WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . 4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . 32 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 68 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . 69 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
Operator Safety SAFETY WARNING Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
SAFETY Operator Safety Safety Training When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer. A Polaris ATV is an off-road vehicle.
Operator Safety SAFETY The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate the Sportsman 6x6 without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
Operator Safety SAFETY S Always keep both hands on the handlebars and both feet on the footrests of the vehicle during operation. S Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions. S Never operate on excessively rough, slippery, or loose terrain. S Always follow recommended turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.
SAFETY Operator Safety S Always use proper procedures if the vehicle stalls or rolls backwards while climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. Always dismount on the uphill side, or to either side if the vehicle is pointed straight uphill. Turn the vehicle around and remount following the procedure described in this manual. S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees.
Operator Safety SAFETY Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris Sportsman 6x6 any equipment that may 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 create a substantial safety hazard and increase the risk of bodily injury.
SAFETY Operator Safety 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.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Carrying a passenger on a Sportsman 6x6. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the vehicle, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN HAPPEN The vehicle could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the Sportsman 6x6 on any public street, road or highway, including dirt and gravel roads. WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet, eye protection and protective clothing.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Stalling or rolling backwards while climbing a hill. WHAT CAN HAPPEN Stalling or rolling while climbing a hill could result in vehicle overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep your body weight toward the front of the vehicle (uphill). Apply the brakes. After the vehicle has completely stopped, lock the parking brake.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the Sportsman 6x6 at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator’s chance of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the vehicle at a speed that’s proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Improperly operating in reverse.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the vehicle. If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the vehicle on such terrain.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn and cause serious injury or death. HOW TO AVOID THE HAZARD Never operate on hills too steep for the vehicle or for your abilities. Never operate the Sportsman 6x6 on hills steeper than 15_. Practice on small hills before attempting larger hills. WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Improperly crossing or turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the Sportsman 6x6 around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 62. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If it’s unavoidable, use extreme caution. WARNING POTENTIAL HAZARD Overloading the vehicle or carrying/towing cargo improperly.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating the vehicle through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the vehicle through deep or fast-flowing water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the vehicle with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner’s manual Supplement for the vehicle. Always maintain proper tire pressure.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the vehicle on a frozen body of water. WARNING POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment.
SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.
SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations 3 WARNING 3 Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: DOperate on public roads. A collision can occur with another vehicle. DCarry passengers. Passengers affect balance and steering and in- crease risk of losing control. DUSE ALCOHOL or DRUGS before or while operating this vehicle. DOperate at speeds too fast for your skills or the conditions. DOperate this vehicle on HILLS steeper than 15 degrees 15°.
SAFETY Safety Decals and Locations 4 5 6 7 8 4 WARNING 7 WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this vehicle if you are under age 16. 7172588 5 ETC This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) to reduce the risk of a stuck or “frozen” throttle. Please refer to your owner’s manual for details.
SAFETY Safety Decals and Locations WARNING S S 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 7172563 TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. VERTICAL WEIGHT: 150 LBS.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.
FEATURES AND CONTROLS 1 2 3 8 7 4 4 5 9 6 1. Service Brake Lever 2. Middle Axle Auxiliary Brake Lever 3. Throttle Lever 4. Box Dump Latch Release 5. Gear Selector 6. Floorboards 7. Backrest 8. Cargo Box 9.
FEATURES AND CONTROLS Electrical Switches and Indicators 1 2 3 4 5 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main switch is on. WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Don’t activate the override switch while the throttle is open. 2. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.
FEATURES AND CONTROLS Throttle Lever WARNING Do not start or operate a vehicle with sticking or improperly operating throttle controls. Doing so could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine.
FEATURES AND CONTROLS Brakes The braking system is controlled by the two brake levers located on the handlebars, directly in front of each handgrip. 1 2 Service Brakes The service brake lever (1) is located on the left handlebar. This lever controls both front and rear wheel braking action. Use this lever for normal braking. Apply the service brakes by squeezing the left brake lever toward the handlebar. These brakes are hydraulically activated disc brakes.
FEATURES AND CONTROLS Brakes Master Cylinders The master cylinders (1) are located on the left and right handlebars. Check fluid levels before each use of the ATV. View the fluid level through the indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. NOTE: 1 2 When checking the fluid level, position the ATV on level ground with the handlebars turned so the top of the reservoir is level.
Parking Brake FEATURES AND CONTROLS WARNING Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the left brake lever two or three times, then squeeze and hold. 2. Push the park brake lock (1) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze and release the brake lever.
FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. There’s about a 7 to 10 mile (11.2 to 16 km) range on the reserve supply. Always refill the gas tank as soon as possible after using the main supply. Always return the valve to the ON position after refueling.
Gear Selector FEATURES AND CONTROLS H L The transmission gear selector (1) is located on the right side of 1 the vehicle directly above and forward of the engine recoil starter. To change gears, stop the N vehicle, and with 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. R Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended.
FEATURES AND CONTROLS Recoil Starter If the battery has been drained or 2 1 damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.
Recoil Starter FEATURES AND CONTROLS 5. Allow the recoil rope to rewind into the recoil assembly, then pull the rope abruptly and forcefully to start the engine. 6. Repeat steps 4-5 if necessary. CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly. Do not extend the starter rope so far that it stops. If the starter rope handle is not seated properly, water may enter the recoil housing and damage components.
FEATURES AND CONTROLS All Wheel Drive (AWD) System 1 2 The Polaris Sportsman 6x6 is equipped with a unique AWD system activated by the AWD switch (1) on the right handlebar. When the switch is off, the vehicle is in rear wheel drive at all times. When the switch is on, the vehicle is in AWD and the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.
FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging Wheel Hubs The hubs normally disengage when operating in reverse. However, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, one front hub is engaged. If both hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted. Disengage the hubs by stopping, shifting to reverse, and backing for a short distance. Then proceed in forward again.
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph. Refer to page 33 for additional information. 3 2 1 1. Rider Information Center 2.
Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the cluster’s electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse. Mode 1 - Odometer The odometer records the miles traveled by the ATV.
Instrument Cluster FEATURES AND CONTROLS Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the diagnostic mode, either shift the machine out of neutral or turn the key switch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode. To enter the diagnostics mode: 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You must enable the programmable service interval before it can be used.
Fuel Safety OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well ventilated area with the engine stopped. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck.
OPERATION Break-in Period The break-in period for your new Polaris Sportsman 6x6 is defined as the first ten hours of operation or the time it takes to use the first two tanks of gasoline. No single action on your part is as important as following procedures for a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.
OPERATION Starting a Cold Engine WARNING Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 1. Place the transmission in neutral and lock the parking brake. Make sure the fuel tank valve is on. 2. Sit on the vehicle and pull the choke knob (1) out until it stops.
Starting a Warm Engine OPERATION Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank valve to ON, sit on the vehicle, and move the engine stop switch to RUN. 3. If the engine has cooled to a point where it does not readily start, intermittent use of the choke button (pulled half way out) may be necessary.
OPERATION Hauling Cargo Your Sportsman 6x6 has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings on the warning labels. Never exceed the specified weights. WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. S Never exceed the stated load capacity for this vehicle. S Do not obstruct the headlight when loading the front rack.
Hauling Cargo OPERATION Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Set the parking brake. 3. Dismount the vehicle. 4. Pull the cargo box release lever forward. 5. Lift the front of the cargo box and dump the cargo. WARNING If the weight distribution in the box is located toward the rear of the box when the release lever is pulled forward, the box may dump on its own, which could cause serious injury.
OPERATION Driving Safely Load Distribution 1 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 54. 2. Always load the cargo box with the load (1) as far forward as possible. 3. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling and control may be affected. 4. Slow down. 5. The cargo box dump latch must be securely latched before loading and operating.
Driving Safely OPERATION Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening. PVT shifting is automatic. 6. Drive slowly.
OPERATION Driving Safely Making Turns Practice making turns at slow speeds. The Sportsman 6x6 is equipped with a solid rear axle that drives all rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning, 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.
Driving Safely OPERATION Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2.
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. WARNING Hard use of the braking system while descending a hill could result in a front-end overturn, causing serious injury or death. Always operate the brakes slightly when descending a hill. Excessive speed can cause loss of control and lead to serious injury or death.
OPERATION Driving Safely Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills. 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle. WARNING Braking and handling are greatly affected when operating in hilly terrain.
OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8’ (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full left. 5.
Driving Safely OPERATION Driving on Slippery Surfaces Whenever operating on slippery surfaces, such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. NOTE: Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. Never brake during a skid. 3.
OPERATION Driving Safely Driving Through Water 1 Your Sportsman 6X6 can operate through water with a maximum recommended depth equal to the footrests (1). Avoid operating the ATV through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.
Driving Safely OPERATION Driving in Reverse This vehicle is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed. Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5.
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Place the transmission in gear and set the parking brake. 2. Always block the rear wheels on the downhill side. See illustration. 3. Shut off the fuel supply.
Driving Safely OPERATION Driving Over Obstacles Keep alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205.158) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
Tool Kit MAINTENANCE AND LUBRICATION To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kit are: S Screwdriver S Open end wrench (8-10 mm) S Open end wrench (12-14 mm) S Box end wrench S Tire pressure gauge S Spark plug wrench and handle S Torx wrench (rack removal) Accessories Polaris has a wide variety of accessories for your vehicle. Contact your Polaris dealer for a complete list.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " E J Perform these procedures more frequently for vehicles subjected to severe use. Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item " Brake pad wear J Battery Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks 10 H Monthly 60 (100) Inspect periodically 20 H Monthly 125 (200) Check terminals; clean; test " Front gearcase oil (if equipped) 25 H Monthly 155 (250) Inspect level; change yearly " Middle gearcase 25 H Monthly 155 (250) Inspect level; change yearly " Rear gearcase oil 25 H Monthly 155 (250) Inspect level; change y
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) " Oil filter change 100 H 6M 620 (1000) Replace with oil change " Oil tank vent hose 100 H 12 M 620 (1000) Inspect routing, condition J Valve clearance 100 H 12 M 620 (1000) Inspect; adjust J Fuel system 100 H 12 M 620 (1000) J Fuel filter 100 H 12 M 620 (1000) Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace l
MAINTENANCE AND LUBRICATION Lubrication Recommendations Lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user’s discretion.
MAINTENANCE AND LUBRICATION Lubrication Recommendations (Loc. 1) (Loc. 9) (Loc. 6) (Loc. 5) (Loc. 2) (Loc. 7) (Loc. 4) (Loc. 3) A (Loc.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Lubrication Always check and change the transmission lubricant at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill hole threads. Polaris recommends the use of Premium AGL Synthetic Gearcase Lubricant. See page 116 for the part numbers of Polaris products. 1 Oil Check 1.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Lubrication Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill plug threads. Polaris recommends the use of Premium ATV Angle Drive Fluid. See page 116 for the part numbers of Polaris products. 1 Oil Check 1. Position the vehicle on a level surface and remove the fill plug (1). 2.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 116 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil Level The oil tank is located on the left side of the vehicle. To check the oil: 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine. Remove the dipstick and wipe it dry with a clean cloth. 4. Screw the dipstick completely in, then remove it and check to see if the oil level is between the full and add marks.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil. Do not allow the vehicle to be without oil overnight.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 8. Reattach the oil line. 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter 2 (1) counterclockwise and remove. 10. Lubricate the gasket on the 1 new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine. 11.
MAINTENANCE AND LUBRICATION Engine Cooling System Coolant To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.
MAINTENANCE AND LUBRICATION Engine Cooling System Recovery Bottle Coolant Level The recovery bottle (1) is located on the left side of the vehicle. To access the recovery bottle, remove the left side panel as outlined on page 93. Maintain the coolant level between the minimum and maximum marks on the recovery bottle. Add coolant as needed. 1 Cooling System Operation The engine coolant level is controlled, or maintained, by the recovery system.
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service Always inspect and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. 1. Remove the seat. 2. Remove the spring clamps securing the air box lid and remove the lid. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, rinse and allow to dry thoroughly. 5. Reinstall the pre-filter over the main filter.
MAINTENANCE AND LUBRICATION Filter Systems Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box. Empty the drain tube if necessary. Breather Filter Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. 1. Remove the clamps and pull the breather filter (1) out of the hoses. NOTE: It’s not necessary to remove the lower hose from the engine. 2. Inspect the filter for debris.
MAINTENANCE AND LUBRICATION Adjustments WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out. 1. Set the handlebars in a straight-ahead position and hold them in this position.
MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the vehicle should be checked periodically for loose nuts and bolts. Have your dealer tighten any loose nuts and bolts before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Handlebar Adjustment The handlebars can be adjusted for rider preference.
MAINTENANCE AND LUBRICATION Adjustments Front Brake Front Wheel and Middle Axle Brake The front and middle axle brakes are hydraulic disc brakes and are activated by moving the brake lever toward the handlebar. These brakes are self-adjusting and require no adjustment. The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level (see page 36).
MAINTENANCE AND LUBRICATION Adjustments Rear Brake The transmission brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The transmission brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear. Change the brake pads when they’re worn to 3/64″ (.1 cm). Inspect the brake disc spline and pad wear surface for excessive wear. 3/64″ (.
MAINTENANCE AND LUBRICATION Adjustments Front Drive Chain Adjustment CAUTION Operating the vehicle with the drive chain slack out of specification could cause serious damage to the transmission and drive components. Never operate the vehicle with the drive chain slack out of specification. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain. Then pull up and down on the chain. At this point the chain should have 3/8″-1/2″ (.95-.1.
MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment To adjust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. Total slack for the rear chain should be adjusted to 3/8″-1/2″ (.95-.1.3 cm) at the tightest point in the chain. 3/8″-1/2″ (.95-.1.3 cm) 3/8″-1/2″ (.95-.1.3 cm) Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200.
MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 3. Place your hand on top of the side panel behind the fuel tank. With a quick and firm motion, push down on the side panel to disengage the top rear two tabs. Then pull up on side panel to disengage front upper and lower tabs. 4.
MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the wheel. WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification.
MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. 1/8I (.3 cm) WARNING Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.
MAINTENANCE AND LUBRICATION Tire Specifications Tire Specifications Polaris Sportsman 6x6 Front - 25 x 8 - 12 Inflation Pressure - 5 PSI Center - 25 x 11 - 12 Inflation Pressure - 5 PSI Rear - 25 x 11 - 12 Inflation Pressure - 5 PSI Cargo Box Load Capacity 800 lbs. (363 kg) Front Rack Load Capacity 75 lbs. (34 kg) Gross Vehicle Weight 1970 lbs. (894 kg) including vehicle, driver and cargo. Vehicle weighs 895 lbs. (406 kg).
MAINTENANCE AND LUBRICATION Spark Plugs S S S Use NGK BKR5E spark plugs. Proper electrode gap is .036″ (.9 mm) Spark plug torque is 14 ft. lbs. (1.9 kg/m) CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.
MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.
MAINTENANCE AND LUBRICATION Recoil Housing Water will enter the recoil housing if the starter handle is disengaged from the rope or if the handle is not securely seated when under water. Drain the recoil housing any time the vehicle has been operated in very wet conditions and also before storage. The drain screw (1) is located at the bottom of the recoil housing, above the front propshaft. Remove the screw with a 10 mm wrench. Reinstall the screw after the housing has been drained.
MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. Disconnect the black (negative) battery cable first. 3.
Battery MAINTENANCE AND LUBRICATION Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging. Power plug leads may need to be bent down so that the battery cover can be installed. Battery Charging The following battery charging instructions apply only to the installation of a sealed battery.
MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100% 12.5-12.8 volts May need slight charge, if no charge given, check in 3 months 3-6 hours 50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify state of charge 0%-25% 11.
Lights MAINTENANCE AND LUBRICATION WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Don’t service the headlamps until they’ve cooled sufficiently. Headlight Lamp Replacement 1. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod.
MAINTENANCE AND LUBRICATION Lights WARNING Operating the vehicle on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your Sportsman 6x6 is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
Lights MAINTENANCE AND LUBRICATION Headlight Housing Replacement 1. Remove the Phillips screws from the bottom of the headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to the left or right and use a very short screwdriver. Removal of the front rack and cover may also allow easier access. 2. Remove the three screws in the back of the headlight pod. 3. Lift the pod cover.
MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1). Apply dielectric grease to the socket and install the new lamp. 3. Test the taillight/brakelight for proper operation. 4. Reinstall the gasket and lens cover.
MAINTENANCE AND LUBRICATION Cleaning and Storage See page 116 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips If your vehicle will be placed in extended or off season storage, perform all necessary repairs and thoroughly clean the vehicle. Drain the recoil housing. Remove the battery and store it in a cool, dry place. See the battery section beginning on page 102.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Engine Anti-Freeze Test engine coolant strength and change if necessary. Replace coolant every two years. Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the maintenance section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Apply Polaris O-Ring Chain Lube to the drive chain(s).
MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. 1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime. Never use abrasive cleaners on plated or painted surfaces. 2. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish. 3.
MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting the Vehicle Follow these procedures before transporting the vehicle with another unit. 1. Turn off the engine and remove the key to avoid loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap and oil cap are installed correctly. 4. Always tie the frame of the ATV to the transporting unit securely using suitable straps and/or rope. 5. Always place the transmission in gear and lock the parking brake.
SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Cargo Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Gearcase Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System
SPECIFICATIONS SPORTSMAN 6x6 Transmission Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size - Front Tire Size - Center Tire Size - Rear Front Brake Rear Brake Parking Brake Headlight Taillights Brakelight Instrument Cluster Automatic PVT (H/L/N/R) 6.69/1 5.17/1 3.
POLARIS PRODUCTS Part No. Description 2871281 2871844 Engine Lubricant Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2873602 2873603 2871653 2872276 2870465 2871654 2872277 Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lube (qt.) Premium AGL Synthetic Gearcase Lube (gal.) Premium ATV Angle Drive Fluid (8 oz.) Premium ATV Angle Drive Fluid (2.5 gal.) Pump for Gallon Jug Premium Demand Drive Hub Fluid (8 oz.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Driving onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline When starting out on an incline, use low range or dismount the ATV (after first applying the park brake) and perform the K-turn as described on page 62.
TROUBLESHOOTING Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or d
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition conn
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris Light Utility Vehicle against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
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.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2006 and later Large Spark Ignition Engine (herein “LSI engine”).
WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the original retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.
WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty maintenance or repairs of emission-related parts. These replacement parts will be provided at no charge if the part is still under warranty.
WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 131
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . . 69 Adjustments . . . . . . . . . . . . . . . . . 86-94 Age Restrictions . . . . . . . . . . . . . . . . . 5 Air Box Drain . . . . . . . . . . . . . . . . . . 85 Air Filter . . . . . . . . . . . . . . . . . . . . . . 84 All Wheel Drive (AWD) . . . . . . . . . . 42 All Wheel Drive System . . . . . . . . . . 43 All Wheel Drive Switch . . . . . . . . . . 33 Auxiliary Brakes . . . . . . . . . . . . . . . . 35 Driving Safely . . . . . . . . . . . .
INDEX M S Main Switch . . . . . . . . . . . . . . . . . . . 33 Maintenance and Lubrication . . . 69-113 Maintenance Log . . . . . . . . . . . . . . 130 Making Turns . . . . . . . . . . . . . . . . . . 58 Master Cylinders . . . . . . . . . . . . . . . . 36 Sidehilling . . . . . . . . . . . . . . . . . . . . 59 Spark Arrestor . . . . . . . . . . . . . . . . . 100 Spark Plug Removal . . . . . . . . . . . . . 97 Spark Plugs . . . . . . . . . . . . . . . . . . . . 97 Specifications . . . . . . . . . . . . . .
