Polaris Sportsman 6x6 - Manuals

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...

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

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

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...

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...

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 ...

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 ...

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...

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...

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...

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 ...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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

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...

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 (...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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 ...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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 ...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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...

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.

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 ...

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...

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...

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...

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 ...

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...

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...

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 ...

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...

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...

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...

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...

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...

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 - ....

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,...

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...

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...

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...

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...

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...

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 ...

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...

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)...

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...

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...

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...

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...

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...

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...

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...

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

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

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...

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...

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...

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

7 VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition swi...

8 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the de...

11 SAFETY Safety Decals and Locations (on hitch) ATTENTION S Operation of this vehicle without the filter element will severely damage the engine. S Clean air filter often, more frequent cleaning required in dusty condi- tions. S Operation of this vehicle without en- gine breather filter(s) can caus...

12 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...

13 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious injury or death.A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can ...

14 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. 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 manua...

15 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate th...

17 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes af- ter leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the vehicle before oper- ating in reverse. When it’s s...

18 SAFETY Operator Safety WARNING 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...

20 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this vehicle on public streets, roads or highways.WHAT CAN HAPPENThe vehicle could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the Sportsman 6x6 on any public street, road or highway, including dirt and gravel roads. W...

21 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling or rolling backwards while climbing a hill.WHAT CAN HAPPENStalling or rolling while climbing a hill could result in vehicle overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If you lose all forward speed:Keep your bo...

22 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the Sportsman 6x6 at excessive speeds.WHAT CAN HAPPENExcessive speed increases the operator’s chance of losing control of the vehicle, which can result in an accident.HOW TO AVOID THE HAZARDAlways operate the vehicle at a speed that’s prope...

23 SAFETY Operator Safety WARNING POTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrests during operation.WHAT CAN HAPPENRemoving even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the vehicle.If the operator’s foot...

24 SAFETY Operator Safety WARNING POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or...

25 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating on excessively steep hills.WHAT CAN HAPPENThe vehicle may overturn and cause serious injury or death.HOW TO AVOID THE HAZARDNever operate on hills too steep for the vehicle or for your abilities. Never operate the Sportsman 6x6 on hills ste...

26 SAFETY Operator Safety WARNING POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual.Always check the terr...

27 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing or turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the Sportsman 6x6 around on any hill until you’ve mastered the turning...

29 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the 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 or overturn.HOW TO AVOID THE HAZARDAvoid operating the vehicle through deep or fast...

30 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this vehicle with improper tires or with improper or uneven tire pressure.WHAT CAN HAPPENUse of improper tires, or operation of the vehicle with improper or uneven tire pressure, could cause loss of control or accident.HOW TO AVOID THE HAZA...

31 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating on frozen bodies of water.WHAT CAN HAPPENSevere injury or death can result if the vehicle and/or the operator fall through the ice.HOW TO AVOID THE HAZARDNever operate the vehicle on a frozen body of water. WARNING POTENTIAL HAZARDOperating...

33 FEATURES AND CONTROLS 1. Service Brake Lever 2. Middle Axle Auxiliary Brake Lever 3. Throttle Lever 4. Box Dump Latch Release 5. Gear Selector 6. Floorboards 7. Backrest 8. Cargo Box 9. Front Rack 1 2 3 4 4 5 6 7 8 9

34 FEATURES AND CONTROLS Electrical Switches and Indicators 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main switch is on. WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Don’t activate the...

36 FEATURES AND CONTROLS Brakes The braking system is controlled by the two brake levers located on the handlebars, directly in front of each handgrip. Service Brakes The service brake lever (1) is located on the left handlebar. This lever controls both front and rear wheel braking action. Use this ...

37 FEATURES AND CONTROLS Brakes Master Cylinders The master cylinders (1) are located on the left and right handlebars. Check fluid levels before each use of the ATV.View the fluid level through the indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid leve...

38 FEATURES AND CONTROLS Parking Brake WARNING Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the left brake l...

39 FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions:OFF: For vehicle storage and when transporting.ON: For normal operation.RES: For reserve supply if main supply is exhausted.There’s about a 7 to 10 mile (11.2 to 16 km) range on the reser...

40 FEATURES AND CONTROLS Gear Selector The transmission gear selector (1) is located on the right side of the vehicle directly above and forward of the engine recoil starter.To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gea...

41 FEATURES AND CONTROLS Recoil Starter If the battery has been drained or damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped wi...

42 FEATURES AND CONTROLS All Wheel Drive (AWD) System The Polaris Sportsman 6x6 is equipped with a unique AWD system activated by the AWD switch (1) on the right handlebar. When the switch is off, the vehicle is in rear wheel drive at all times. When the switch is on, the vehicle is in AWD and the f...

43 FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging Wheel Hubs The hubs normally disengage when operating in reverse. However, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, one front hub is engaged. If both hubs are engaged, steering effort incre...

44 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limi...

45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instru...

46 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - TachometerThe reverse override button on the left handlebar is also the mode button . NOTE: If using the mode...

47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.To leave the diagno...

48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory...

49 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well ventilated area with the en- gine stopped. S Do not smoke or allow open flames or sparks in or nea...

50 OPERATION Vehicle Break-in Period The break-in period for your new Polaris Sportsman 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 following procedures for a proper break-in period. ...

51 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...

52 OPERATION Starting a Cold Engine WARNING Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes befo...

53 OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank valve to ...

54 OPERATION Hauling Cargo Your Sportsman 6x6 has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings on the warning labels. Never exceed the specified weights. WARNING Overloading the vehicle or carrying or towing cargo improperly can al...

55 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. 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 box release lever forward.5. Lift the front of the cargo box and dump the...

56 OPERATION Driving Safely Load Distribution 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 54. 2. Always load the cargo box with the load (1) as far forward as possible. 3. Always operate the vehicle with extreme caution whene...

57 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parki...

58 OPERATION Driving Safely Making Turns Practice making turns at slow speeds.The Sportsman 6x6 is equipped with a solid rear axle that 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,...

59 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill. Sidehilling can be a dangerous type of driving and should be avoided if at all poss...

60 OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: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 Hard use of the braking system while descending a hill ...

61 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills.3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening.6. Remain alert and be pre...

62 OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death.Avoid climbing steep hills (15 _ maximum). Use extreme caution when operating on hills, and follow proper operating procedures ...

63 OPERATION Driving Safely Driving on Slippery Surfaces Whenever operating on slippery surfaces, such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding q...

64 OPERATION Driving Safely Driving Through Water Your Sportsman 6X6 can operate through water with a maximum recommended depth equal to the footrests (1). Avoid operating the ATV through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, bal...

65 OPERATION Driving Safely Driving in Reverse 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. Open the throttle just enough to maintain a desired speed.Follow...

66 OPERATION Driving Safely Parking On An Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Place the transmission in gear and set the parking brake.2. Always block the rear wheels on the downhill side. See illustration. 3. Shut off the fuel supply.

67 OPERATION Driving Safely Driving Over Obstacles Keep alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle...

68 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with ...

69 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...

70 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust ...

74 MAINTENANCE AND LUBRICATION Lubrication Recommendations Lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Items not listed in the chart should be lubricated at the General Lubrication interval. Maintenance Chart Key " More often under s...

76 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Lubrication Always check and change the transmission lubricant at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill hole threads. Polaris recommends t...

77 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Lubrication Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill plug threads. Polaris recommends the...

78 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’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate ...

79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil Level The oil tank is located on the left side of the vehicle. To check the oil:1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds.3. Stop the engine. Remove the dipstick and wipe it dry wit...

80 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin.If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result...

81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 7. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 8. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the g...

82 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/...

83 MAINTENANCE AND LUBRICATION Engine Cooling System Recovery Bottle Coolant Level The recovery bottle (1) is located on the left side of the vehicle. To access the recovery bottle, remove the left side panel as outlined on page 93.Maintain the coolant level between the minimum and maximum marks on ...

84 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service Always inspect and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70.1. Remove the seat.2. Remove the spring clamps securing the air box lid and remove the lid. 3. Loosen the clamp ...

85 MAINTENANCE AND LUBRICATION Filter Systems Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box. Empty the drain tube if necessary. Breather Filter Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Cha...

86 MAINTENANCE AND LUBRICATION Adjustments WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check...

87 MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the vehicle should be checked periodically for loose nuts and bolts. Have your dealer tighten any loose nuts and bolts before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Han...

88 MAINTENANCE AND LUBRICATION Adjustments Front Brake Front Wheel and Middle Axle Brake The front and middle axle brakes are hydraulic disc brakes and are activated by moving the brake lever toward the handlebar. These brakes are self-adjusting and require no adjustment.The following checks are rec...

89 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The transmission brake is a hydraulic disc brake and is activated by the same lever that 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...

90 MAINTENANCE AND LUBRICATION Adjustments Front Drive Chain Adjustment CAUTION Operating the vehicle with the drive chain slack out of specification could cause serious damage to the transmission and drive components. Never operate the vehicle with the drive chain slack out of specification. Check ...

91 MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment To adjust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. Total slack for the rear chain should be adjusted to 3/8 ″ -1/2 ″ ...

92 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixtu...

93 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 3. Place your hand on top of the side panel behind the fuel tank. W...

94 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 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 w...

95 MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. WARNING Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death. Always replace tires when ...

96 MAINTENANCE AND LUBRICATION Tire Specifications Tire Specifications Polaris Sportsman 6x6 Front - 25 x 8 - 12 Inflation Pressure - 5 PSI Center - 25 x 11 - 12 Inflation Pressure - 5 PSI Rear - 25 x 11 - 12 Inflation Pressure - 5 PSI Cargo Box Load Capacity 800 lbs. (363 kg) Front Rack Load Capaci...

97 MAINTENANCE AND LUBRICATION Spark Plugs S Use NGK BKR5E spark plugs. S Proper electrode gap is .036 ″ (.9 mm) S Spark plug torque is 14 ft. lbs. (1.9 kg/m) CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug conditi...

98 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinc...

99 MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precisio...

100 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow compone...

101 MAINTENANCE AND LUBRICATION Recoil Housing Water will enter the recoil housing if the starter handle is disengaged from the rope or if the handle is not securely seated when under water.Drain the recoil housing any time the vehicle has been operated in very wet conditions and also before storage...

102 MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negativ...

103 MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging.Power plug ...

104 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

105 MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.Hot components can cause serious burns to skin. Don’t serv...

106 MAINTENANCE AND LUBRICATION Lights WARNING Operating the vehicle on streets or roads, especially in darkness, could result in an accident and serious injury or death.Your Sportsman 6x6 is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only . Use ca...

107 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the Phillips screws from the bottom of the headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to the left or right and use a very short screwdriver. Removal of...

108 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced.1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1). Apply die...

109 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 113 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an...

110 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips If your vehicle will be placed in extended or off season storage, perform all necessary repairs and thoroughly clean the vehicle. Drain the recoil housing. Remove the battery and store it in a cool, dry place. See the battery section ...

111 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years.1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud ...

112 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks

113 POLARIS PRODUCTS Part No. Description Engine Lubricant 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (qt.) 2873603 Premium AGL Synthetic Gea...

114 SPECIFICATIONS SPORTSMAN 6x6 Gross Vehicle Weight 1965 lbs. (891 kg)(machine, driver, cargo) Fuel Capacity 4.25 gallons (16.09 liters) Hitch Tongue Capacity 150 lbs. (68.1 kg) Hitch Towing Rating 1500 lbs. (681 kg) Unbraked Trailer Towing Capacity* 1900 lbs. (863 kg)Front Rack Capacity 75 lbs. (...

115 SPECIFICATIONS SPORTSMAN 6x6 Transmission Automatic PVT (H/L/N/R) Gear Reduction - Low 6.69/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - High 3.34/1 Drive Ratio - Front 2/1 Drive Ratio - Final 12/38 80P Tire Size - Front 25 x 8 - 12 (5 psi) Tire Size - Center 25 x 11 - 10 (5 psi) Tire Size...

116 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Starting out going up a steep in-cline. Apply the parking brake, dismount ,and performthe “K” turn as outlined on page ...

117 TROUBLESHOOTING Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, Fails to Start Possible Cause Solution Out...

118 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

119 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...

120 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, 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 failu...

121 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...

122 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for expor...

123 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...

124 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2005 and la...

125 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser...

126 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engin...

127 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) " E Engine oil level -- Pre-Ride -- Make adjustments as need- ed. See Pre-Ride Checklist on page 51. " E Air filter, pre-filter...

128 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty maintenance or repairs of emiss...

129 INDEX A Accessories 69 . . . . . . . . . . . . . . . . . . . . Adjustments 86-94 . . . . . . . . . . . . . . . . . Age Restrictions 13 . . . . . . . . . . . . . . . . Air Box Drain 85 . . . . . . . . . . . . . . . . . . Air Filter 84 . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 42...