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JVC GZE10RUS Camcorder User Manual

1. ANTONS OT WA OLX NO OL V Sw si BW OI V vear o MIS 0 1023 amem annoys 199VH2 AY annoys 3N19N3 AN WYYOVIG NI 9NI2VUI ASI TANTS Ol S3NI1 03HSVO YO 01108 AB 03183638438 3NV SIVIM 9X9 NYWSLYOdS 2002 120 TROUBLESHOOTING Clutch Drive Belt 8 Cover Related Issues Diagnosis Possible Causes Solutions What to do Loading the 6x6 into a pick Shift transmission to low range during up or tall trailer when in high loading of the 6x6 to prevent belt burn range ing Starting out going up a When starting out on an incline use steep incline low range or dismount the 6x6 after first applying the park brake and per form the K turn as described on page 67 of this manual Driving at low RPM or low Drive at higher speed or use Low ground speed at approxi Range The use of Low Range is high mately 3 7 MPH ly recommended for cooler PVT oper ating temperatures and longer compo nent life Insufficient warm up of Warm engine at least 5 min then with 6x6s exposed to low ambi transmission in neutral advance ent temperatures throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will be come more flexible and prevent belt burnin
2. 120 Understanding Warnings 7 127 Vehicle Break in Period 50 Vehicle Identification Numbers 6 Vehicle Nomenclature 37 Warranty usce eoe eer 124 125 AWARNING Always use an Never carry Never use Never use a approved helmet on public passengers with drugs and protective roads or alcohol gear NEVER operate without proper training or instruction M at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS Y use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns Y avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH Geo POLARIS The Way Out Part No 9916797 PRINTED IN THE USA
3. DUBAI Never activate override button while throttle is open Loss of control may result NOTE This vehicle is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Only open the throttle enough to maintain a desired speed Opening the throttle more than required may cause excessive fuel to build in the exhaust resulting in engine popping and or engine damage AWARNING Indicates a potential hazard which could result in serious injury or death 69 RIDING Riding Safely Backing Up AWARNING Backing your 6x6 can be dangerous You could hit an obstacle or person behind you or the vehicle could tip over on a steep incline causing severe injury or death Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power is required for vehicle movement Avoid backing on steep inclines Avoid turning at sharp angles in reverse 70 RIDING Riding Safely Trail Obstacles Keep Alert Look ahead and learn to read the trail as you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Hidden or unseen hazards on the trail can be dangerous Personal injury or the vehicle overturning can occur from unseen obstacles e Keep alert and con
4. ATTENTION e Operation of this vehicle without the filter element will severely damage the engine Clean air filter often more e Specific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual frequent cleaning required in dusty conditions Factory setting Operation of this vehicle without t S engine breather filter s can A0 10 80 F at 0 3000 feet cause engine damage Consult 5 to 27 C at 0 900 meters owner s manual for details 7079902 20 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT_CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the training course contact an authorized Polaris dealer or call Polaris at 1 800 342 3764 A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle WHAT CAN HAPPEN Use by children of vehicles that are not recommended for their age can lead to severe injury or death of the child Even
5. SO POLARIS 2002 oportsman 6x6 TUI San Manual a yenn Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age ZAWARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm AWARNING Indicates a potential hazard that could result in serious injury or death We ve created a web site just for YOU e Technical tips New product introductions Event schedules e Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out WELCOME Thank you for choosing Polaris and welcome to our world wide family of Polaris enthusiasts Polaris proudly produces an exciting line of recreational products including snowmobiles all terrain vehicles personal watercraft utility vehicles and Victory motorcycles We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today Many years of experience in engineering design and development have gone into making your Polaris vehicle the finest machine we ve ever produced Follow the instructions and recommendations in this Owner s Manual for safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance Major re
6. AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER e Operate on public roads A collision can occur with another vehicle e Carry passengers Passengers affect balance and steering and in crease risk of losing control USE ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS e Use an approved HELMET AND PROTECTIVE GEAR e Avoid paved surfaces Pavement may seriously affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle e REVERSE operation can be dangerous even at low speeds Steer ing becomes difficult To prevent flipover avoid sharp turns PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 16 SAFETY Safety Decals and Locations SAFETY Safety Decals and Locations 4 AWARNING ETC This vehicle is equipped with a 5 Polaris Electronic Throttle Control ETC to reduce
7. NOTE The override switch also allows activation of AWD in reverse if AWD switch is on 48 CONTROLS AND FEATURES Features A red AWD light on the switch indicates when the vehicle is in AWD There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction 4 CAUTION Do not switch on AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before turning the AWD switch on Disengaging Wheel Hubs When backing uphill while in AWD and then going forward downhill one or both hubs may remain engaged If one or both hubs remain engaged they can be disengaged by stopping shifting to and moving in reverse Then proceed in forward again AWARNING If both hubs were engaged and only one released during operation loss of control could result If you experience hub engaging symptoms use the above disengaging technique before proceeding Failure to disengage front hubs as directed above could result in severe injury or death If the hubs remain engaged after following these instructions return the vehicle to your dealer for service You can tell if only one
8. The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury AWARNING Indicates a potential hazard that could result in serious injury or death 4 CAUTION Indicates a potential hazard that may result in minor personal injury or damage to the machine CAUTION Indicates a situation that may result in damage to the machine NOTE NOTE will alert you to important information or instructions SAFETY Key Safety Issues Protect Your Sport Know all local state province riding laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended maintenance program as outlined This preventive maintenance program is designed to ensure that all critical components on this vehicle are thoroughly inspected at various intervals All information in this manual is based upon the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Illustrations included in this manual are general representations of parts having a similar function Your model may differ THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE This Vehicle handles d
9. ARE THE ACTS LISTED BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance 4 CAUTION Remember exhaust system components are very hot during and after use of the vehicle e Do not touch hot exhaust system components Serious burns can result e Beespecially careful when traveling through tall grass The po tential for fire exists USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Standard 5100 1A 57 RIDING Daily Pre Ride Inspection Inspect your 6x6 each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result A WARNING If a proper inspection is not performed serious injury or death can result Always inspect your 6x6 before riding following the checklist carefully Before riding your vehicle inspect all operating controls and parts Item Inspection Procedure e Tires check condition and pressures e Fuel and oil tanks fill both tanks to their proper levels All brakes check operation adjustment and fluid level in cludes auxiliary brake Throttl
10. Important Information Due to our concern for the safety of our customers and the general public Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris 6x6 any equipment which is intended to increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle substantially increase the risk of bodily injury Please be aware that these modifications may create a substantial safety hazard Polaris hereby informs you that the warranty on your vehicle is terminated if any such equipment has been added to the vehicle or any modifications have been made to the vehicle which increase its speed or power We also advise you to strictly follow the recommended maintenance program outlined in this manual This preventive maintenance program is designed to ensure that all critical components on the vehicle are thoroughly inspected by your dealer at various mileage intervals NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Be certain any accessories added to this vehicle have been approved by Polaris Familiarize yourself with their function and affect on the vehicle 11 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing Riding this vehicle re
11. Replacement 1 Follow steps 1 3 of Headlight Housing Replacement on pre vious page 2 Unplug light from harness 3 Using a screwdriver turn the light 1 4 turn counter clockwise 4 Install new light and use a screw driver to seat it into place 1 4 turn clockwise 5 Reassemble pod 114 MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning the 6x6 Keeping your 6x6 clean will not only improve its appearance but it can also extend the life of various components With a few precautions your 6x6 can be cleaned much like an automobile Washing the 6x6 If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the drive chain wheel bearings transmission seals body panels brakes and warning labels Many expensive repair bills can result from using high pressure detergent systems The best and safest way to clean your 6x6 is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots Waxing the 6x6 Your 6x6 can be waxed with any quality brand automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish 115 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage of the 6x6 If your 6x6 is to be placed in extended or off season storage the following steps
12. SAFETY Operator Safety 23 A WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway even a dirt or gravel one In many states it is illegal to operate vehicles of this type on public streets roads and highways A WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT_CAN HAPPEN Could result in vehicle overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never a
13. close fitted engine parts 5 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined earlier on the daily pre ride inspec tion checklist found on page 12 6 Pull only light loads 7 Break in oil and filter Change at 20 hours or 200 miles 50 OPERATION Daily Pre Ride Inspection Inspect your 6x6 each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result A WARNING If a proper inspection is not performed serious injury or death can result Always inspect your 6x6 before riding following the checklist carefully Before riding your vehicle inspect all operating controls and parts Item Inspection Procedure e Tires check condition and pressures e Fuel and oil tanks fill both tanks to their proper levels e All brakes check operation adjustment and fluid level in cludes auxiliary brake Throttle check for free operation and closing Headlight Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Drive chain condition and slack refer to drive chain adjust ment Air cleaner element check for dirt clean or replace Steering check for free operation noting any unusual loose ness in any area Loose part
14. damage 1 89 Remove the clamps and pull the filter out of the hoses NOTE It will not be necessary to remove the lower hose from the engine Inspect filter for debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed Breather Check hoses for cracks filter deterioration abrasion or leaks Replace as needed Reinstall filter and clamps with arrow pointing toward engine NOTE The breather filter is intended to be used with airbox pre filter in place Without the pre filter the breather filter can clog quickly Never operate your vehicle without the pre filter NOTE Inspect the filter monthly or every 20 hours of operation whichever comes first Replace filter as needed MAINTENANCE AND LUBRICATION Adjustments AWARNING Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact your Polaris dealer He she has the training and tools to make these adjustments Toe Alignment You can check the toe alignment of the vehicle using the following method The recommended toe alignment is 1 8 to 1 4 toe out If you discover improper adjustment have your dealer correct it CE A fore 20092008 q DA Q G e Q Q AS 1 Set handlebars in a straight ahead position and hold them in this posi tion NOTE The steering frog can be used as an indicator of whether the handleb
15. front hub is engaged if the handlebars pull to one side If both front wheel hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted 49 OPERATION Vehicle Break in Period The break in period for your new Polaris 6x6 is defined as the first ten hours of operation or the time it takes to use the first two tanks of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully 44 CAUTION Use only Polaris Premium 4 All Season synthetic oil or API certified SP oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result 1 Fill fuel tank with either unleaded or leaded fuel which has a mini mum pump octane number of 87 R M 2 2 Check oil reservoir lev el indicated on dipstick ADD 8 OZ NORMAL p E CINES Add oil if necessary 3 Drive slowly at first Maintain Oil Level In Normal Range Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 4 CAUTION Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to
16. in reverse AWARNING Avoid turning at sharp angles in reverse as tipover and serious injury may result 61 RIDING Riding Safely Sidehilling Sidehilling your 6x6 is one of the most dangerous types of riding and should be avoided if possible In the event you do enter into a situation where sidehilling is necessary always 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately AWARNING Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the vehicle could occur e Avoid crossing the side of a steep hill if possible Use extreme care when operating your 6x6 in hilly terrain 62 RIDING Riding Safely Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during cold freezing weather special attention must be paid to prevent vehicle turnover Always 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 Driving with Demand 6 D
17. nb Le PU ERE ee eet 88 Adjustments iov sur ick a ant 90 Spark PIUJS tutor ces iE ede nse ht edson 103 Spark AMOS mi as pee 104 Recoil MOUSING ore cds airis E 106 EVE uc si 107 BAS tus Sota a anA anaa a abd esed e d a AT 108 LIS S siete at eun i Bottes god ite dp tetas retos a anneal RU d 111 Cleaning and Storage Lssuuussuuss 115 Specifications 118 119 Wiring Diagram serere 120 Trouble Shooting 121 123 Warranty i242 Rma dee 124 125 VEHICLE IDENTIFICATION NUMBERS Important Record these numbers from your vehicle in the spaces provided 1 Frame VIN 2 Engine Serial Number Right front side of engine crankcase Remove the spare key and store in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key The vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essential to the recovery and identification of your vehicle Dealer Imprint SAFETY Understanding Warnings The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A
18. of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer There is a charge of 35 00 payable to Polaris Industries Inc REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally neglec
19. off all electrical power to the entire vehicle including lights To stop the engine slide the stop switch right or left to the off position 38 CONTROLS AND FEATURES Controls Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded and engine speed returns to idle when the lever is released This vehicle is equipped with a Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle In the event the throttle should stick in an open position engine RPM will diminish and power to the rear wheels will cease Choke Knob 2 Refer to the engine starting procedure on pages 52 53 for correct choke and throttle settings during starting AWARNING The Electronic Throttle Control ETC limits engine power in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms AWARNING Do not start or operate this vehicle with sticking or improperly operating throttle controls A stuck or improperly operating throttle could cause an accident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle problems arise Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding
20. oil Catch and discard used oil properly 4 Clean and reinstall the drain plug 5 Add Polaris Premium Synthetic Gearcase Lubricant PN 2871478 12 oz bottle until oil reaches the bottom of the filler hole 6 Check for leaks 7 Reinstall propshaft shield or footwell and screws removed in step 1 80 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Lubrication The front gearcase fill plug 3 is located as shown The front gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Front gearcase oil should be changed annually With the 6X6 on a level surface remove fill plug and check the lubricant level Lubricant should be kept at the bottom of fill plug thread The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Gearcase Oil Changing Procedure 1 Remove fill plug 2 Remove gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug and tighten securely 14 ft Ibs 1 93 kgm 4 Add GL 80 90 Weight Gear Lube to the bottom thread on the fill hole 5 Reinstall filler plug 6 Check for leaks 81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It is a fully synthetic high performance multi viscosi
21. or at 20 Bushings grease with grease gun hrs Middle Axle Grease Locate fitting on eccentric and Every 3 months Bearings grease with grease gun or 50 hrs Center Grease Locate fitting on swing arm Every 3 months Swing Arm housing and grease with or 50 hrs Housing grease gun Rear Strut Grease Locate fitting on rear strut Every 3 months and grease with grease gun or 50 hrs More often under severe use such as wet or dusty conditions Grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U Joint Lube NOTE Hours are based on 10 mph average 79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Lubrication The transmission fill plug 1 is located on the right side of the machine behind the propshaft shield or footwell The transmission lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the 6X6 on a level surface remove fill plug 2 and check the lubricant level Lubricant level is correct when it reaches the bottom of the filler hole The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 Transmission Oil Changing Procedure 1 Remove propshaft shield from the right side of the vehicle 2 Remove fill plug 3 Remove transmission drain plug located on the bottom left hand side and drain the
22. point of adjuster Adjuster Sleeve Locknut 94 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation ar rows on the tire point toward forward rotation 2 Attach the wheel nuts and fin ger tighten them Tapered side of nut goes in 3 Lower the vehicle to the ground Rear Wheel Assembly 4 Securely tighten the wheel nuts to the following torque Torque center and rear wheel nuts to 50 ft lbs 6 9 kg m Torque front wheel nuts to 20 ft lbs 2 1 kg m 4 CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear Make sure the tapered end of the rear wheel nut goes into the taper on the wheel 95 MAINTENANCE AND LUBRICATION Adjustments Tire Inspection 4 CAUTION Maintain proper tire pressure according to charts below Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires m
23. seat Reach under the right hand fender and then back for access Remove the spark plug cap and then the spark plug by rotating counterclockwise Reverse the procedure for spark plug installation Torque to 17 ft Ibs 2 3 kg m Never deviate from the recommended spark plug as engine damage can occur 103 MAINTENANCE AND LUBRICATION Spark Arrestor AWARNING Because exhaust system temperatures can reach 1000 F do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot Because of the increased fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area The exhaust con tains poisonous carbon monoxide gas Do not go under the machine while it is inclined Failure to heed these warnings could result in serious personal injury or death 104 MAINTENANCE AND LUBRICATION Spark Arrestor Cont The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Place the transmission in Remove the cleanout plug A located on the bottom of the muffler as shown above neutral and start the en gine Purge accumulated carbon from the system by momentarily revving the engine several times Ifsome carbon i
24. the choke button all the way in CAUTION Proper engine warm up is essential each time before driving to avoid engine damage AWARNING Carbon monoxide exhaust gas is poisonous Always start the vehicle outdoors Never run the engine in an enclosed area OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke since the spark plug can easily become wet fouled 1 Place the transmission in neutral and push the vehicle to a level sur face Lock the parking brake Turn the fuel tank valve to ON Siton the vehicle Un WN mittent use of the choke button pulled half way out is permitted Ifthe engine has cooled to a point where it does not readily start inter 6 If the engine is over choked by mistake when warm depress the throttle lever fully while cranking to aid in starting 7 Release the throttle lever immediately after the engine starts If the en gine does not start and all conditions are favorable change the spark plug 53 OPERATION Carrying Loads Your 6x6 has been designed to carry or tow a certain amount of load Always read and understand the load distribution warnings listed on the warning labels Never exceed the following weights Maximum Capacities Front Rack Cargo Bed Level Ground Cargo Sportsman 6x6 875 75 lbs 34 kg 800 Ibs 363 kg lbs 397 kg Improper loading of the front rack can obstruct the headlight beam reducing ni
25. the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function Should you experience any shifting problem see your dealer AWARNING Do not attempt to shift the transmission while the vehicle is mov ing or while operating on hilly terrain Always place the transmission in gear with the parking brake ap plied whenever the vehicle is left unattended 45 CONTROLS AND FEATURES Controls Recoil Starter If the battery is weak and cannot start the engine use of the recoil starter located on Recoil Starter the right side of the machine will allow vehicle operation until repairs can be made 1 Be certain the parking brake is set See page 42 2 Grasp the recoil starter tightly and pull slightly un til the starter mechanism engages 3 Pull the rope abruptly to start the engine CAUTION Do not extend the starter rope so far that it stops This will cause damage to the recoil assembly Make sure the manual start handle is fully seated on the recoil housing especially when travelling in wet areas If it is not sealed properly water may enter the recoil housing and damage components 46 CONTROLS AND FEATURES Featur
26. though a child may be within the age group for which some vehicles are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris wheeled vehicle 21 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Carrying a passenger on this vehicle WHAT_CAN HAPPEN Greatly reduces your ability to balance and control this vehicle Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The operator requires the space of the entire seat to shift position as needed during operation The seat is not for carrying passengers A WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets A 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 22
27. through rough terrain swamps moun tains etc low ground speeds High Range High ground speeds speeds above 7 MPH 122 TROUBLESHOOTING The following information is provided to help you identify probable causes for questions you may have about the operation of your vehicle See your Polaris dealer with any additional questions you may have ENGINE CRANKS BUT FAILS TO START Fuel Valve Off Clogged Fuel Valve ENGINE STOPS OR LOSES POWER Turn Fuel Valve to Res Fuel Vent Line Kinked or Plugged Water in Fuel Stop Switch Off Spark Plug No Spark to Spark Plug Contact Your Dealer Overuse of Choke Spark Plug Fouled Engine Overheated Clean Radiator screen Clean Engine Exterior Air Filter Clogged Reverse Speed Limiter Malfunction Water in Fuel Contact Your Electronic Dealer Throttle Control Malfunction Contact Your Dealer 123 WARRANTY LIMITED WARRANTY Polaris Industries Inc 1225 Highway 169 North Minneapolis Minnesota 55441 5078 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris Light Utility Vehicle against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date
28. 9 Air Cleaner o ooooocooomcmmoo oo 88 All Wheel Drive ooooo ooooo o 48 Backing Up siii id Sela ies 69 70 Battery Fluid o oo ooooooo 108 Battery Installation 109 Battery Maintenance 108 110 Battery Removal 109 Brake Auxiliary sees 41 Brake Front cion bd ebb 92 Brake Parking lesse 42 Brake REAP sa ev eA Sine Aer DES 93 Brakelight Lamp Replacement 114 Brakes Front 40 Brakes Rear o a TS 40 Breather Filter o oooo ooo 89 Camber And Caster 91 Carburetor Adjustment 100 Carburetor Adjustments 101 Carrying Loads 00 54 56 Choke Adjustment 94 Choke Lever 00 00 00 39 Cleaning aoo use cR eH S 115 COntIOlS ies hene hem cR Seres 37 46 Controls And Features 37 49 Coolant Level ooo ooooo oooo 87 Coolant Level Inspection 86 Crossing Streams lusus 68 Daily Pre ride Inspection 51 58 Disengaging Wheel Hubs 49 Drive Chain Adjustment 98 99 Dumping Cargo Bed 56 Engine Cooling System 86 87 Engine Electrical Switches 38 Engine Idle Rpm Adjustment 100 Engine Specifications 119 Features hai ete te eed 8 47 49 Filter Systems oooooooooo oo o 88 89 Frame VIN ococco
29. ID THE HAZARD Always inspect your 6x6 each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off the vehicle If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your 6x6 during operation 26 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the vehicle You may also regain traction unexpectedly which may cause the vehicle to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control A WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly a
30. ITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Always use Polaris engine oil 2 Never substitute or mix oil brands as serious engine damage and voiding of warranty can result 125 ACCESSOTIES o duni ure idos 117 Adjustments oooo ooooo oo 90 102 Air Box Drain o o ooooooooo o o 8
31. Maite see a aes lattes 7 9 Safety Decals And Locations 13 20 Safety Training 00 3 Serial Number 00 6 Side Panel Removal 102 Sidehilling eese 62 Spark Arrestor 57 104 106 Spark Plug Removal103 Spark Plugs cite tas 103 Specifications o oo 118 119 Starting A Cold Engine 52 Starting A Warm Engine 53 Steering Inspection 91 Stop SWwitCh oooooooocmomo 38 Storage Of The 6x6 0 116 Suspension Springs 91 Table Of Contents 4 5 Taillight Lamp Replacement 114 Throttle Lever 000 39 Tire Inspection 00 96 Tire Specifications 97 Toe Alignment 000 90 Tool CAE is uud pe a ae ob ele 73 Torque Specifications 97 Towing Capacities o ooo 54 Trail Obstacles ooooo oooo 71 Transmission Gear Selector Operation 45 Transmission Lubrication 80 Transmission Oil Changing 80 Transporting The 6x6 117 Traveling Downhill 65 Traveling Uphill 66 Troubleshooting 121 123 Turning Around On A Hill 67 INDEX Welcome canoa dr ts 2 Wheel Installation 95 Wheel Removal esses 95 Wiring Diagram
32. NG Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the Maintain upper and lower level marks between upper and To refill use only distilled water Tap water contains minerals which are harmful to a battery lower level marks 108 MAINTENANCE AND LUBRICATION Battery Battery Removal 1 Disconnect hold down straps holding the electrical box and battery in position and remove battery cover Remove the battery vent tube from the battery Disconnect the black negative battery cable first Disconnect the red positive battery cable next nA RU N Liftthe battery out of the ATV being careful not to tip it sideways and spill electrolyte 4 CAUTION If electrolyte spills immediately wash it o
33. Polaris Premium 4 All Season synthetic oil or API certified SP oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result 82 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4 CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Suggested break in oil change is at 20 hours 200 miles or one month whichever comes first Severe use requires more frequent service Severe use includes continuous duty in dusty or wet conditions and cold weather riding Severe use cold weather riding is all riding below 10 F and riding between 10 F and 30 F when most trips are slow speed Be sure to change the oil filter whenever changing oil Polaris PN 3084963 1 Place vehicle on a level surface Clean area around drain plug at the bottom of the oil tank Place a drain pan beneath the oil tank and remove the drain plug Allow oil to drain completely ae O9 PED Install a new sealing washer PN 5850135 on oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 6 Reinstall drain plug and torque to 14 17 ft Ibs 1 93 2 35 kg m 7 Disconnect the lower oil delivery hose Remove the fitting C from the oil tank Clean the
34. Total slack for the rear chain however should be adjusted to 1 4 1 2 6 1 3 cm 3 16 3 8 48 cm 95 cm 1 4 1 2 6 1 3 cm 99 MAINTENANCE AND LUBRICATION Adjustments Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted as follows Tf the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Warm up the engine by running the ve hicle approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 100 MAINTENANCE AND LUBRICATION Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures certain adjustments can be made to improve its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 346 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained changes to the carburetor and drive system can be made to allow efficient operation These changes include 1 Carburetor re jetting to compensate f
35. a dny TL pi l avaa 7 1109812 LL T dv 02 ES E 5s lt bd horwu3ao TE l St m m TEN ENE WIRING DIAGRAM 33038v meo HOI S 1H 7 ATGN3SSY HOLIMS a83iqNvH 1331 LL HOLIMS SNVUL UV3H C D H2LIAS i 391145 3 ele 1 Sany YOLVOIONI HI iib No NY ami ae HOLIMS 213 o HOLLNS ABCDEF dom ch om ch ch MINES OL 480 l ona i a 1 1 Ti wi _ 20v I God 110h Lr N3d0 ATWNBON HOLIMS E Qm HV39 HOH 03501 ATIVNHON HOLIMS
36. ain proper tire pressure as described in the Owner s Manual See page 96 A WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Polaris Industries Inc or equivalent components designed for use on this vehicle and should be installed and used according to instructions If you have questions consult an authorized Polaris dealer 35 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your 6x6 on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator as well as the force that is created by a moving vehicle A WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs b
37. als of important components are explained in the following chart Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts 4 CAUTION Due to the nature of the adjustments marked with a Mi it is recommended that service be performed by an authorized Polaris dealer B gt More often under severe use such as dirty or wet conditions NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Hours or Frequency Odometer Headlamp Inspection Pre ride Pre ride Check operation daily apply Polaris di electric grease to connector when re placed Tail lamp inspection Pre ride Pre ride Check operation daily apply Polaris di electric grease to socket when replaced Brake System Pre ride inspection item oem p p pe Fevers e me Revie rene 3 eemenes renee eem qnem 3 pcc E Coolant Level Inspection o T engine coolant every two years I Air Filter Main Element Weekly Weekly Inspect Re
38. and cause an accident Always check the lever for free movement and return before starting the engine and occasionally during riding 39 CONTROLS AND FEATURES Controls Front and Rear Brakes The master cylinders which are located on the left and right handlebars should be checked before each ride The fluid level can be seen through an indicator window 3 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the handle bars should be turned so until the top of the reservoir is level If the fluid level is low add DOT 3 PN 2870990 only AWARNING Once a bottle of brake fluid is opened use what is necessary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury cu x sto sul ie The service brakes are applied by squeezing the left side brake lever toward the handlebar These brakes are hydraulically activated disc type brakes which are activated by one lever only Always test brake lever travel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master c
39. ars are straight The frog should always point straight back from the steering post 2 Place stands in front of the ma chine perpendicular to the rear tires 3 Tie an elastic string around the stands making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine e ds 0 8 TIPP EO ED 0 x k d KC Sas um ESL veo 2x Wil j 3 k 4 Measure from string to rim at front and rear of front rim Rear rim mea surement should be 1 16 1 8 2 to 3 cm more than front rim mea surement 90 MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts If loose nuts and bolts are found have your dealer tighten them before riding your vehicle Camber and Caster The camber and caster are non adjustable Handlebar Adjustment Your 6x6 has handlebars which can be adjusted for your personal fit 1 Remove handlebar cover and loosen the four bolts 2 Adjust handlebar to desired height Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right 3 Torque handlebar adjuster block bolts to 10 to 12 ft lbs AWARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause l
40. ay affect vehicle handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less Tread Depth 1 8 3 cm AWARNING Operating your 6x6 with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less 96 MAINTENANCE AND LUBRICATION Adjustments Tire Specifications Tire Specifications Sportsman 6x6 Front 25 x 8 00 12 Inflation Pressure 5 PSI Center 25 x 11 00 10 Inflation Pressure 5 PSI Rear 25 x 11 00 10 Inflation Pressure 5 PSI Cargo Bed Load Capacity 800 Ibs 363 kg Front Rack Load Capacity 75 lbs 34 kg Gross Vehicle Weight 1970 lbs 894 kg including vehicle driver and cargo Vehicle weighs 895 lbs 406 kg The following items should be checked occasionally for tightness or if they have been loosened for maintenance service Axle and Wheel Nut Torque Specifications em SmeWeon 0 Front Spindle Nut s 100 In Lbs Front Wheel Nuts 20 Ft Lbs Center and Rear Axle Nut s 80 Ft Lbs Center and Rear Wheel Nuts 50 Ft Lbs Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations Service work must be performed by your authorized Polaris dealer 97 MAINTENANCE AND LUBRICATION Adjustments Front Drive Chain Ad
41. coccocooooo 6 Front Gearcase Lubrication 81 Front Wheel Hub Tightening 97 FuelSystem uo ar IER s 43 44 Gearcase Oil Changing 81 Handlebar Adjustment 91 Headlight Adjustment 112 Headlight Housing Replacement 113 Headlight Lamp Replacement 111 Identification Numbers 6 Indicator Lamp Replacement 114 Indicator Lights o o o o 47 Jetting Chatte ccein eie vieiis 101 Light Switches 0ooooooooo oo o 47 Lights Adjustment Replacement 111 114 Load Distribution 59 Lubrication Recommendations 77 84 Main Switch 0000 38 Maintenance And Lubrication 73 117 Maintenance Record 85 Making Turns 00000 61 Noise Control System 57 Oil Chansons Meeks a ds 83 Oil Filter Change 83 Oil System esses 43 44 82 Operating Safety o ooooo oooo 56 Operation zie e xU RETE 50 55 Operator Safety ooooooo o o 21 36 Parking On An Incline 72 Periodic Maintenance Schedule 74 76 Premium 4 Synthetic Lubricant 82 Pyt SYSE y fe cien CE a 107 Recoil Starter oo oooooooo o 46 Riding 4 cc oe 58 72 Riding Geat yo cece oras 12 Riding On Slippery Surfaces 63 64 Riding Safely oooo o ooo 59 72 Safety seid Meares be bes teed a ES 8 36 Salety eode oos
42. d explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck If you should get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gaso line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Shut off fuel valve whenever the vehicle is stored or parked NOTE The taillight is on whenever the main switch key is in the on position Turn the key off to prevent battery drain Z WARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm 44 CONTROLS AND FEATURES Controls Transmission Gear Selector Operation The transmission gear selector is located on the right side of the vehicle directly above and forward Shift Patterns of the engine recoil starter The transmission selector lever has four positions high forward reverse neutral and low forward Use of low forward gear is recommended in heavy pulling situations to extend belt life To change gears stop the vehicle and with
43. ding On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water which exceeds the recommended maxi mum depth pg 68 go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sud den throttle changes 10 SAFETY Key Safety Issues Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads e Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Avoid turning at sharp angles in reverse e Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual e Never modify this vehicle through improper installation or use of accessories e Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT vehicle SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or Polaris at 1 800 342 3764 Additional
44. dipstick Dispose of used filter and oil properly 84 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Servicing Servicing Interval Date Dealer Performed or Person 5mm pp Cem 1 L Le o ooo 85 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level In spection NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry the level in the radiator should be inspected and coolant added if necessary AWARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure cap To access the radiator pressure cap Remove the four screw securing front rack Remove front cover by placing your fingers under the front of the cover and pulling upward NOTE Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement contact your dealer for the correct replacement part To insure that the coolant maintains its ability to protect the engine it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added Polaris recommends th
45. e check for free operation and closing Headlight Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Drive chain condition and slack refer to drive chain adjust ment Air cleaner element check for dirt clean or replace Steering check for free operation noting any unusual loose ness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Operators helmet goggles and clothing Engine coolant check for proper level at the recovery bottle Check condition and operation of the dump box bed latch mechanism 58 RIDING Riding Safely Load Distribution Maximum Cargo Bed Sportsman 6x6 800 lbs 363 kg Me Maximum Front Rack 75 lbs 34 kg 1 Always load the cargo bed placing the load as far forward as possible 2 Always operate the vehicle with extreme care whenever hauling or towing loads as balance handling and control may be affected 3 Slow down and drive in low range only 4 Thecargo bed dump latch must be securely latched before loading and operating Unintentional bed tilting will result if weight is placed in the rear of the bed and the latch is not secured AWARNING Never operate this vehicle with the cargo bed in the raised position The cargo bed could c
46. e brake until vehicle is on reasonably level ground AWARNING Avoid climbing steep hills Loss of vehicle control or overturning of vehicle could occur e Use extreme care when operating your 6x6 in hilly terrain 67 RIDING Riding Safely Crossing Streams AER C Your Polaris 6X6 can operate through water up to maximum recommended depths reaching the footrests Before fording streams always 1 Determine water depths and current 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal e Avoid operating the 6X6 through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 4 CAUTION If your 6X6 becomes immersed take it to your dealer before starting the engine Major engine damage can result if the machine is not thoroughly inspected 68 RIDING Riding Safely Backing Up Backing Up 1 When backing up always avoid backing downhill Back slowly When in reverse apply the brakes lightly for stopping Avoid turning at sharp angles in reverse Never open the throttle suddenly while backing
47. e use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Using a funnel slowly add coolant as necessary through the radiator filler neck 86 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle Recovery N Asc The engine coolant level is N controlled or maintained by the UR MENGE 7 recovery system The recovery E m system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Pr
48. efore or while driving this vehicle 36 CONTROLS AND FEATURES Controls Sportsman 6x6 Vehicle Nomenclature 1 Service Brake Lever 6 Floor Boards 2 Middle Axle Auxiliary Brake 7 Back Rest 3 Throttle Lever 8 Bed 4 Bed Dump Latch Release s 9 Front Rack 5 Gearbox Shift Lever 37 CONTROLS AND FEATURES Controls Engine Electrical Switches OFF RUN OFF AWARNING Activating the override button while throttle is open can cause loss of control resulting in severe injury or death 1 Override Switch Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To obtain additional power while backing up depress the override button NOTE The override switch also allows activation of All Wheel Drive AWD in reverse if AWD switch is on 2 Main Switch To start the engine slide the stop switch 3 to the center run position and turn the main key switch clockwise past the on position Release the key when the engine starts This switch must be turned clockwise to the on position to start the engine 3 Engine Stop Switch The engine will not start or run when the switch is in its off position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch shut
49. eight uos vene dia ud 337 Ground Clearance 0 ccc eect e 5 5 Weight xus nenret o ina ea P REO 895 Ibs Front Susp MacPherson Strut oo ooooooo oo 6 7 Travel Rear Susp Swing Arm with Scissor Stabilizer 7 5 Travel Front Tirene geet bie UR UEFA V Ye E 25x 8 12 Center Tire usb ep Gey og es Sees Pad tir s 25x11 10 Rear Titel A RE xe e eng 25x11 10 Front Brake aserat avene e aee s Fixed Disc Hydraulic Floating Caliper Rear Brake keserin as Fixed Disc Hydraulic Floating Caliper Auxiliary Brake 00 02 ee eee eee Fixed Disc Hydraulic Floating Caliper Fuel Capacity cel ds ae ee ERIS 4 25 U S Gal Engine Oil Capacity e erre recre erein pae ooo 2 U S Qts Headline ade Cen 12V 60W WTalllislit 525 avs Sae O Va E 12V 5W Exhaust eke hehe testi athed Ep UE Ed EP USFS Approved Pront Rack 2 25 c eb ed ri Su YN Standard Hitch o2 Rete Rad M Ri SP MEM SIM Standard Tool Kit soode oeste pp Lees LER e ren Standard Gross Vehicle Weight ooooooooooo oo 1970 Ibs including machine driver amp cargo Load Capacity cans eee aes OLOR boc EPA 75 Lbs Front 800 Lbs Cargo Bed Transmission eet vex A E We Ss PVT Gear Box iia ni ita s tse Uu e a E Hi Lo R N Drive Cha oracion apa ahaa ee 520 O Ring Turn Radius Unlord dia tr tete 98 Final Drive Sprocket ses eer E 12 38 80 Pitch Axle tO Arlt wig c OLCEDRRIYS S 30 30 116 Pitch 118 SPECIFICATIONS Engine Specifications 2002 Sport
50. emium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area To access the recovery bottle on Gen IV machines it is necessary to remove the left side panel as described on page 102 87 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service It is recommended that the air filter be replaced yearly When riding in extremely dusty conditions replacement will be required more often 1 Nn Remove seat 2 Remove spring clamps securing the airbox lid and remove lid 3 4 Remove fabric type pre filter from main filter Wash pre filter in soapy Loosen clamp and remove filter water and dry it Reinstall pre filter over main filter Replace main filter as required Reinstall filter into air box and tighten clamp Do not over tighten clamp or filter damage may occur 4 CAUTION Operation of your 6X6 without a breather filter can cause engine damage Pre filter 88 MAINTENANCE AND LUBRICATION Filter Systems Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box and empty if necessary Breather Filter and Hoses Operation of your vehicle without a breather filter can cause engine
51. es Light Switches and Indicator Lights 1 Main switch Handlebar light switch and headlight Hi Lo beam control NOTE Will not light unless main switch is on Headlight Hi beam indicator Blue Transmission reverse indicator Yellow Transmission neutral indicator Green All Wheel Drive indicator Red Engine hi temp warning indicator Red NOTE Will light only if engine overheats With engine running verify function of indicator lights each time vehicle is used Y ANA Bow AWARNING This vehicle is not equipped with highway approved lighting This vehicle is designed for off road use only and must not be ridden on streets or highways Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness 47 CONTROLS AND FEATURES Features All Wheel Drive System T mw H IET lum AWD Button Reverse Speed Limiter Override Button The Polaris 6x6 is equipped with a unique Polaris exclusive AWD All Wheel Drive system which is activated by a switch on the right handlebar When the switch is off the 6x6 is in rear wheel drive at all times When the switch is on the 6x6 is in AWD and the front wheels will automatically engage anytime the rear wheels lose traction When the rear wheels regain traction the front wheels will automatically disengage
52. ff with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV Battery Installation and Connections AWARNING To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery can cause serious injury or death Battery terminals and connections should be kept free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery 109 MAINTENANCE AND LUBRICATION Battery 1 Set the battery in its holder 2 Install the battery vent tube It must be free from obstructions and se curely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte severe burns could result First connect and tighten the red positive cable 3 4 Second connect and tighten the black negative cable 5 Reinstall battery cover and attach the hold down strap 6 Verify that cables are properly routed NOTE e When your ATV is placed in storage for three months or more the battery should be rem
53. fitting screen Reinstall the fitting screen torquing to 14 17 ft lbs Reattach oil line If banjo fitting D is used torque to 14 17 ft Ibs If hose clamp E is used tighten securely 83 MAINTENANCE AND LUBRICATION Lubrication Recommendations 8 10 11 12 13 14 15 16 17 18 Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Using a clean dry cloth clean filter sealing surface on crankcase Lubricate the O Ring on the new filter with a film of new engine oil Check to make sure the O Ring is in good condition Also make sure the O ring from the old filter is not still on the engine Install new filter and tighten by hand 1 2 to 3 4 turn after gasket contact Approximately 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall drain plug Remove dipstick and add 2 quarts 1 9 1 of Polaris Premium 4 synthetic oil Reinstall dipstick NOTE If sump is not drained add about 1 3 4 quarts initially Place gear selector in neutral and set parking brake Start engine and let it idle for one to two minutes Stop engine and inspect for leaks Re check oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the
54. g Slow and easy clutch en Fast effective use of the throttle for gagement efficient engagement Towing Pushing at low Use Low Range only RPM low ground speed Plowing snow dirt etc util Use Low Range only ity use 121 TROUBLESHOOTING Stuck in mud or snow Shift the transmission to Low Range carefully use fast aggressive throttle application to engage clutch WARN ING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects Shift the transmission to Low Range from a stopped position carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Belt slippage from water or Shift the transmission to neutral Using snow ingestion into the PVT the throttle vary the engine rpm from system idle to full throttle Repeat several times as required During this proce dure the throttle should not be held at the full position for more than 10 sec onds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction For inspection of clutch components please contact your Polaris dealer Poor engine performance Fouled plugs foreign material in gas tank fuel lines or carburetor Contact you dealer for further service informa tion GENERAL RANGE OPERATION GUIDELINES Low Range Heavy pulling basic operational speeds less than 7 MPH riding
55. ght visibility Do not obstruct the headlight beam with cargo Maximum Towing Capacities Level Ground Maximum towed load weight 1250 lbs 568 kg on level ground only 850 lbs 386 kg up to 15 grade Maximum vertical hitch weight 30 lbs 14 kg Use of low forward is recommended in heavy pulling situations to extend belt life Maximum grade while trailer towing 15 do not tow any trailer on a grade steeper than 15 54 OPERATION Carrying Loads AWARNING Overloading the vehicle or carrying or towing cargo improperly can be dangerous Improper loading can drastically alter 6x6 handling and braking stability e Never exceed the stated load capacity for this vehicle e Do not obstruct the headlight when loading the front rack e Cargo should be properly distributed and carried as low and forward in the cargo bed as possible Reduce speed and allow greater distance for braking Heavy loads can cause braking and control problems Use extreme caution when applying brakes with a loaded ve hicle Generally avoid terrain or situations which may require backing downhill Always attach the tow load to the hitch point designated for your vehicle Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never ex ceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 55 OPERATION Carrying L
56. hill at high speed Always follow proper procedures for going down hills and for brak ing on hills as described in this manual Check the terrain careful ly before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehicle Never attempt to turn the vehicle around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to either side if pointed straight uphill Turn the ve hicle around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over ob stacles as described in this manual Always be careful of skidding or sli
57. ifferently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions e Read this manual and all labels carefully and follow the operating procedures described e Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certi fied instructor Contact an authorized Polaris dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this vehicle e Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels and has completed a certi fied training course e Always avoid operating this vehicle on any paved surfaces includ ing sidewalks driveways parking lots and streets e Never operate this vehicle on any public street road or highway even a dirt or gravel one e Never operate this vehicle without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ve hicle e Never operate at excessive speeds Al
58. imited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Optional Suspension Springs Although your Polaris 6x6 suspension has the capability of providing you with the best ride possible the following accessory springs are available to better suit your individual riding preference NOTE Optional springs may be a different color than standard springs Owner may paint springs to desired color using Polaris touch up paint available through your dealer SOFT FIRM Sportsman 6x6 7041375 067 7041450 195 N A Front Strut Spring OPTION STANDARD 64 113 Ib in 101 Ib in 91 MAINTENANCE AND LUBRICATION Adjustments Front Brake Front Wheel and Middle Axle Brake The front and middle axle brakes are hydraulic disc type brakes which are activated by the brake lever being moved toward the handlebar These brakes are self adjusting and require no adjustment The following checks are recommended to keep the brake system in good operating condition How often they need checking depends upon the type of driving that has been done Always keep brake fluid at an adequate level see page 40 Normal func tioning of the diaphragm is to extend into the reser voir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is indi cated and the diaphragm should be replaced Al
59. into the rear cab 102 MAINTENANCE AND LUBRICATION Spark Plugs Use NGK BKRSES spark plugs e Proper electrode gap is 025 06 cm e Spark plug torque is 17 ft Ibs 2 3 kg m for a used spark plug 11 ft lbs 1 52 kg m for a new spark plug Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color 1 Normal The insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement AWARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury The spark plug is removed by using the special wrench provided in the tool pouch under the
60. it may be helpful to turn handlebars to left or right and use a short stubby screwdriver Removal of the front rack and cover may also allow easier access Remove three Phillips screws at back of headlight pod Lift pod cover up Disconnect O Ring speedometer harnesses from speedometer Unplug indicator light harness and remove pod cov er Unplug headlamp from wiring har ness pivot pins lease from locking tabs from locking tabs 13 cm Distance from headlamp parting line to end of adjustment knob stop is 5 1 8 13 cm of pod ing and reassemble pod 10 Adjust headlight aim by turning adjusting knob 113 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement Taillight Brakelight Lamp Replacement Tf the taillight brakelight does not work the lamp may need to be replaced 1 Remove the taillight assembly by removing the two screws securing it to the vehicle 2 Twist the lamp harness 1 4 turn to Harness release the lock Pull the lamp har ness out of the back of the assem bly 3 Remove the lamp from the harness and replace it with the recom mended lamp 4 Test the taillight brakelight to see that it s working Taillight Assembly 5 Replace the lamp harness into the back of the taillight assembly twist ing 1 4 turn to lock in place 6 Reinstall the taillight assembly to the vehicle Indicator Lamp
61. justment 4 CAUTION Never adjust or operate the vehicle with the drive chain slack out of the 3 16 3 8 48 cm 95 cm specification Severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain Then pull up and down on the chain At this point the chain should have 3 16 3 8 48 cm 95 cm deflection If the per chain needs adjustment use the Splicelink Clip followi dure Opening ollowing procedure Position Adjustment Procedure 1 Loosen chain guide 2 Loosen two eccentric locking bolts 3 Loosen caliper mount bolts Front Drive Chain Adjustment 4 Insert a pin punch through the sprocket hub and into the ec centric axle housing 5 Roll the vehicle ahead or back to adjust chain slack to the proper dimension 6 Tighten caliper mount bolts 10 12 ft Ibs 1 4 1 7 kg m 7 Tighten the eccentric locking bolts to 45 ft Ibs 6 2 kg m 8 Confirm correct tension by rolling the 6x6 forward checking chain tension in several places around the chain 9 Reinstall chain guard NOTE Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide 98 MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment All procedures used in adjusting the front chain apply to the rear chain adjustment
62. lose unexpectedly while driving severely injuring the driver The rear tires will catch the rear of the bed damaging the vehicle and creating hazardous driving conditions 59 RIDING Riding Safely 1 Situpright with both feet on the footrests and both hands on the handle bars 2 After starting the engine and allowing it to warm up shift the transmis sion into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening and PVT shifting is done automatically 6 Drive slowly practice maneuvering and using the throttle and brakes on level surfaces AWARNING Indicates a potential hazard which could result in serious injury or death 60 RIDING Riding Safely Making Turns Polaris 6x6s are equipped with solid rear axles which drives all rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same learning technique should be used for turning
63. n on a regular basis In the event you purchased a used Polaris vehicle from a party other than a Polaris dealer you can obtain this safety training at no charge from any authorized Polaris dealer Failure to follow the warnings contained in this manual can result in SEVERE INJURY OR DEATH NOTE Illustrations used in this manual are for general representation only Your model may differ TABLE OF CONTENTS Vehicle Identification Numbers 6 A A 7 20 Understanding Warnings 0oooococcooconc o 7 Key Safety Issues ooooococccooccono 8 Decals and Locations cooooooocommmm 13 Operator Salely xseecsecex der za aos ui 21 Controls and Features 37 49 COMO Si tos ie ue 37 xr DEPT 47 Operation scort re 50 56 Pro Rido ie ccicw eatin prisene apan Aa DECORE RC CX 50 Vehicle Break In Period sese 51 Starting the Engl a bases xeu wie 52 Carrying Loads 49 veas tit Ln b Ee Eus 54 Noise Emission Control System 57 Riding 2 4o rr hy Romane 58 72 Pre Ride Inspection se au xcd pe co ras 58 Riding Safely essetis O OT EN EE 59 TABLE OF CONTENTS Maintenance and Lubrication 73 117 TOOS dos A Sama ate vs 73 Periodic Maintenance Schedule 74 Lubrication Recommendations 77 Maintenance Record 22 00 cess eee e eee 85 Cooling SVSIBImb 35 s Seige ier ef as vut eter d 86 Filter SVSIBITIS u iore eo
64. nd be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle 27 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT_CAN HAPPEN Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain Always be especially cautious on these kinds of terrain 28 SAFETY Operator Safety 29 A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Vehicle could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner s Manual See page 61 Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the 6x6 on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting large hills Never operate vehicle on hill
65. ng cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See pages 54 and 59 33 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified in your Owner s Manual See page 68 Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads A WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as jumps Don t try to show off 34 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control and increases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle See page 96 Always maint
66. nplug headlamp from wiring harness Remove boot and locking collar from back of lamp housing Grasp base of lamp and lift it out Reverse previous steps to replace lamp and reassemble pod Make sure tab on lamp locates properly in housing ES AO n 111 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 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 headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 2 NOTE Rider weight must be included on the seat Adjust beam to desired position by turning the adjustment knob 112 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement Headlight Housing Replacement 1 Remove O Ring from headlight Pull headlight housing up to re Lift adjusting knob up to remove Carefully pull assembly up and out Reverse steps to install new hous Remove Phillips screws from bottom of headlight pod at each front corner NOTE To aid in accessing these screws
67. oads Dumping the Cargo Bed 1 Select a level site to dump the cargo bed Do not attempt to dump or unload the vehicle while parked on an incline 2 Set the parking brake 3 Dismount the vehicle 4 Pull the cargo bed release mechanism lever forward and lift the front of the cargo bed to dump AWARNING Never carry passengers on the bed If the weight distribution on the bed is located toward the rear of the bed and the release lever is pulled forward the bed will want to dump on its own Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo bed AWARNING In the event of an accident have a qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage 56 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U S Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING
68. olaris at no charge The part number is printed on the decal The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of this vehicle Be certain any accessories added to this vehicle have been approved by Polaris Familiarize yourself with their function and affect on the vehicle 13 SAFETY Safety Decals and Locations 1 AWARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Front Rack Load 75 lbs AWARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT 5 CENTER 5 REAR 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1965 LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and firmly secured to the rack For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information 14 Safety Decals and Locations SAFETY o o o o SAFETY Safety Decals and Locations 3
69. onths U joints Grease or 50 hours Front Drive Axle Grease Locate grease fitting and Every 3 months U Joint AWD grease with grease gun or 50 hours Models Front Prop Shaft U Joint Transmission plug 77 MAINTENANCE AND LUBRICATION Lubrication Recommendations Steering Post Inner Tie Rod End Bushings Demand 6 Hubs Upper Front A Arm Pivot Shaft Ball Joint 4 00 position Demand 6 Premium Remove set screw in hubs Ro Annually or at Hubs All Hub Lube tate wheels to 4 00 position Iflu 100 hrs Wheel Drive bricant is not visible add more Reinstall set screw Ball Joint Grease Locate zerk on back side of struts Every 3 months and grease with grease gun or at 50 hrs Front A Arm Grease Locate zerk on pivot shaft and Every 3 months Pivot Shaft grease with grease gun or at 50 hrs Steering Post Grease Locate fitting on steering post and Every 3 months Bushings grease with grease gun or at 50 hrs 78 MAINTENANCE AND LUBRICATION Lubrication Recommendations Middle Axle Bearings Swing Arm Bushings Rear Axle Bearing Rear Strut U Joint Center Swing Arm Housing Front Drive Grease Locate grease fitting and grease Every 3 months Axle U Joints with grease gun or 50 hrs Rear Axle Grease Locate fitting on eccentric and Every 3 months Bearing grease with grease gun or 50 hrs Swing Arm Grease Locate fitting on swing arm and Monthly
70. or atmospheric pressure and oxy gen loss 2 Transmission convertor modification to adjust for engine horsepower loss Contact your dealer Contact your dealer for altitude adjustments They have the training and special tools required to perform all necessary modifications for you Pilot screws are sealed with metal plugs and are serviceable only by dealers Jetting Chart 2002 Sportsman 6x6 AMBIENT TEMPERATURE Below 5 C Above 5 C 0 1800 147 5 142 5 Altitude 0 6000 Meters Feet Over 1800 140 135 Over 6000 101 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1 Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times 2 Remove seat Grasp Pull forward and out to disengage rear of side panel near two rear tabs rear cab With a quick and firm motion pull the panel forward and outward to disengage the two rear tabs 3 Place hand on top of E side panel behind the e s e a m Push down to disengage top rear and firm motion pus two tabs down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tab 4 To reinstall side panel align panel tabs with To reinstall align panel tabs with slots on front cab Push slots Push upward and forward un panel upward and til tabs lock forward until tabs lock Bend rear of side panel and insert the two tabs
71. oved charged to proper level and stored in a cool dry place e Before reusing take the battery to your dealer for testing and re charging Power plug leads may need to be bent down so that the battery cov er may be installed e When installing a new battery make certain it is fully charged prior to it s initial use Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery It can also hinder vehicle performance AWARNING Indicates a potential hazard that could result in serious injury or death 110 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement Headlight Lamp Replacement AWARNING Due to the nature of these vehicles and where they are ridden headlight and taillight lenses become dirty Frequent washing is necessary to maintain lighting quality Poor lighting while riding can result in severe injury or death Snap pins into tabs Position Sor Slip O Ring knob in slot and secure in Route plug locking Adjustment over tabs Knob Stop handlebar over pin E 1 Using a small flat blade screwdriver push in on the lock tab through the two small openings at the front of the headlight pod 2 Lift the pod lightly while depressing the tabs Remove the screw in the back of the headlight pod Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover U
72. pairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD Master Service Dealer Technician Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction Return to your dealership for all of your service needs during and after the warranty period Polaris also takes great pride in our PAA Parts Apparel and Accessories which are available on our online store www purepolaris com Have your accessories and clothing delivered right to your door Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc Copyright 2001 Polaris Industries Inc All Rights Reserved Printed in the U S A ATTENTION This is an ADULT VEHICLE ONLY not a toy Operation is prohibited for anyone under 16 years of age READ AND UNDERSTAND WARNINGS AND OWNER S MANUAL BEFORE OPERATION A KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for your personal safety the safety of others and the protection of our environment dh SAFETY TRAINING When you purchased this vehicle your dealer offered a hands on safety training course covering all aspects of vehicle safety In addition you were provided with certain printed material which instructs you on safe operating procedures You should review this informatio
73. pect daily adjust and lubricate if needed e qem em e eemeemeve pem E i rere me ere 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours or Frequency Odometer m Valve Clearance 100 hrs Inspect Adjust Che Wedd Check for leaks at tank cap lines fuel valve filter pump and carburetor Re place lines every two years Radiator 100s 12 months Inspect clean external surface sire Someses oon aren oo peru 7 pem que LE pas e pe W shiftselectorbox 200hr 24 months Change lubricant every two years 5 Toe adjustment As required As required Periodic inspection adjust when parts are replaced Recoil housing Drain moisture out after riding in water Idle Speed As Required As Required Adjust 76 MAINTENANCE AND LUBRICATION Lubrication Recommendations em tomes memos reme Brake Fluid DOT 3 Only Maintain proper level As required See page 40 change every two years or 200 hours Drive Chains O Ring chain lube Lubricate as often as re As required or SAE 80 90 quired before each ride in wet conditions Gear Selector 10W Maintain oil level at the Change every 2 Non detergent Oil center of the shift rail Do years or 200 not overfill hours Transmission Oil Polaris Premium Fill to bottom of the filler Change annually Synthetic gearcase hole or at 100 hours lube Front Prop Shaft Grease Locate Fittings and Every 3 m
74. place if necessary 74 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Cont 4 CAUTION Due to the nature of the adjustments marked with a Bl it is recommended that service be performed by an authorized Polaris dealer P More often under severe use such as dirty or wet conditions NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Hours or Frequency Odometer Brake pad wear 10 hrs 100 Monthly Inspect periodically miles a Engine breather filter Monthly Ins replace annually and as need ed ui Battery Monthly Check Terminals clean check fluid level I Transmission Oil Level Monthly Inspect monthly change annually I General Lubrication 3 months Lubricate all fittings pivots cables etc Throttle Cable ETC Switch 50 hrs 6 months Inspect adjust lubricate replace if nec essary pre ride inspection item Choke Enricher Cable 50 hrs 6 mon Inspect adjust lubricate replace if nec essary Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage Engine Oil Level Change 100 hrs 1000 6 months Check Level Daily Break in Service at miles 1 month Change oil more often in cold weather use Oil Filter 100 hrs 1000 6 months Replace with oil change miles Coolant strength pressure test 100 hrs 6 mon Inspect strength seasonally pressure system test system annually Drive Chains 50 hrs 6 mon Ins
75. pply engine power Never apply the rear brake while rolling backwards Apply the service brake gradually When fully stopped apply auxiliary brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the vehicle around and remount following the procedure described in the Owner s Manual See page 67 In the event of an accident have a qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage 24 SAFETY Operator Safety 25 4 WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT_CAN HAPPEN Increases your chances of losing control of the vehicle which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you select reverse gear make sure there are no obstacles or people behind you When it is safe to proceed go slowly SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVO
76. quires special protective clothing which will make you feel more comfortable and reduce chances of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a serious head injury Select an approved helmet which meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI Z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings Z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf type boots with heels such as moto cross boots 5 Clothing To protect your body long sleeves and pants should always be worn Riding pants with kneepads a jersey and shoulder pads provide the best protection 12 SAFETY Safety Decals and Locations NOTE Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing replacement will be provided by P
77. rive All Wheel Drive engaged can assist in controlling the vehicle in slippery areas Before riding your vehicle on a frozen body of water be sure that the ice is thick enough to support the machine and its operator as well as the force that is created by a moving vehicle Severe injury or death can result if the vehicle and or its operator break through the ice 4 CAUTION Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur 63 RIDING Riding Safely Riding On Slippery Surfaces AWARNING Failure to exercise care when operating on slippery surfaces can be dangerous Loss of tire traction and vehicle control can result in an accident including an overturn e Never apply brakes during a skid Complete loss of control can result Do not operate on excessively slippery surfaces if possible Always reduce speed and use additional caution 64 RIDING Riding Safely Traveling Downhill CEL PEOR UNS M a f iEn r 27 A Zp WAL cous Whenever descending a hill always 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing AWARNING Loss of vehicle control due to excessive speed can occur Loss of control may result in serious injury or death 65 RIDING Riding Safely Traveling Uphill 15 Maximum Whenever traveling uphill always tra
78. s visually inspect vehicle for any damaged or loose nuts bolts or fasteners Operators helmet goggles and clothing Engine coolant check for proper level at the recovery bottle Check condition and operation of the dump box bed latch mechanism 51 OPERATION Starting a Cold Engine 1 Place the transmission in neutral and reset the parking brake 2 Turn the fuel tank valve to ON 3 Sit on the vehicle 4 Pull the choke button A all the way out 5 Set the engine stop switch to run 6 Turn the ignition key past the ON position to engage the starter NOTE the choke is on FULL when the knob is pulled out all the way The choke is OFF when the knob is pushed in This is a variable choke and can be adjusted gradually depending on how much choke is needed for starting 7 Do not press the throttle while starting the engine 8 Activate the starter for a maximum of five seconds releasing the key or button when the vehicle starts If engine does not start release the starter and wait five seconds then activate the starter for another five seconds Repeat this procedure until engine starts NOTE Do not press the throttle while starting the engine After the Engine Starts 1 Ifthe engine slows or stops pushing the choke button in half way will allow proper engine warm up 2 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Then push
79. s expelled cover the exhaust outlet and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the parking brake and block the wheels Make sure the ma chine is in neutral and repeat steps 2 and 3 If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the parking brake and block the wheels Make sure the ma chine is in neutral and repeat steps 2 and 3 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug 105 MAINTENANCE AND LUBRICATION Recoil Housing Drain the recoil housing after operating the vehicle in very wet conditions This should also be done before storing the vehicle The drain screw is located at the bottom of the recoil housing Remove the screw with a 10mm wrench Reinstall screw once housing has been drained Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water Crankcase Drain Recoil Drain above front propshaft on shaft drive models After travelling in wet areas the recoil housing and star
80. s steeper than 15 SAFETY Operator Safety A WARNING 15 Maximum POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner s Manual See pages 62 through 67 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The vehicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 30 SAFETY Operator Safety A WARNING ELN El LLU POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner s Manual See page 65 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible 31 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperl
81. should be taken to preserve its condition 1 Remove the spark plug and Perform all necessary repairs and thoroughly clean the ve hicle Turn the fuel valve to off and Drain jube attached drain the carburetor here pour approximately one ounce of Premium 4 oil into the cylin der Operate the starter for a few seconds and reinstall the spark plug 4 Remove the battery Store it in a cool dry place out of the sun Lubricate suspension pivot points lower steering post and rear axle fit tings Drain the recoil housing Block the vehicle so all tires are suspended off the ground Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ventilation of the vehicle 116 MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting the 6x6 Whenever the 6x6 is to be transported the following measures should be taken 1 Turn the fuel valve to off 2 Be certain the fuel cap and oil cap are installed correctly 3 Always tie the vehicle to the transporting unit securely using suitable straps and or rope 4 Always place the transmission in gear and lock the parking brake Accessories Polaris has a wide variety of accessories for your 6x6 Contact your Polaris dealer for a complete list 117 SPECIFICATIONS Hr A A e Saeed 48 WILL A qd E RE eL da 46 Length ied een A pb Xn 105 WheelBase vit AA WE Eb eee A 76 5 Seat H
82. sman 6x6 Engine o ob Xon vs oos e eros eg eR EH50PLE 06 Displacement cour o PY ASP E 499 cc Type asp Rer Rar beh ae 4 Cycle Single Cylinder Cooling ow sce te a te Mal eee tet bogs Pes S dag Liquid Bore x Stroke endera trenera npor dead lawasen eee 92 x 75 mm Lube ue ar heey E eee ea eae Oho eect Dry Sump Statin aves ited nds Electric Manual TOO A veg p OE E IRE RN CDI Spark Plug vir Pepe e mes BKRS5E NGK Alt tnator nds A RS 250W COMPRAMOS 5 1x a acute aoe E 10 2 1 Full Stroke Timing 2 4 o RR a a ET 30 3500 Carburetion 2240 6 ur Hood Re Y vr ee ds 1 BST34 CV Type Main Jet ouo gong Gea Lae bea a ees pass 142 5 Pilot Jet mii b REIR EEREESUbP EUR REDE Ra 40 Jet Needle erre rcv tese Cet se a 4HB41 3 Needle Jet csi is ee ee See SS hea Se E E Q 4 829 Pilot Screw ee e RAS hi che eg 3 Polaris Industries Inc reserves the right to make changes in design and specifications and or to make additions or improvements to its products without notice 119 anys 9 18 6 u311V w
83. stantly look for obstacles on the trail 71 RIDING Riding Safely Parking On An Incline Whenever the Vehicle is Parked 1 2 3 4 Place the transmission in gear Set the parking brake Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown above Shut off fuel supply AWARNING Always check to be sure that the parking brake has been disengaged before operating the vehicle An accident could result if the parking brake is left on while the vehicle is operated The parking brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the park brake for more than five minutes Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a side hill position 72 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 73 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication interv
84. ted 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 124 WARRANTY This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABIL
85. ter should always be drained completely by removing the recoil Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if crankcase drain is opened 106 MAINTENANCE AND LUBRICATION PVT System 107 AWARNING The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Donot modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components e Routine maintenance is the responsibility of the owner Always follow recommended maintenance procedures See your deal er e This PVT system is intended for use on Polaris products only e The PVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death MAINTENANCE AND LUBRICATION Battery AWARNING Whenever removing the battery disconnect the negative black cable first When reinstalling the battery connect the negative black cable last or an explosive situation could result causing serious injury or death AWARNI
86. tes AWARNING Always check to be sure that the parking brake has been disengaged before operating the vehicle An accident could result if the parking brake is left on while the vehicle is operated The parking brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more than five minutes Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a side hill position 42 CONTROLS AND FEATURES Controls Engine Fuel and Oil System The fuel tank filler cap 1 is located directly behind the handlebar Its capacity is 4 25 U S gallons 16 1 with 1 2 gallon 1 9 1 in reserve Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane The fuel tank supply valve 2 located on the left side of the vehicle has three positions OFF For vehicle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after having used the reserve supply Always remember to take the fuel valve off RES after refueling your machine 43 OFF CONTROLS AND FEATURES Controls Engine Fuel and Oil System AWARNING Gasoline is highly flammable an
87. the risk of a stuck or frozen throttle Please refer to your Owner s Manual for details Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 7078254 Passengers can be thrown off This can cause serious injury or death Never carry passengers Remove flammable containers from box before refueling Maximum Box Load 800 Ibs 4 WARNING Pushing reverse override button may cause sudden in creases in pow er and traction if too much throttle is ap plied Loss of control or for ward flipover may result es pecially in AWD See Own er s Manual ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual 7079780 7079604 AWD Models 18 SAFETY Safety Decals and Locations AWARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7078689 19 SAFETY Safety Decals and Locations TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND 850 LBS 368 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 35 LBS 16 KG 7078261 On Hitch
88. ty oil designed to provide the ultimate in lubrication performance and protection Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable Oil may need to be changed more frequently if Polaris Premium 4 is not used You will also need to follow the manufacturers recommendations for ambient temperature operation Oil System The oil tank is located on the left side of the vehicle ADD 8 OZ NORMAL FULL To check the oil WE 1 Set machine on a level Maintain Oil Level In Normal Range surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine remove dipstick and wipe dry with a clean cloth 4 Screw in the dipstick completely remove it and read the oil level NOTE The dipstick must be screwed in to keep the angle and depth of stick consistent 5 Remove dipstick and check to see that the oil level is between the full and add marks Add oil as indicated by the level on the dipstick Do not overfill If oil level rises above the full mark water and or fuel may be collecting in the tank and oil should be changed CAUTION Use only
89. vel straight uphill and 1 Avoid steep hills 2 Keep both feet on the footrests 3 4 5 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 in clude quick dismounting of the vehicle AWARNING Braking and handling are greatly affected whenever operating in hilly terrain Loss of vehicle control or overturning of the vehicle could occur e Avoid climbing steep hills 15 maximum e Use extreme care when operating your vehicle in hilly terrain 66 RIDING Riding Safely Turning Around On A Hill If the vehicle stalls while climbing a hill never back it down the hill One maneuver which can be used when it is necessary to turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while maintaining body weight uphill 2 Leave transmission in forward and shut off engine 3 Dismount on left or uphill side of vehicle 4 Staying uphill of vehicle turn handlebars full right facing front of ve hicle 5 While holding service brake release parking brake lock and slowly al low vehicle to roll around to your right until it is pointing across the hill or slightly downward 6 Lock the parking brake and remount vehicle from the uphill side maintaining body weight uphill 7 Restart engine with transmission still in forward and proceed slowly controlling speed with the servic
90. ways fill the reservoir as indicated whenever the cover is loosened or re moved to insure proper diaphragm operation Use Polaris DOT 3 brake fluid PN 2870990 thickness of a dime Middle Axle Brake Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage and looseness Check security and surface condition of the disc Pads should be changed when worn to 3 64 1 cm or about the 92 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The transmission brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system The transmission brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear Wear Line 3 64 1 cm e Pads should be changed when worn to 3 64 1 cm which is about the thickness of a dime e Inspect the brake disc spline and pad wear sur face for excessive wear 93 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide the bolts off inline cable adjuster sleeve Loosen adjuster locknut 2 Turn adjuster until 1 16 to 1 8 freeplay is achieved at thumb lever Flip throttle lever several times to confirm adjustment 3 Tighten locknut and slide boots over cable adjuster until they touch at the middle
91. ways travel at a speed which is proper for the terrain visibility and operating conditions and your experience e Never attempt wheelies jumps or other stunts Always inspect your vehicle each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the vehicle during operation e Always go slowly and be extra careful when operating on unfamil lar terrain Always be alert to changing terrain conditions when operating the vehicle Never operate on excessively rough slippery or loose terrain e Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Always have the vehicle checked by an authorized Polaris dealer if it has been involved in an accident SAFETY Key Safety Issues Never operate the vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of any
92. y crossing hills or turning on hills WHAT_CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Never attempt to turn the vehicle around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground See pages 62 and 67 Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehicle 32 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when riding over large obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual on page 71 A WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carryi
93. ylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs AWARNING Improperly operating the vehicle with a spongy brake lever can result in loss of braking Loss of braking could cause an accident Never operate the vehicle with a spongy feeling brake lever 40 CONTROLS AND FEATURES Controls Brakes Rear Auxiliary Brake The braking system is controlled by two levers located on the handlebars directly in front of the handgrips 1 Service Brakes front wheel and transmission Left Handlebar Lever This lever controls braking action to all six wheels It is the normal service brake system to use for braking 2 Auxiliary Brakes Right Handlebar Lever This lever controls the auxiliary brake for the rear axles It is to be used for additional braking effect or in the event of failure of the normal service brake system 41 CONTROLS AND FEATURES Controls Parking Brake Setting the Parking Brake 1 Squeeze the left hand brake lever two or three times and hold it 2 Rotate the park brake lock 3 into the notches on the master cylinder body Release the brake lever 3 To release the parking brake lock squeeze the brake lever It will return to its released position The parking brake will slowly relax or lose holding power if left unattended for more than five minutes Do not depend on parking brake to hold vehicle for more than five minu

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