Polaris Sportsman 6x6 - Manual

Polaris Sportsman 6x6

Polaris Sportsman 6x6 – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 2 – WARNING; The engine exhaust from this
  • Page 3 – Indicates a potential hazard that could result in serious
  • Page 5 – WELCOME
  • 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.
  • Page 7 – TABLE OF CONTENTS
  • Page 8 – Maintenance and Lubrication
  • 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
  • Page 10 – SAFETY; Understanding Warnings; are used. Become familiar with their meanings before reading the
  • Page 11 – Key Safety Issues; Protect Your Sport; permission of Polaris Industries Inc.
  • Page 12 – SERIOUS INJURY OR DEATH can result if you do not; Take a
  • Page 15 – Safe Riding Gear
  • Page 16 – Safety Decals and Locations; for a replacement. Any safety decal needing replacement will be
  • Page 17 – MAXIMUM WEIGHT CAPACITY
  • Page 22 – Moving parts hazard under belt-clutch guard. To; NO STEP
  • Page 23 – ATTENTION
  • Page 24 – Operator Safety; not know how to operate the vehicle properly in different
  • Page 26 – increases your chances of a severe injury in the event of an
  • Page 27 – described in the Owner’s Manual. See page 67. In the event of
  • Page 28 – and operating conditions and your experience.; obstacles or people behind you. When it is safe to proceed, go
  • Page 29 – schedules described in the Owner’s Manual.
  • Page 30 – cautious in order to reduce the chance of skidding or sliding out
  • Page 31 – terrain until you have learned and practiced the skills
  • Page 33 – described in the Owner’s Manual. See pages 62 through
  • Page 34 – A special
  • Page 35 – mastered the turning technique as described in the Owner’s
  • Page 36 – as described in the Owner’s Manual on page 71.; cargo or pulling a trailer. See pages 54 and 59.
  • Page 37 – deeper than that specified in your Owner’s Manual. See
  • Page 39 – sure the ice is thick enough and sound enough to support the
  • Page 40 – CONTROLS AND FEATURES; Controls; Sportsman 6x6 Vehicle Nomenclature; Service Brake Lever
  • Page 41 – Engine Electrical Switches; Main Switch; of control resulting in severe injury or death.
  • Page 42 – Throttle Lever
  • 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
  • Page 44 – Brakes/Rear Auxiliary Brake; The braking system is controlled by two levers located on the
  • 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.
  • Page 46 – Engine Fuel and Oil System
  • Page 47 – The taillight is on whenever the main switch (key) is in the on
  • Page 48 – Transmission Gear Selector Operation
  • Page 49 – Do not extend the starter rope so far that it stops This will cause; CAUTION
  • 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
  • Page 51 – All Wheel Drive System
  • 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,
  • 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
  • Page 54 – Daily Pre-Ride Inspection; Inspect your 6x6 each time before riding to ensure it is in proper; Item/Inspection Procedure
  • 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!
  • Page 56 – Starting a Warm Engine; Warm engines do not normally require the use of the choke since the
  • Page 57 – Carrying Loads; Your 6x6 has been designed to carry or tow a certain amount of load.; Maximum Capacities; grade. Maximum vertical hitch
  • Page 59 – Dumping the Cargo Bed; Select a level site to dump the cargo bed. Do not attempt to dump or
  • 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
  • Page 61 – RIDING
  • 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
  • Page 63 – shifting is done automatically.
  • 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
  • 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.
  • 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
  • Page 67 – Failure to exercise care when operating on slippery surfaces can
  • Page 68 – Traveling Downhill; Whenever descending a hill always:; Loss of vehicle control due to excessive speed can occur. Loss
  • 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
  • Page 70 – Turning Around On A Hill; hill or slightly downward.; Use extreme care when operating your 6x6 in hilly terrain.
  • Page 71 – Crossing Streams; If your 6X6 becomes immersed, take it to your dealer before
  • Page 72 – Backing Up; This vehicle is equipped with a reverse speed limiter. The
  • Page 73 – Backing your 6x6 can be dangerous!; You could hit an obstacle or person behind you or the vehicle
  • 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.
  • 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
  • Page 76 – MAINTENANCE AND LUBRICATION; Tool Kit; storage compartment under the seat. Items included in the kit are:
  • Page 77 – Periodic Maintenance Schedule; NOTE; Due to the nature of the adjustments marked with a
  • Page 78 – More often under severe use, such as dirty or wet conditions; : Inspection may reveal the need for replacement parts. Always
  • Page 80 – Lubrication Recommendations
  • 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.
  • Page 84 – Front Gearcase Lubrication
  • Page 85 – Premium 4 Synthetic Lubricant
  • Page 86 – Oil and Filter Change; Oil may be hot. Do not allow hot oil to come into contact with skin
  • Page 88 – Periodic Maintenance Record; Use the following chart to record periodic maintenance work:
  • Page 89 – Engine Cooling System; Radiator Coolant Level In-; Never remove the pressure cap when the engine is warm or hot.
  • Page 90 – Coolant Level
  • Page 91 – Filter Systems; Air Filter Service; clamp or filter damage may occur.; Operation of your 6X6 without a breather filter can cause engine
  • Page 92 – Air Box Drain
  • Page 93 – Adjustments; Toe Alignment; dealer. He/she has the training and tools to make these
  • Page 94 – Steering Inspection; adjuster block tightening bolts can cause limited steering or; SOFT
  • Page 95 – Front Brake; Front Wheel and Middle Axle
  • Page 96 – Rear Brake; Wear Line
  • Page 97 – Throttle Cable Free Play Adjustment; freeplay is achieved at thumb lever.
  • Page 98 – Wheel Removal Procedure; tire wear. Make sure the tapered end of the rear wheel nut goes into
  • 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
  • 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
  • Page 101 – Front Drive Chain Adjustment; Adjustment Procedure; Never adjust or operate the vehicle with the drive chain slack out
  • Page 102 – Rear Axle Drive Chain Adjustment
  • Page 103 – Carburetor/Engine Idle RPM Adjustment; Recommended engine idle RPM is 1200
  • Page 104 – Carburetor Adjustments; certain adjustments can be made to improve its operation and; Jetting Chart
  • Page 105 – Side Panel Removal
  • Page 106 – Spark Plugs; Spark Plug Removal and Replacement; Never attempt to remove a spark plug while the engine is warm.
  • Page 107 – Spark Arrestor
  • Page 109 – Recoil Housing
  • Page 110 – PVT System; Failure to comply with this warning can result in severe injury
  • Page 111 – Battery; Replenishing the Battery Fluid
  • 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.
  • 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,
  • Page 115 – High Beam Headlight Adjustment; make a mark on the wall at the same height.
  • Page 116 – Headlight Housing Replacement
  • Page 117 – Taillight/Brakelight Lamp Replacement
  • Page 118 – Cleaning and Storage; Cleaning the 6x6
  • Page 119 – Storage of the 6x6
  • Page 120 – Transporting the 6x6; Always place the transmission in gear and lock the parking brake.; Accessories; Polaris dealer for a complete list.
  • Page 121 – SPECIFICATIONS
  • Page 122 – Engine Specifications
  • Page 123 – WIRING DIAGRAM
  • Page 124 – TROUBLESHOOTING; Clutch Drive Belt & Cover Related Issues: Diagnosis; Possible Causes
  • Page 127 – WARRANTY; LIMITED WARRANTY
  • Page 128 – HOW TO OBTAIN WARRANTY SERVICE
  • Page 129 – INDEX
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Summary

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...

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