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Polaris 600 XC SP Offroad Vehicle User Manual

1. 32 FEATURES AND CONTROLS Electrical Switches and Indicators SL ers E d Q 2 3 5 1 Light Switch Hi Lo Beam Control The lights won t turn on unless the main switch is on 4 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 override switch while the throttle is open 2 Override Switch Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To obtain additional power while backing depress the override button The override switch also allows activation of All Wheel Drive AWD in reverse if the AWD switch is on 3 Engine Stop Switch The engine will not start or run when the switch is off Its purpose is OFF RUN qE to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights To stop the engine slide the stop switch either right or left to the OFF position 4 Main Switch To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts The taillight is on whenever the main switch is on Turn
2. 44 48 Jetting Chart 115 K T t 1 62 L Light Switch 33 Lights ss ree reet 105 108 Load Distribution 56 Low Range 98 Lubrication Recommendations 74 81 Main Switch 33 Maintenance and Lubrication 69 113 Maintenance Log 130 Making Turns 58 Master lt 36 N Noise Emission Control System 68 Odometer voee eere 46 Oil Change 80 81 Oil Filter Change 80 81 Oil Level i bon ee eretti 79 Oil Pump Priming 92 Operating Safety 55 Operation 49 67 Operator 5 5 26 Override Switch 33 P Parking on an Incline 66 Periodic Maintenance Chart 70 73 Polaris Products 116 Pre Ride Inspection 51 Premium 4 Synthetic Lubricant 78 PVT Breakin RI 50 PVT System 98 99 R Radiator Coolant Level 82 Recoil Housing 101 Recoil Starter 40 41 Recovery Bottle Coolant Level 83 Reverse Speed Limiter 33 Rider Information Center 45 48 S Safe Riding 31 Safety sese e erbe erem pes 5 31 Safety Decals and Locations 27 30 Safety Training
3. ESS Oe OG SEDGE WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Front Rack Load 75 Ibs 4 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI Kpa FRONT 5 34 5 CENTER 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1965 LBS 893 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in bed and firmly secured to the rack For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information 7172591 SAFETY Safety Decals and Locations ee WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER eOperate on public roads A collision can occur with another vehicle eCarry passengers Passengers affect balance and steering and in crease risk of losing control eUSE ALCOHOL or DRUGS before or while operating this vehicle eOperate at speeds too fast for your skills or the conditions eOperate this vehicle o
4. 129 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 130 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 131 INDEX A Accessories eee eee 69 Adjustments 86 94 Age Restrictions 5 Air Box Drain 85 Air Filters seda ee gic yg 84 All Wheel Drive AWD 42 All Wheel Drive System 43 Wheel Drive Switch 33 Auxiliary 35 B Battery zie 102 104 Battery Charging 103 104 Battery Installation 102 Battery Removal 102 Battery Storage 103 Belt 50 Belt Life i 39 Brake Front 88 Brake Parking 37 Brake Rear 89 Brakes x Lo Ne e 35 36 Break in 50 Breather 85 C Camber and Caster 87 Carburetor Adjustment 91 Cargo Capacities 54 Choke Adjustment 89 Chrome Wheel Care 112 Cleaning and Storage 109 113 Cleaning the ATV 109 Clutch 50 Clutching 115 Controls ere AREA 32 48 Coolant ssepe r
5. Avoid turning at sharp angles in reverse 65 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 66 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 4 WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 67 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 158 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8340 Violations are subject to monetary penalties F
6. POLARIS The Way Out AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your servi
7. 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 116 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Drive Belt and Cover Problems Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or low ground speed at approximately 3 7 MPH Insufficient warm up of ATVs exposed to low am bient temperatures Shift transmission to low range during loading of the ATV to prevent belt burning When starting out on an incline use low range or dis mount the after first applying the park brake and perform the K turn as described on page 62 Drive at a higher speed or use low range more frequently The use of low range is highly recommended for cooler PVT operating temperatures and longer component life Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage Use the throttle quickly and effectively ment Towing pushing at low RPM low ground speed Utility use plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Use low range only Use low range only Shift t
8. Fuel and oil Coolant level if applicable Inspect lubricate if necessary Ensure free operation wl ole NI a BR nspect condition and pressure nspect ensure fastener tightness nspect ensure tightness Ensure proper levels Ensure proper level Coolant hoses if applicable Throttle Indicator lights switches Engine stop switch Drive chain Inspect for leaks Ensure proper operation Ensure operation Ensure proper operation Check condition slack lubricate as needed Inspect clean 90 91 Air filter pre filter Air box sediment tube Headlamp Drain deposits whenever visible Check operation apply Polaris dielec 105 tric grease when lamp is replaced Check operation apply Polaris dielec 108 tric grease when lamp is replaced Check condition and operation of the mechanism Wear helmet goggles protective clothing Brake light tail lamp Dump box latch Riding gear 51 OPERATION Starting a Cold Engine 4 amp 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 before operating the vehicle Place the transmission in neutral and lock the parking brake Make sure the fuel tank valve is on Sit on the
9. Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement 6 A cet 207 9 6 0 3 520 Cro ups ke y NS KM 7 2 TT i 23 yd 3 Lo gt i oS NOTE f you discover improper alignment see your Polaris dealer for service 86 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 Handlebar Adjustment The handlebars can be adjusted for rider preference 4 amp WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious person
10. damage See your owner s manual ETC Owner s Manual This vehicle is equipped with a 7172564 7079780 5 Polaris Electronic Throttle Control ETC to reduce the risk of a stuck or frozen throttle Please refer to your owner s manual for details ePassengers can be thrown off This can cause serious injury or death eNever carry passengers Maximum Box Load 800 Ibs 29 Remove flammable containers from box before refueling SAFETY Safety Decals and Locations AWARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP s TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68KG 7170509 on hitch ATTENTION Operation of this vehicle without the Specific carburetor jetting and adjust filter element will severely damage ments are required depending on tem the engine perature and altitude See your owner s Clean air filter often more frequent manual cleaning required in dusty condi Factory setting Hense BEEN 40 to 80 F at 0 3000 feet Operation of this vehicle without en 5 to 27 C at 0 900 meters gine breather filter s can cause en gine damage Consult
11. rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same learning technique should be used for turning in reverse 4 WARNING Turning at sharp angles in reverse can result in tipover and serious injury Avoid turning at sharp angles while operating in reverse 58 OPERATION Driving Safely Sidehilling 4 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 possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 59 OPERATION Driving Safely Driving
12. 1 16 to 1 8 freeplay is achieved at the thumb lever Flip the throttle lever several times to confirm adjustment 3 64 1 cm 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the middle point of the adjuster 1 3 1 Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations Service must be performed by your authorized Polaris dealer 89 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 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 8 1 2 95 1 3 cm deflection If the chain needs adjustment use the following procedure NOTE See the proper splicelink clip opening position 1 1 Remove the chain guard and loosen the chain guide 2 Loosen the two eccentric locking bolts 2 3 Loosen the caliper mount bolts 4 Insert a pin punch 3 through the sprocket hub and into the eccentric axle housing 5 Roll the vehicle ahead or back to adjust chain slack to the
13. 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 4M Clutches drive 100 H 620 1000 Inspect clean replace worn and driven parts Shift selector 200 H 2 1240 2000 Change lubricant every two lubricant years Brake fluid 200 H 1240 2000 Change every two years 1860 6000 Idle speed Adjust as needed Inspect periodically adjust when parts are replaced Auxiliary brake Inspect daily adjust as needed Adjust as needed p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services Headlight aim 73 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 NOTE The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Maintenance Chart Key gt More often under severe use such as wet or dusty conditions X Use Polaris Premium Season Grease or grease conforming to NLGI No 2 e Use Polaris Premium U Joint Lube every 500 miles before lo
14. 6 Service Brakes 35 Setting the Parking Brake 37 Side Panel Removal 93 S Sidehilling 59 Spark 100 Spark Plug Removal 97 Spark 97 Specifications 114 115 Starting a Cold Engine 52 Starting a Warm Engine 53 Steering Inspection 87 Stop 33 Storage Tips 110 111 Suspension Springs 87 Switches and Indicators 33 Tachometer 46 Taillight Brakelight Lamp Replacement 108 Throttle 34 Tire Specifications 96 Tire Tread Depth 95 Toe Alignment 86 TOOL Kiting cece ip ee ease eae ges 69 Torque Specifications 96 Towing 54 Transmission Lubrication 76 Transporting the Vehicle 113 Trip Meter sisi es tin rernm 46 Troubleshooting 117 120 Turning Around on a Hill 62 V Vehicle Identification Numbers 4 W Warranty 121 129 Washing the ATV 109 Waxing the ATV 109 Wheel Installation 94 Wheel Removal 94 133
15. Activate the AWD switch only when the rear wheels have traction 4 WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces 63 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 balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal NOTE After running the vehicle in water it s critical to have it serviced as outlined in the maintenance schedule beginning on page 70 The following areas need special attention engine oil transmission oil front an
16. Downhill Whenever descending a hill follow these precautions 1 2 3 Drive directly downhill Transfer your weight to the rear of the vehicle Slow down 4 Apply the brakes slightly to aid in slowing 4 WARNING 60 Hard use of the braking system while descending a hill could result in a front end overturn causing serious injury or death Always operate the brakes slightly when descending a hill Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 2 3 4 6 Always travel straight uphill Avoid steep hills Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 4 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure 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 outlined in the owner s manual 61 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to t
17. HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Keep your body weight toward the front of the vehicle uphill Apply the brakes After the vehicle has completely stopped lock the parking brake If you begin rolling backwards Keep your body weight toward the front of the vehicle uphill Do not apply engine power Do not apply the rear brakes Gradually apply the service brake When fully stopped apply the auxiliary brake as well and then lock the parking brake Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described in the owner s manual See page 62 In the event of an accident have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering 15 SAFETY Operator Safety 4 amp WARNING 16 POTENTIAL HAZARD Operating the Sportsman 6x6 at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the vehicle which can result in an accident HOW TO AVOID THE HAZARD Always operate the vehicle at a speed that s proper for the terrain visibility and operating conditions and your experience WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The Sportsman 6x6 could collide with an obstacle or person resulting in severe
18. INDEX iis ose e eel eve dx XR Os vex 132 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 switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number 2 Key Number 3 SAFETY Operator Safety 4 amp 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 occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures SAFETY Operator Safety Safety Train
19. You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 Limited Warranty California Only POLARIS warrants to the owner of 2006 and later LSI engines that the LSI engine 1 has been designed built and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and 2 is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below 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 and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission related part What is Covered Under This Warranty Repair and or replacement of any warranted emission related part will be performed at no charge provided the work is performed at an authorized d
20. caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 amp 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 Read this manual and all labels carefully and follow the operating procedures described Never operate the Sportsman 6x6 without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this vehicle Never permit a guest to operate the vehicle unless the guest has read this manual and all product labels and has completed a certified safe ty training course Always avoid operating this vehicle on paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on a public street road or highway in cluding a dirt or gravel road Never operate this vehicle without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ve hicle Never operate at ex
21. corrosion and oxidation 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 or grime Never use abrasive cleaners on plated or painted surfaces Polish the clean chrome wheels periodically Use an automotive grade chrome polish Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 112 MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting the Vehicle Follow these procedures before transporting the vehicle with another unit 1 Turn off the engine and remove the key to avoid loss during transporting Turn the fuel valve off Be sure the fuel cap and oil cap are
22. hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly crossing or turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the Sportsman 6x6 around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 62 Use extra caution when turning on any hill Avoid crossing the side of a steep hill If it s unavoidable always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehicle MU 21 SAFETY Operator Safety 4 amp WARNING 22 POTENTIAL HAZARD Operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If it s unavoidable use extreme caution WARNING POTENTIAL HAZARD Overloading the vehicle or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the sta
23. installed correctly Always tie the frame of the to the transporting unit securely using suitable straps and or rope Always place the transmission in gear and lock the parking brake 113 SPECIFICATIONS SPORTSMAN 6x6 Ground Clearance 5 5 in 14 cm Dry Weight 895 Ibs 406 kg Minimum Turning Radius 119 in 302 cm unloaded Engine Oil Capacity Two quarts 1 89 liters 114 Wheelbase 77 in 195 6 cm SPECIFICATIONS SPORTSMAN 6x6 Parking Brake Hydraulic lock all wheel Headlight 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Taillights 8 26W Brakelight 26 9W LCD Jetting Chart Altitude AMBIENT Below 40 F 40 and above TEMPERATURE Below 5 C 5 and above Meters 0 1800 147 5 Feet 0 6000 1800 3700 6000 12000 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 10 MH Blue Green Red 40 Feet 0 6000 PN 5630513 PN 7041157 PN 7041198 PN 5131446 242 Re 0 1800 3700 10 WH Blue Green d 4 6000 12000 PN 5630710 PN 7041157 PN 7041198 PN 5131446 242 115 POLARIS PRODUCTS Part No Description Engine Lubricant 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871557 2871312
24. owner s manual for details 7079902 under seat 30 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 injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings Z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 31 FEATURES AND CONTROLS Jy UR Service Brake Lever Middle Axle Auxiliary Brake Lever Throttle Lever Box Dump Latch Release Gear Selector Floorboards Backrest Cargo Box Front Rack
25. register your vehicle in your new country 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 the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Vehicles registered to Government officials or mili tary personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 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 2006 and later Large Spark Ignition Engine herein LSI engine The California Air Resources Board has designated this engine for this vehicle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six 6 or four 4 wheel drive and or a round steering wheel In California this LSI engine mu
26. system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in neutral and start the engine 3 Purge carbon from the system by momentarily revving the engine several times 4 If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times 5 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug 100 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
27. the key off to prevent battery drain 5 All Wheel Drive AWD Switch 33 FEATURES AND CONTROLS Throttle Lever 4 amp WARNING Do not start or operate a vehicle with sticking or improperly operating throttle controls Doing so could cause an accident and lead to severe injury or death Always contact your dealer for service repairs if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Engine speed and vehicle movement are controlled by pressing the throttle lever 1 The throttle lever is spring loaded and engine speed returns to idle when the lever is released This vehicle is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle should stick in an open position engine RPM will diminish and power to the rear wheels will cease 4 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 34 FEATURES AND CONTROLS Brakes The braking system is controlled by the two brake levers located on the handlebars dir
28. to 13 cm remove from the locking tabs 7 Carefully pull the assembly up and out of pod 8 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm See illustration 9 Adjust the headlight aim by turning the adjusting knob 107 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 dielectric grease to the socket and install the new lamp 3 Test the taillight brakelight for proper operation 4 Reinstall the gasket and lens cover 108 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 116 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 automobile Washing the ATV The best and safest way to clean your is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water sp
29. to maintain lighting quality Hot components can cause serious burns to skin Don t service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 we Using a small flat blade screwdriver push in on the lock tabs through the two small openings at the front of the headlight pod Lift the pod slightly while depressing the tabs Remove the three screws in the back of the headlight pod Lift the pod cover Disconnect the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover Unplug the headlamp from the wiring harness Remove the boot and locking collar from the back of the lamp housing Grasp the base of the lamp and lift it out Reverse the previous steps to replace the lamp and reassemble the pod Make sure the tab on the lamp locates properly in the housing Snap pins into tabs Position knob in slot and secure in Route plug locking Adjustment over handlebar tabs Knob Stop B 105 MAINTENANCE AND LUBRICATION Lights A 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 caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness High Beam Headlight Adjustme
30. vehicle and pull the choke knob 1 out until it stops The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 2 NOTE Ifthe knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut 2 clockwise Turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 4 52 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the switch when the vehicle starts If the engine does not start release the starter and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in 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 2 Position the vehicle on a level surface with the transmission in neu
31. 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until the battery voltage is 12 8 V or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging 4 WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 103 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 104 MAINTENANCE AND LUBRICATION Lights 4 amp 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
32. 310 500 Inspect adjust lubricate ETC Switch replace if necessary Choke cable 50H 310 500 Inspect adjust lubricate replace if necessary Carburetor air 50H 310 600 Inspect ducts for proper intake ducts sealing air leaks flange hub bear 310 500 Minen clean replace as if equipped needed Drive belt 310 500 Inspect adjust replace as needed Cooling system 50H 310 500 Inspect coolant strength if applicable seasonally pressure test system yearly Engine oil change 100 H 620 1000 Perform a break in oil change at 25 hours one month 72 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km gt Oil filter change 100 H 620 1000 Replace with oil change O Oil tank vent hose 100 H 620 1000 Inspect routing condition 100 H 620 1000 Inspect adjust Fuel system 100 H 12M 620 1000 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years H Fuel filter 100 H 620 1000 Replace yearly Radiator 100 H 12M 620 1000 Inspect clean external if applicable surfaces Cooling hoses 100 H 12M 620 1000 Inspect for leaks if applicable gt mous won 820 030 Exhaust muffler 100 H 12M 620 1000 Inspect pipe H Spark plug 100 H 620 1000 Inspect replace as needed aas Ignition Timing 100 H Wiring 100 H 12M 620
33. BRICATION Adjustments Side Panel Removal Remove the seat 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 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tabs To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until the tabs lock Bend the rear of the side panel and insert the two tabs into the rear cab Step 2 Step 3 93 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 wheel 4 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Wheel Installation 1 2 4 5 94 Place the transmission in gear and lock the parking brake Place the wheel in the correct position on the wheel hub Be sure t
34. ENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn and cause serious injury or death HOW TO AVOID THE HAZARD Never operate on hills too steep for the vehicle or for your abilities Never operate the Sportsman 6x6 on hills steeper than 15 Practice on small hills before attempting larger hills 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The vehicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 19 SAFETY Operator Safety 4 amp WARNING 20 POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a
35. a caution to reduce the chance of skidding or sliding out of control 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating the vehicle on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 17 SAFETY Operator Safety 4 amp WARNING 18 POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the vehicle on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed SAFETY Operator Safety 4 WARNING POT
36. al injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Locate handlebar bolts 1 by removing the upper headlight pod 2 Loosen the four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts Optional Suspension Springs Although the Polaris Sportsman 6x6 suspension has the capability of providing the best ride possible the following accessory springs are available to better suit individual riding preferences NOTE Optional springs may be a different color than standard springs Springs may be painted to a desired color using Polaris touch up paint available through Polaris dealers SOFT lt ____________________ FIRM Front Strut Spring 7041375 067 7041450 067 N A OPTION STANDARD 64 113 Ib in 101 Ib in 87 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 recommended to keep the brake system in good operating condition Check more often if brakes are used heav
37. as possible 3 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 4 Slow down 5 The cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured 4 WARNING 56 Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 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 parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening PVT shifting is automatic 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 57 OPERATION Driving Safely Making Turns Practice making turns at slow speeds The Sportsman 6x6 is equipped with a solid rear axle that drives all
38. balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 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 Always check for obstacles or people behind the vehicle before oper ating in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your vehicle and always maintain proper tire pressure Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or towing Allow a greater distance for braking Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 10 SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris Sportsman 6x6 any equipment that may inc
39. breather filter 1 out of the hoses remove the lower hose from the engine Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace as needed Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and clamps with the arrow pointing toward the air box NOTE The breather filter is intended to be used with the air box pre filter in place Without the pre filter the breather filter can clog quickly CAUTION Operating the vehicle without both the pre filter and breather filter can cause engine damage Always reinstall both filters when they ve been removed for service 85 MAINTENANCE AND LUBRICATION Adjustments 4 amp 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 the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out 1 Set the handlebars in a straight ahead position and hold them in this position iu s 2 Id Sasy 5 os 26 0G 0 200 IM 040 202890 82905 LL NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2
40. ce needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2005 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2006 Sportsman 6X6 Owner s Manual P N 9920163 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 4 SAFETY EIN DELETE 5 FEATURES AND CONTROLS 32 OPERATION xd Rick cda Rua Rack tcd ec 49 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 SPECIFICATIONS 114 POLARIS PRODUCTS 116 TROUBLESHOOTING 5 rs uos rry 117 WARRANTY huida RR C 121 MAINTENANCE LOG i pee ar ER Rh 130
41. cessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your vehicle before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual SAFETY Operator Safety Always keep both hands on the handlebars and both feet on the foot rests of the vehicle during operation Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow recommended turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Always have the vehicle inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascending a hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhi
42. cy does not apply to vehicles registered to government offi cials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country be fore you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty cov erage You may also be required to obtain documentation from Polaris Industries in order to
43. d rear gearcases and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after becoming immersed If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine 64 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 these precautions when operating in reverse 1 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 the override button while the throttle is open Loss of control may result CAUTION Opening the throttle more than required may cause fuel to build in the exhaust resulting in engine popping and or engine damage 4 WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Avoid backing on inclines
44. dic Maintenance Chart beginning on page 70 Maintain the oil level at the bottom of the fill plug threads Polaris recommends the use of Premium ATV Angle Drive Fluid See page 116 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface and remove the fill plug 1 2 View the oil level and add the recommended oil as needed 3 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Oil Change 1 Remove the fill plug 2 Remove gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 4 Add the recommended fluid to the bottom of the fill plug threads 5 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 6 Check for leaks 77 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 in lubrication performance and protection See page 116 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more powe
45. e button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE f you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 48 OPERATION Fuel Safety 4 amp WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area with the en gine stopped Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothi
46. eU 82 Cooling System Operation 83 COIIOSIOD serea enna hene ns 112 Crankcase Emission Control System 68 D Diagnostic Mode Instrumentation 47 48 Disengaging Wheel Hubs 43 Drive Chain Adjustment 90 91 Driving Downhill 60 Driving in Reverse 65 Driving on Slippery Surfaces 63 Driving Over Obstacles 67 Driving Procedures 57 132 D Driving 56 67 Driving Through Water 64 Driving Uphill 61 Dumping Cargo 55 E Emission Control Systems 68 Emissions Warranty 129 Engine Break in 50 Engine Cooling System 82 83 Engine Idle RPM Adjustment 91 Engine Storage 110 Equipment Modifications 11 Exhaust Emission Control System 68 F Features so cem Ie pa es 32 48 Filter Systems 84 85 Front Gearcase Lubrication TI Front Wheel and Middle Axle Brake 88 Front Wheel Hub Tightening 89 Fuel Tank 55 e see 38 Fuel Valve ves cheats eee 38 G H Gear 39 Handlebar Adjustment 87 Hauling 54 55 Headlight Adjustment 106 Headlight Housing Replacement 107 Headlight Lamp Replacement 105 High 98 Hour Meter 46 I J K Instrument Cluster
47. ealer There will also be no charge for any diagnostic labor performed at an authorized dealer which leads to the determination that a warranted emission related part is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as necessary shall be warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system ii Air fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an au
48. ealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when mainte nance and installation are in accordance with Polaris recommendations 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 export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any ques tions This poli
49. ectly 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 lever for normal braking Apply the service brakes by squeezing the left brake lever toward the handlebar These brakes are hydraulically activated disc brakes Always test brake lever travel and check the reservoir fluid level before riding The lever should feel firm when squeezed Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before operating See your dealer for proper diagnosis and repairs Auxiliary Brakes The auxiliary brake lever 2 is located on the right handlebar It controls braking action for the middle axle rear brake only Use the auxiliary brakes for additional braking or if the service brake system fails 4 WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever 35 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
50. ederal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle is the only adjustment 1 Polaris recommends that the or operator perform Any other AN adjustments should be performed by AS A an authorized Polaris dealer PRESE EM E E P The emissions label 1 is located E on the recoil cover or stator cue oe housing E Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 68 MAINTENANCE AND LUBRICATION Tool Kit To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Items included in the kit are Screwdriver Open end wrench 8 10 mm Open end wrench 12 14 mm Box end wrench Tire pressure gauge Spark plug wrench and handle Torx wrench rack removal Accessories Polaris has a wide variety of accessories for your vehicle Contact your Po
51. el or tilted slightly rearward 2 Remove the spark plug rotate the piston to BDC and pour approximately two ounces of Premium 4 Synthetic 4 cycle oil into the cylinder Reinstall the spark plug 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 Turn the engine over several times using the recoil starter to ensure coverage of piston rings cylinder walls and crankshaft bearings 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline 110 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Engine Anti Freeze Test engine coolant strength and change if necessary Replace coolant every two years Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Apply Polaris O Ring Chain Lube to the drive chain s Storage Area Covers Set the tire pressure and safely support the with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote
52. eled by the Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature elevation and electrical loads 46 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 diagnostic mode either shift the machine out of neutral or turn the key switch off and on NOTE Any movement of the tires will also take the machine out of the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activa
53. engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range When basic operation is at speeds less than 7 MPH 11 KPH For heavy pulling When operating in rough terrain swamps mountains etc at low ground speeds High Range When basic operation is at speeds greater than 7 MPH 11 KPH When operating at high ground speeds 98 MAINTENANCE AND LUBRICATION PVT System 4 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 precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of fo
54. ery 1 Ensure that the battery is fully charged Set the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Reinstall the battery cover and attach the hold down strap Qv deoa qa Verify that cables are properly routed 102 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 leads may need to be bent down so that the battery cover can be installed Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing to maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register
55. ey switch is in the ON position NOTE Ifthe engine is cold use the choke as outlined on page 52 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 40 FEATURES AND CONTROLS Recoil Starter 5 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 6 Repeat steps 4 5 if necessary CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 41 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 front wheels will automatically engage any time the rear wheels lose traction When the rear wheels regain tract
56. fluid level is full When fluid is low the eye will be clear NOTE When checking the fluid level position the ATV on level ground with the handlebars turned so the top of the reservoir is level If the fluid level is low add DOT 3 brake fluid DO NOT OVERFILL See page 116 for the part numbers of Polaris products 4 WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill 4 WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 36 FEATURES AND CONTROLS Parking Brake 4 amp 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 1 lever two or three times then squeeze and hold 2 Push the park brake lock 1 forward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked posit
57. front rack 1 Remove the front cover 2 by placing 0 your fingers under the front of 1 9 the cover and pulling upward E n nh 4 2 Remove the pressure cap 5 i 3 Using a funnel slowly add coolant as necessary through the radiator filler neck 4 Replace the pressure cap and secure the front cover and rack NOTE Use of anon standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 82 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 the TE recovery Add coolant as x _ needed 1 d Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pres
58. gear the transmission is in 3 4 5 6 High Range L Low Range Neutral 7 R Reverse P Park 2 2 AWD Indicator This indicator illuminates when the electrical portion of the AWD system is enabled 8 3 Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Check Engine Warning Indicator The word HOT will display alphanumerically when the engine is overheating Do not continue to operate the if this warning appears or serious engine damage could result 8 Mode Indicator B 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Tachometer The reverse override button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles trav
59. ghs 895 Ibs 406 kg Axle and Wheel Nut Torque Specifications Check the following nuts for tightness occasionally or if they ve been loosened for service Front Spindle Nut s 100 in Ibs 11 Nm Front Wheel Nuts 27 ft lbs 37 Nm Center and Rear Axle Nut s 80 ft Ibs 108 Nm Center and Rear Wheel Nuts 50 ft Ibs 68 Nm 96 MAINTENANCE AND LUBRICATION Spark Plugs Use BKRSE spark plugs e Proper electrode gap is 036 9 mm Spark plug torque is 14 ft Ibs 1 9 kg m CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE Thetip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is b
60. he mark 4 on the tank NOTE not over tighten Maximum torque for the screen fitting is 25 ft Ibs 84 Nm 80 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 8 9 10 11 12 Reattach the oil line Place shop towels beneath the oil filter Using an oil filter wrench turn the filter 1 counterclockwise and remove Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Also make sure the gasket from the old filter is not still on the engine Install the new filter and tighten by hand 1 2 to 3 4 turn after gasket contacts the engine Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should 13 14 be clean and free of burrs nicks or scratches After draining reinstall the drain plug CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil 0 40W Never substitute or mix oil brands Remove the dipstick 2 and add two quarts 1 9 1 of the recommended oil Reinstall the dipstick NOTE Ifthe sump is not drained add about 1 3 4 quarts initially 15 16 17 18 Place the gear selector in neutral and
61. he transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to neutral Using the throttle vary the engine RPM from idle to full throttle Repeat several times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Always use the recommended belt Improper break in Always break in a new belt and or clutch by avoiding aggressive or high speed operation during the first two full tanks of fuel 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 connec
62. he valve stem is toward the outside and the rotation arrows on the tire point toward forward rotation Attach the wheel nuts and finger tighten them Make sure the tapered side of the rear wheel nut fits into the taper on the wheel 1 Lower the vehicle to the ground Torque all wheel nuts to specification See page 96 MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less 4 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 the tread depth measures 1 8 3 cm or less 4 WARNING Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire always use original equipment size and type 1 8 3 cm 95 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 Ibs 363 kg Front Rack Load Capacity 75 Ibs 34 kg Gross Vehicle Weight 1970 Ibs 894 kg including vehicle driver and cargo Vehicle wei
63. hould never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill Maximum Cargo Capacities Level Ground Total Cargo 875 Ibs 397 kg Front Rack Cargo 75 Ibs 34 kg 800 lbs 363 Ko Maximum Towing Capacities Towed Load level ground 1500 Ibs 681 kg Towed Load up to 15 incline 850 Ibs 386 kg Vertical Hitch Weight 150 Ibs 68 1 kg Towing Grade 15 54 OPERATION Hauling Cargo Dumping Cargo 1 AR WN Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Set the parking brake Dismount the vehicle Pull the cargo box release lever forward Lift the front of the cargo box and dump the cargo WARNING If the weight distribution in the box is located toward the rear of the box when the release lever is pulled forward the box may dump on its own which could cause serious injury Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box Never carry passengers in the cargo box 55 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
64. hub engagement symptoms are present use the disengaging procedure before proceeding 43 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 limits the ATV s speed to approximately 7 9 mph Refer to page 33 for additional information PESLARIS 1 Rider Information Center Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster Do not allow insect sprays to come into contact with the lens 44 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 Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the cluster s electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator As the shift lever is moved this indicates the
65. ibrated 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 mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area NOTE Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line 1 approximately 2 from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 45 60 seconds 3 Remove the vent line clamp The oil pump will now be properly primed and ready for operation 2 92 1 2 MAINTENANCE AND LU
66. il reservoir level indicated on the dipstick Add the pe e recommended oil as needed to bring the level 1 within the normal range 1 3 Drive slowly at first Select an open area that will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 51 6 Pull only light loads during the break in period 7 Perform a break in oil change at 20 hours or one month whichever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period 50 OPERATION Pre Ride Inspection 4 amp 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 d o Brake system lever travel Ensure proper operation Brake fluid Auxiliary brake Front suspension Ensure proper level Ensure proper operation Inspect lubricate if necessary Rear suspension Steering Tires Wheels fasteners Frame nuts bolts fasteners
67. ily under normal operation 1 Always keep brake fluid at an adequate level see page 36 NOTE Under normal functioning the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should 3 64 be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Replace brake pads when they are worn to 3 64 1 cm Middle Axle Brake 88 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 Change the brake pads when they re worn to 3 64 1 cm Inspect the brake disc spline and pad wear surface for excessive wear Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until
68. improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use 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 HAZARD Always use the size and type of tires specified in the owner s manual Supplement for the vehicle Always maintain proper tire pressure WARNING POTENTIAL HAZARD Operating the vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the vehicle may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the Sportsman 6x6 through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this vehicle and should be installed and used according to approved instructions See your authorized Polaris dealer for more information SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the vehicle on a frozen body of water 4 WARNING POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction ti
69. ing When you purchased your new your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of the in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals 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 A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A
70. injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing 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 is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the vehicle during operation 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the vehicle could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extr
71. ion j 455 Important Safeguards The parking brake may relax if left on for a long period of time AI ways block the wheels to prevent rolling Always block the wheels on the downhill side of the vehicle if leav ing it parked on a hill Another option is to park the vehicle in a sidehill position Never depend on the parking brake alone for more than five minutes if the vehicle is parked on a hill Always block the wheels to pre vent rolling 37 FEATURES AND CONTROLS Fuel Valve The fuel valve 1 is located on the left side RES panel It has three positions OFF For vehicle storage and when transporting OFF ON For normal operation RES For reserve supply if main supply is ON exhausted There s about a 7 to 10 mile 11 2 to 16 km range on the reserve supply Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 38 FEATURES AND CONTROLS Gear Selector The transmission gear selector 1 H L 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 gears with e
72. ion the front wheels will automatically disengage NOTE The override switch 2 allows activation of AWD in reverse if the AWD switch is on There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and hub damage Always switch to AWD while the rear wheels have traction or are at rest 42 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 increases but remains balanced from left to right and vehicle speed is somewhat restricted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE Ifthe hubs remain engaged after following this procedure return the vehicle to your dealer for service To continue using AWD while operating in reverse activate both the override switch and the AWD switch See page 33 4 WARNING Operating with only one front hub engaged could result in loss of control accident and severe injury or death When
73. lack A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 14 ft Ibs 1 9 kg m 97 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 pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 KPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 KPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the
74. laris dealer for a complete list The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Be sure any accessories added to the vehicle have been approved by Polaris Familiarize yourself with their function and effect on the vehicle 69 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 and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 130 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation E
75. le tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions 71 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first ee EC EC A Brake pad wear s far Monthly 60 100 Inspect periodically Batey 20H Monthly 125 200 Check terminals clean test Front gearcase oil Monthly 155 250 Inspect level change yearly if equipped Middle gearcase Monthly 155 250 Inspect level change yearly oil if equipped Rear gearcase oil 25H Monthly 155 250 Inspect level change yearly if equipped gt Transmission 25H Monthly 155 250 Inspect level change yearly Engine breather 25H Monthly 155 250 Inspect replace if necessary filter if equipped Engine oil change 25H 1M 155 250 Perform a break in oil break in change at one month General 50H 3M 310 500 Lubricate all fittings pivots lubrication cables etc Shift Linkage 310 500 Inspect lubricate adjust m seeng ew se gt Frontsuspension so SM f 310600 gt Rearsuspension son SM f 310500 Carburetor float 50H 310 500 Drain bowl periodically and bowl prior to storage Throttle Cable 50H
76. ll and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehicle Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible SAFETY Operator Safety Always use proper procedures if the vehicle stalls or rolls backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill Always dismount on the uphill side or to ei ther side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described in this manu al Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always be alert to the potential for skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control Avoid operating the vehicle through deep or fast flowing water If it s unavoidable travel slowly
77. lways 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 the use of Premium AGL Synthetic Gearcase Lubricant See page 116 for the part numbers of Polaris products Oil Check 1 Position the ATV on a level surface and remove the propshaft shield from the right side of the vehicle 2 Remove the fill plug 1 and add the recommended lubricant as needed to maintain the oil level at the proper level NOTE Do not fill to the bottom of the fill hole threads 3 Reinstall the fill plug and propshaft shield Oil Change 1 Position the ATV on a level surface and remove the propshaft shield from the right side of the vehicle 2 Remove the transmission drain plug 2 located on the bottom left hand side and drain the oil into an appropriate container Discard used oil properly 3 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft Ibs 19 Nm 4 Remove the fill plug and add the recommended lubricant Refer to the specifications section beginning on page 114 for capacities 5 Reinstall the fill plug and check for leaks 6 Reinstall the propshaft shield 76 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Lubrication Always check and change the front gearcase oil at the intervals outlined in the Perio
78. me may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating the vehicle could result in an accident and cause severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating the vehicle 25 SAFETY Operator Safety A A 26 WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems CAUTION Exposure to hot components could result in a fire Always keep combustible materials away from the exhaust system 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 decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal
79. n Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 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 failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the cust
80. n HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS eUse an approved HELMET AND PROTECTIVE GEAR eAvoid paved surfaces Pavement may seriously affect handling and control eUse proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns eUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle eREVERSE operation can be dangerous even at low speeds Steer ing becomes difficult To prevent flipover avoid sharp turns PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 7172589 28 SAFETY Safety Decals and Locations WARNING Os A WARNING Pushing reverse override button may cause ALL WHEEL DRIVE SWITCH Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 7172588 sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch
81. ng immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Turn the fuel valve off whenever the vehicle is stored or parked 4 WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 49 OPERATION 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 Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Lack of proper lubrication will cause serious engine damage Always check the oil level when refueling the vehicle Engine and Drivetrain Break in 1 Fill the fuel tank with either unleaded or leaded fuel that has a minimum pump octane number of 87 R M 2 2 Check the o
82. ng periods of storage or after pressure washing or submerging meme Brake Fluid DOT 3 only See page 36 Drive Chains O Ring chain lube Lubricate as often as required before or SAE 80 90 each ride in wet conditions Gear Selector Oil Premium 4 Maintain oil level at the center of the Synthetic OW 40 shift rail Do not overfill Transmission Oil Polaris Premium See page 76 Synthetic Gearcase Lube Front Prop Shaft Yoke 6e Grease Locate fittings and grease Loc 1 AWD Hubs Loc 2 Premium Demand Remove set screw in hubs Rotate Drive Hub Fluid wheels to 4 00 position A If lubricant is not visible add more Reinstall set Screw Ball Joint Loc 3 Grease Locate zerk on back side of struts and grease with grease gun Rear Axle Bearing Grease Locate fitting on eccentric and grease Loc 4 with grease gun Swing Arm Bushings Grease Locate fitting on swing arm and grease Loc 5 with grease gun Middle Axle Bearings p Grease Locate fitting on eccentric and grease Loc 6 with grease gun Center Swing Arm p Grease Locate fitting on swing arm housing and Housing Loc 7 grease with grease gun Rear Strut Loc 8 p Grease Locate fitting on rear strut and grease with grease gun Tie Rod Ends Loc 9 Grease with grease gun 74 MAINTENANCE AND LUBRICATION Lubrication Recommendations Loc 1 75 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Lubrication A
83. ng all scheduled inspection and maintenance services performed at the intervals specified in the 2006 and later owner s manual and to retain records of these services as having been performed These records should be transferred to each subsequent owner of the LSI engine POLARIS cannot deny a claim solely because there are no records of scheduled maintenance however a warranty claim may be denied if the failure to perform the scheduled maintenance and inspection resulted in the failure of a warranted emission related part As a minimum the LSI engine owner is responsible for the scheduled inspection and maintenance of emissions related items as specified in the maintenance section of the owner s manual 127 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 emission related parts These replacement parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emission related part is found to be defective during the warranty period you must notify the Polaris Warranty De
84. ngine speed above idle or while the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended N Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time 39 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 with automatic decompressors This makes recoil starting possible by reducing the amount of compression during starting The decompressor senses when the engine is spinning fast enough to start and restores compression when running 1 Position the vehicle on a level surface and lock the parking brake see page 37 2 Shift the transmission into neutral 3 Make sure the engine stop switch is set to RUN and the main k
85. nt 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 2 3 4 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine and turn the headlight switch to high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 106 Adjust the beam to the desired position by turning the adjustment knob either clockwise or counterclockwise 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 the front rack and cover may also allow easier access 2 Remove the three screws in the back of the headlight pod 3 Lift the pod cover Disconnect the speedometer harnesses from the speedometer and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Pull the headlight housing up to release from the locking tabs 6 Lift the adjusting knob up
86. nt of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing D
87. ollow the age recommendations for this vehicle WHAT CAN HAPPEN Severe injury and or death could occur if a person under the age of 16 operates the Sportsman 6x6 Even though a child may be within the recommended age group for operating some vehicles he she may not have the skills abilities or judgment needed to operate the Sportsman 6x6 safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris Sportsman 6x6 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Carrying a passenger on a Sportsman 6x6 WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the vehicle which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers 4 WARNING POTENTIAL HAZARD Operating a Sportsman 6x6 on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN Sportsman 6x6 tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the vehicle and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the Sportsman 6x6 on pavement If it s unavoidable travel slowly and avoid sudden turn
88. omer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control 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 replaceme
89. omponents or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650
90. ots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 109 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 beginning on page 102 Fluid Levels Inspect the following fluid levels and change if necessary front gearcase transmission front hubs brake fluid change every two years or as required if fluid looks dark or contaminated Engine 1 Support the front end of the machine so the engine is lev
91. partment at 1 763 417 8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed 128 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an en gine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replac ing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials c
92. proper dimension 6 Tighten the caliper mount bolts to 10 12 ft Ibs 13 5 16 3 Nm 7 Tighten the eccentric locking bolts to 60 ft Ibs 80 Nm 8 Confirm correct tension by rolling the vehicle forward checking chain tension in several places around the chain 9 Reinstall the chain guard NOTE Reposition the chain guide to allow 1 8 3 cm clearance between the sprocket and guide 90 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 95 1 3 cm at the tightest point in the chain 3 8 1 2 95 1 3 cm 3 8 1 2 95 1 3 cm Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Start the engine and allow it to warm up for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 91 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT Your Polaris ATV is cal
93. r output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0 40W Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil 0 40W Never mix brands 78 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil Level The oil tank is located on the left side of the vehicle To check the oil 1 2 3 4 Position the vehicle a level surface Start the engine and let it idle for 20 30 seconds Stop the engine Remove the dipstick and wipe it dry with a clean cloth Screw the dipstick completely in then remove it and check to see if the oil level is between the full and add marks NOTE The dipstick must be screwed all the way in to keep the 5 angle and depth consistent Add oil as needed to bring the level to the ADD 8 OZ ned FULL Pw normal range 1 Do not overfill 1 NOTE If oil level rises above the full mark water and or fuel may be collecting in the tank and the oil should be changed 79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4 CAUTION Hot oil can cause
94. rce on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remove the drain plug and allow the water to drain Replace the drain plug 2 Start the engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed and shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 99 MAINTENANCE AND LUBRICATION Spark Arrestor 4 amp 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
95. rease the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris Sportsman 6x6 is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 11 SAFETY Operator Safety 4 amp WARNING 12 POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized Polaris dealer or call Polaris at 1 800 342 3764 WARNING POTENTIAL HAZARD Failure to f
96. s or stops 4 WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in serious injury or death 13 SAFETY Operator Safety 4 amp WARNING 14 POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN The vehicle could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the Sportsman 6x6 on any public street road or highway including dirt and gravel roads WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating a Sportsman 6x6 without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling or rolling backwards while climbing a hill WHAT CAN HAPPEN Stalling or rolling while climbing a hill could result in vehicle overturn HOW TO AVOID THE
97. 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 in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 2 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain plug and torque to 14 17 ft 165 19 23 Nm 6 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 7 Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1 2 turns into the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with t
98. set the parking brake Prime the oil pump using the procedure on page 92 then stop the engine and inspect for leaks Recheck the oil level on the dipstick and add oil as necessary to bring the level to the upper full mark on the dipstick Dispose of the used filter and oil properly 81 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 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 116 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator Coolant Level 4 amp WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Access the radiator pressure cap iB by removing the four screws 2 O securing
99. st be designed built and equipped to meet the state s stringent anti smog stan dards Polaris must warrant the emission control system on your LSI engine for the peri od of time described below provided there has been no abuse neglect or improper maintenance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLARIS will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 2006 and later LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities As the LSI engine owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Own er s Manual POLARIS recommends that you retain all receipts covering main tenance on your LSI engine but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Asthe LSI engine owner you should however be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications
100. sure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle 83 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 ieee the spring clamps securing the air box lid and remove the id 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water rinse and allow to dry thoroughly 5 Reinstall the pre filter over the main filter Replace the main filter if necessary 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp or filter damage may occur CAUTION Operating the vehicle without a pre filter can cause engine damage Always reinstall the pre filter before operating 84 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 Chart beginning on page 70 1 NOTE It s not necessary to 2 Remove the clamps and pull the
101. ted The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 47 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 this feature is set at 50 hours You must enable the programmable service interval before it can be used Once the service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time th
102. ted load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when hauling cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See pages 54 55 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the vehicle through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the vehicle through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 64 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving 23 SAFETY Operator Safety 4 amp WARNING 24 POTENTIAL HAZARD Operating this vehicle with
103. thorized dealer determines that other LSI engine components have been damaged due to the failure of a warranted emission related part during the warranty period POLARIS will repair and or replace the necessary components 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 engine is being serviced under warranty POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine for any damage to goods or loss of time or inconvenience This limited warranty also does not apply to any emission related part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions specified in the 2006 and later Owner s Manual including a Improper or inadequate maintenance of any warranted emission related part b Improper installation adjustment or repair of the LSI engine or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2006 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for havi
104. tions and tighten Engine Turns Over Fails to Start Possible Cause Solution Turn fuel valve to reserve refuel Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 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 Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution Kinked or plugged fuel vent line Inspect and replace 119 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solutio
105. tral Lock the parking brake turn the fuel tank valve to ON sit on the vehicle and move the engine stop switch to RUN If the engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 53 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 4 WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Never exceed the stated load capacity for this vehicle Do not obstruct the headlight when loading the front rack Cargo should be properly distributed and carried as low and for ward in the cargo box as possible Reduce speed and allow a greater distance for braking Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill Always attach the tow load to the hitch point Do not tow any trailer on a grade steeper than 15 Vehicle s
106. urn around 62 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the brake until the vehicle is on more level ground 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 quick sharp turns which can cause skids NOTE Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Never brake during a skid 3 Drive with AWD engaged to assist in controlling the vehicle in slippery areas CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning
107. when under water Fa C 9 Drain the recoil housing any time the vehicle has been operated in very wet conditions and also before storage The drain screw 1 is located at the bottom of the recoil housing above the front propshaft Remove the screw with a 10 mm wrench Reinstall the screw after the housing has been drained N Hf 1 n NOTE Do not open the crankcase drain 2 unless the engine has ingested water Some engine oil will be lost if crankcase drain is opened 101 MAINTENANCE AND LUBRICATION Battery 4 amp 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 negative black cable last Battery Removal 1 Disconnect the hold down strap holding the battery in position and remove battery cover 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Lift the battery out of the ATV Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 103 before installing the batt
108. xtended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 70 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions m Have an authorized Polaris dealer perform these services 4 WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first aid cun Miles Km Pre Ride Make adjustments as need S onpagest i e ce Pre Ride Brake everwaver Brake systems mene wmeesmsees meme Frame testeners Eumesree meme Air filter pre filter Daily Inspect clean often replace as needed Air box sediment Daily Drain deposits when visib

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