 54 and 59.

33 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENCould cause loss of control or a collision. Could cause vehicle to overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Use extreme caution when riding over large obstacles, su...

Page 37 - deeper than that specified in your Owner’s Manual. See

34 SAFETY Operator Safety POTENTIAL HAZARDOperating this vehicle through deep or fast flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to an accident.HOW TO AVOID THE HAZARDNever operate this vehicle in fast flowing water or in water deeper...

Page 39 - sure the ice is thick enough and sound enough to support the

36 SAFETY Operator Safety WARNING WARNING POTENTIAL HAZARDRiding on frozen lakes and rivers.WHAT CAN HAPPENSevere injury or death can result if the vehicle and/or the operator break through the ice.HOW TO AVOID THE HAZARDNever ride your 6x6 on a frozen body of water before you are sure the ice is th...

Page 40 - CONTROLS AND FEATURES; Controls; Sportsman 6x6 Vehicle Nomenclature; Service Brake Lever

37 CONTROLS AND FEATURES Controls Sportsman 6x6 Vehicle Nomenclature 6. Floor Boards 7. Back Rest 8. Bed 9. Front Rack 1. Service Brake Lever 2. Middle Axle Auxiliary Brake 3. Throttle Lever 4. Bed Dump Latch Release(s) 5. Gearbox Shift Lever 1 2 3 4 4 5 6 7 8 9

Page 41 - Engine Electrical Switches; Main Switch; of control resulting in severe injury or death.

38 CONTROLS AND FEATURES Controls Engine Electrical Switches 1 2 3 RUN OFF OFF 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 acti...

Page 42 - Throttle Lever

39 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 (...

Page 43 - Front and Rear Brakes; Once a bottle of brake fluid is opened, use what is necessary and; Improperly operating the vehicle with a spongy brake lever can

40 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 fl...

Page 44 - Brakes/Rear Auxiliary Brake; The braking system is controlled by two levers located on the

41 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 i...

Page 45 - Parking Brake; Setting the Parking Brake; Always check to be sure that the parking brake has been; Do not leave the vehicle on a hill depending on the parking; on a hill or park the vehicle in a side hill position.

42 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 br...

Page 46 - Engine Fuel and Oil System

43 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 oct...

Page 47 - The taillight is on whenever the main switch (key) is in the on

44 CONTROLS AND FEATURES Controls Engine Fuel and Oil System NOTE: The taillight is on whenever the main switch (key) is in the on position. Turn the key off to prevent battery drain. WARNING Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whene...

Page 48 - Transmission Gear Selector Operation

45 CONTROLS AND FEATURES Controls Transmission Gear Selector Operation The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter. The transmission selector lever has four positions: high forward; reverse; neutral; and low forwa...

Page 49 - Do not extend the starter rope so far that it stops This will cause; CAUTION

46 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.1. Be certain the parking brake is set. See page 42. 2. Grasp the recoil star...

Page 50 - Features; Light Switches and Indicator Lights; Will not light unless main switch is on.; This vehicle is not equipped with highway approved lighting. This

47 CONTROLS AND FEATURES Features Light Switches and Indicator Lights 1. Main switch2. 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 indica...

Page 51 - All Wheel Drive System

48 CONTROLS AND FEATURES Features All Wheel Drive System 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 6...

Page 52 - A red AWD light on the switch indicates when the vehicle is in AWD.; Disengaging Wheel Hubs; When backing uphill while in AWD and then going forward downhill,

49 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 ...

Page 53 - OPERATION; Vehicle Break-in Period; “SH” oil. Never substitute or mix oil brands. Serious engine; during the first three hours of use. Excessive heat can build up and

50 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 w...

Page 54 - Daily Pre-Ride Inspection; Inspect your 6x6 each time before riding to ensure it is in proper; Item/Inspection Procedure

51 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. If a proper inspection is not performed serious injury or death can result.Always inspect your 6x6 before ri...

Page 55 - Starting a Cold Engine; After the Engine Starts; Proper engine warm up is essential each time before driving to; Carbon monoxide exhaust gas is poisonous!

52 OPERATION Starting a Cold Engine 1. Place the transmission 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 the way out. 5. Set the engine stop switch to “run”.6. Turn the ignition key past the “ON” position to engage...

Page 56 - Starting a Warm Engine; Warm engines do not normally require the use of the choke since the

53 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 ve...

Page 57 - Carrying Loads; Your 6x6 has been designed to carry or tow a certain amount of load.; Maximum Capacities; grade. Maximum vertical hitch

54 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 - 87...

Page 59 - Dumping the Cargo Bed; Select a level site to dump the cargo bed. Do not attempt to dump or

56 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 ca...

Page 60 - purposes of maintenance, repair, or replacement of any device or; USFS Approved Spark Arrestor; the USFS Forest Service Standard 5100-1A.; Remember, exhaust system components are very hot during and

57 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 eleme...

Page 61 - RIDING

58 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. If a proper inspection is not performed serious injury or death can result.Always inspect your 6x6 before ridin...

Page 62 - Riding Safely; Load Distribution; towing loads as balance, handling, and control may be affected.; The cargo bed could close unexpectedly while driving, severely

59 RIDING Riding Safely Load Distribution 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 carg...

Page 63 - shifting is done automatically.

60 RIDING Riding Safely 1. Sit upright with both feet on the footrests and both hands on the handle- bars. 2. After starting the engine and allowing it to warm up, shift the transmis- sion into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brake.5. Slowly ...

Page 64 - Making Turns; Practice making turns at slow speeds.; turn while supporting your weight on the outer footrest. This; Avoid turning at sharp angles in reverse as tipover and serious

61 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...

Page 65 - Sidehilling; Sidehilling your 6x6 is one of the most dangerous types of riding; while keeping your feet on the footrests.; Avoid crossing the side of a steep hill if possible.

62 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 th...

Page 66 - Riding On Slippery Surfaces; Whenever riding on slippery surfaces such as wet trails or loose; sharp turns which can cause skids.; Never engage Demand Drive while wheels are spinning as severe

63 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 aler...

Page 67 - Failure to exercise care when operating on slippery surfaces can

64 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. S Never apply brakes during a skid. Complete loss of control can resul...

Page 68 - Traveling Downhill; Whenever descending a hill always:; Loss of vehicle control due to excessive speed can occur. Loss

65 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 m...

Page 69 - Traveling Uphill; Whenever traveling uphill always travel straight uphill and:; clude quick dismounting of the vehicle.; Braking and handling are greatly affected whenever operating in

66 RIDING Riding Safely Traveling Uphill 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 ac...

Page 70 - Turning Around On A Hill; hill or slightly downward.; Use extreme care when operating your 6x6 in hilly terrain.

67 RIDING Riding Safely Turning Around On A Hill 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 the parking brake while maintaining body weight uphill.2...

Page 71 - Crossing Streams; If your 6X6 becomes immersed, take it to your dealer before

68 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 ro...

Page 72 - Backing Up; This vehicle is equipped with a reverse speed limiter. The

69 RIDING Riding Safely Backing Up 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 whi...

Page 73 - Backing your 6x6 can be dangerous!; You could hit an obstacle or person behind you or the vehicle

70 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 s...

Page 74 - Trail Obstacles; Look ahead and learn to read the trail as you ride. Stay on the right; Keep alert and constantly look for obstacles on the trail.

71 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.P...

Page 75 - Parking On An Incline; Whenever the Vehicle is Parked; always block the rear wheels on the down hill side as shown above.; Do not leave the vehicle on a hill depending on the park

72 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...

Page 76 - MAINTENANCE AND LUBRICATION; Tool Kit; storage compartment under the seat. Items included in the kit are:

73 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: S screwdriver S open end wrench (8-10 mm) S open end wrench (12-14 mm) S box end wrench S tire pressure gauge S spark plug...

Page 77 - Periodic Maintenance Schedule; NOTE; Due to the nature of the adjustments marked with a

74 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 chartMaintenance intervals are based u...

Page 78 - More often under severe use, such as dirty or wet conditions; : Inspection may reveal the need for replacement parts. Always

75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule (Cont.) " 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 R...

Page 80 - Lubrication Recommendations

77 MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec. Method Frequency* Brake Fluid DOT 3 Only Maintain proper level. See page 40. As required; change every two years or 200 hours Drive Chains O-Ring chain lube or SAE 80/90 Lubricate as often as re- quired (before each ride in we...

Page 83 - Transmission Lubrication; The transmission fill plug (1) is located on the right side of the; Transmission Oil Changing Procedure; and drain the oil. Catch and discard used oil properly.

80 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), whicheve...

Page 84 - Front Gearcase Lubrication

81 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 annual...

Page 85 - Premium 4 Synthetic Lubricant

82 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...

Page 86 - Oil and Filter Change; Oil may be hot. Do not allow hot oil to come into contact with skin

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 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...

Page 88 - Periodic Maintenance Record; Use the following chart to record periodic maintenance work:

85 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.

Page 89 - Engine Cooling System; Radiator Coolant Level In-; Never remove the pressure cap when the engine is warm or hot.

86 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level In- spection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant ...

Page 90 - Coolant Level

87 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 controlled or maintained by the recovery system. The...

Page 91 - Filter Systems; Air Filter Service; clamp or filter damage may occur.; Operation of your 6X6 without a breather filter can cause engine

88 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 a...

Page 92 - Air Box Drain

89 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 pul...

Page 93 - Adjustments; Toe Alignment; dealer. He/she has the training and tools to make these

90 MAINTENANCE AND LUBRICATION 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 ...

Page 94 - Steering Inspection; adjuster block tightening bolts can cause limited steering or; SOFT

91 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-ad...

Page 95 - Front Brake; Front Wheel and Middle Axle

92 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 ch...

Page 96 - Rear Brake; Wear Line

93 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 ...

Page 97 - Throttle Cable Free Play Adjustment; freeplay is achieved at thumb lever.

94 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...

Page 98 - Wheel Removal Procedure; tire wear. Make sure the tapered end of the rear wheel nut goes into

95 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 re...

Page 99 - Tire Inspection; Tire Tread Depth; Always replace tires when tread depth is worn to 1/8; The use of non-standard size or type tires may affect vehicle

96 MAINTENANCE AND LUBRICATION Adjustments Tire Inspection Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. CAUTION Maintain proper tire pressure according to charts below. Improper tire inflation may affect vehicle maneuverability.When replacing a tire always...

Page 100 - Tire Specifications; they have been loosened for maintenance service.; Axle and Wheel Nut Torque Specifications; Front Wheel Hub Tightening; component operations. Service work must be performed by your

97 MAINTENANCE AND LUBRICATION Adjustments Tire Specifications 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...

Page 101 - Front Drive Chain Adjustment; Adjustment Procedure; Never adjust or operate the vehicle with the drive chain slack out

98 MAINTENANCE AND LUBRICATION Adjustments Front Drive Chain Adjustment 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 - .95 cm) def...

Page 102 - Rear Axle Drive Chain Adjustment

99 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). 1/4 ″ -1/2 ″ (.6-1.3 cm) 3/16 ″ -3/8 ″ (.48 cm - ....

Page 103 - Carburetor/Engine Idle RPM Adjustment; Recommended engine idle RPM is 1200

100 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,...

Page 104 - Carburetor Adjustments; certain adjustments can be made to improve its operation and; Jetting Chart

101 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 lo...

Page 105 - Side Panel Removal

102 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1. Side panel removal may be difficult until the locking tabs and 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 out...

Page 106 - Spark Plugs; Spark Plug Removal and Replacement; Never attempt to remove a spark plug while the engine is warm.

103 MAINTENANCE AND LUBRICATION Spark Plugs S Use NGK BKR5ES spark plugs. S Proper electrode gap is .025 ″ (.06 cm). S 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...

Page 107 - Spark Arrestor

104 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING S 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. S Because of the increased fire hazard, make sure that there are no co...

Page 109 - Recoil Housing

106 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. Reinstall screw once h...

Page 110 - PVT System; Failure to comply with this warning can result in severe injury

107 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 ...

Page 111 - Battery; Replenishing the Battery Fluid

108 MAINTENANCE AND LUBRICATION Battery 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.To refill use only distilled water. Tap water contains minerals whi...

Page 112 - Battery Removal; position and remove battery cover.; Battery Installation and Connections; Rinse well with tap water and dry off with clean rags. Coat the; tablespoon baking soda and one cup water to prevent damage to; cable last. An exploding battery can cause serious injury or death.

109 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)...

Page 114 - Headlight Lamp Replacement; Using a small flat blade screwdriver, push in on the lock tab; Due to the nature of these vehicles and where they are ridden,

111 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement . 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 t...

Page 115 - High Beam Headlight Adjustment; make a mark on the wall at the same height.

112 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 a...

Page 116 - Headlight Housing Replacement

113 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 screwdriv...

Page 117 - Taillight/Brakelight Lamp Replacement

114 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced.1. Remove the taillight assembly by removing the two screws securing it to the vehicle. 2. Twist the lamp harness 1/4 tur...

Page 118 - Cleaning and Storage; Cleaning the 6x6

115 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 ca...

Page 119 - Storage of the 6x6

116 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. 2. Turn the fuel valve to “off” an...

Page 120 - Transporting the 6x6; Always place the transmission in gear and lock the parking brake.; Accessories; Polaris dealer for a complete list.

117 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 sec...

Page 121 - SPECIFICATIONS

118 SPECIFICATIONS Height 48 ″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width 46 ″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length 105 ″ . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 122 - Engine Specifications

119 SPECIFICATIONS Engine Specifications 2002 Sportsman 6x6 Engine EH50PLE-06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement 499 cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 4 Cycle, Single Cylinder . . . . . . . ...

Page 123 - WIRING DIAGRAM

Page 124 - TROUBLESHOOTING; Clutch Drive Belt & Cover Related Issues: Diagnosis; Possible Causes

121 TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the 6x6 into a pick- up or tall trailer when in high range. Shift transmission to low range during loading of the 6x6 to prevent belt burn- ing. Starting out going up a steep incl...

Page 127 - WARRANTY; LIMITED WARRANTY

124 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 th...

Page 128 - HOW TO OBTAIN WARRANTY SERVICE

125 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 prod...

Page 129 - INDEX

126 INDEX Accessories 117 . . . . . . . . . . . . . . . . . . . . . . . Adjustments 90-102 . . . . . . . . . . . . . . . . . . . Air Box Drain 89 . . . . . . . . . . . . . . . . . . . . . Air Cleaner 88 . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 48 . . . . . . . . . . . . . . . . ...