WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
WARNING Indicates a potential hazard that could result in serious injury or death.
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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.
ATTENTION! This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 16 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various areas which are being 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.
TABLE OF CONTENTS Vehicle Identification Numbers . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 Understanding Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 7 Key Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Decals and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Controls and Features . . . . . .
TABLE OF CONTENTS Maintenance and Lubrication . . . . . . . . . . 73 - 117 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . 74 Lubrication Recommendations . . . . . . . . . . . . . . . . . . . 77 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Filter Systems . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS 2 1 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.
SAFETY Understanding Warnings The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING Indicates a potential hazard that could result in serious injury or death.
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.
SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
SAFETY Key Safety Issues S S S S S S S S 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.
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. S 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. S Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing. Riding this vehicle requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a serious head injury.
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 Polaris at no charge. The part number is printed on the decal.
SAFETY Safety Decals and Locations 1 WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch Maximum Front Rack Load 75 lbs. 2 WARNING 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.
SAFETY Safety Decals and Locations 3 15
SAFETY Safety Decals and Locations 3 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: D Operate on public roads. A collision can occur with another vehicle. D Carry passengers. Passengers affect balance and steering and increase risk of losing control. D USE ALCOHOL or DRUGS before or while operating this vehicle. D Operate at speeds too fast for your skills or the conditions. D Operate this vehicle on HILLS steeper than 15 degrees 15°.
SAFETY Safety Decals and Locations 5 7 8 4 6 17
SAFETY Safety Decals and Locations 4 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. 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 6 S Passengers can be thrown off. This can cause serious injury or death. S Never carry passengers. Maximum Box Load 800 lbs.
SAFETY Safety Decals and Locations 9 WARNING 9 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.
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) ATTENTION Operation of this vehicle without the filter element will severely damage the engine. D Clean air filter often, more frequent cleaning required in dusty conditions D Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owner’s manual for details.
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 Industries Inc.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet, eye protection and protective clothing.
SAFETY Operator Safety 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 apply engine power. Never apply the rear brake while rolling backwards.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury.
SAFETY Operator Safety 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 AVOID 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.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain.
SAFETY Operator Safety 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.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Operating on excessively steep hills.
SAFETY Operator Safety 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.
SAFETY Operator Safety WARNING 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.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly 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.
SAFETY Operator Safety 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.
SAFETY Operator Safety 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.
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 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.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs.
CONTROLS AND FEATURES Controls Sportsman 6x6 Vehicle Nomenclature 1. 2. 3. 4. 5. Service Brake Lever Middle Axle Auxiliary Brake Throttle Lever Bed Dump Latch Release(s) Gearbox Shift Lever 6. 7. 8. 9.
CONTROLS AND FEATURES Controls Engine Electrical Switches 1 3 2 OFF RUN OFF WARNING 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.
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 2 1 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.
CONTROLS AND FEATURES Controls Front and Rear Brakes The master cylinders, which are 3 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.
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.
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.
CONTROLS AND FEATURES Controls Engine Fuel and Oil System 2 1 The fuel tank filler cap (1) is located directly behind the handlebar. Its capacity is 4.25 U.S. gallons (16 l) with 1/2 gallon (1.9 l) in reserve. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 (R+ M)/2 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.
CONTROLS AND FEATURES Controls Engine Fuel and Oil System WARNING Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well ventilated area. D Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. D Do not over fill the tank. Do not fill the tank neck.
CONTROLS AND FEATURES Controls Transmission Gear Selector Operation The transmission gear selector is located on the right side of the vehicle Shift Patterns directly above and forward of the engine recoil starter. The transmission selector lever has four positions: H L high forward; reverse; neutral; and low forward. N Use of low forward gear is recommended in heavy pulling situations to extend R belt life. To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear.
CONTROLS AND FEATURES Controls Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. 1. Be certain the parking brake is set. See page 42. 2. Grasp the recoil starter tightly and pull slightly until the starter mechanism engages. 3. Pull the rope abruptly to start the engine.
CONTROLS AND FEATURES Features Light Switches and Indicator Lights 2 6 3 1 7 5 4 1. Main switch 2. Handlebar light switch and headlight Hi-Lo beam control NOTE: Will not light unless main switch is on. 3. Headlight Hi beam indicator (Blue) 4. Transmission reverse indicator (Yellow) 5. Transmission neutral indicator (Green) 6. All Wheel Drive indicator (Red) 7. Engine hi temp warning indicator (Red) NOTE: Will light only if engine overheats.
CONTROLS AND FEATURES Features All Wheel Drive System 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.
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. CAUTION Do not switch on AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.
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. CAUTION Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil.
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. 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.
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. A 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.
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 surface. 2. Lock the parking brake. 3. Turn the fuel tank valve to ON. 4. Sit on the vehicle. 5. If the engine has cooled to a point where it does not readily start, intermittent use of the choke button pulled half way out is permitted. 6.
OPERATION Carrying Loads Your 6x6 has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following weights. Maximum Capacities (Level Ground) Front Rack Cargo Cargo Bed Sportsman 6x6 - 875 lbs. (397 kg) 75 lbs. (34 kg) 800 lbs. (363 kg) Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo.
OPERATION Carrying Loads WARNING Overloading the vehicle or carrying or towing cargo improperly can be dangerous. Improper loading can drastically alter 6x6 handling and braking stability. D Never exceed the stated load capacity for this vehicle. D Do not obstruct the headlight when loading the front rack. D Cargo should be properly distributed and carried as low and forward in the cargo bed as possible. D Reduce speed and allow greater distance for braking.
OPERATION Carrying Loads Dumping the Cargo Bed 1. Select a level site to dump the cargo bed. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Set the parking brake. 3. Dismount the vehicle. 4. Pull the cargo bed release mechanism lever forward and lift the front of the cargo bed to dump. WARNING Never carry passengers on the bed.
NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S.
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. 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.
RIDING Riding Safely Load Distribution Maximum Cargo Bed Sportsman 6x6 800 lbs. (363 kg) 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. The cargo bed dump latch must be securely latched before loading and operating.
RIDING Riding Safely 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 and PVT shifting is done automatically. 6.
RIDING Riding Safely Making Turns Practice making turns at slow speeds. Polaris 6x6s are equipped with solid rear axles which drives all rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the 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.
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.
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.
RIDING Riding Safely Riding On Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can be dangerous. Loss of tire traction and vehicle control can result in an accident, including an overturn. S Never apply brakes during a skid. Complete loss of control can result. S Do not operate on excessively slippery surfaces if possible. S Always reduce speed and use additional caution.
RIDING Riding Safely Traveling Downhill Whenever descending a hill always: 1. 2. 3. 4. Drive directly downhill. Transfer your weight to the rear of the vehicle. Slow down. Apply the brakes slightly to aid in slowing. WARNING Loss of vehicle control due to excessive speed can occur. Loss of control may result in serious injury or death.
RIDING Riding Safely Traveling Uphill 15_ Maximum Whenever traveling uphill always travel straight uphill and: 1. 2. 3. 4. 5. Avoid steep hills. Keep both feet on the footrests. Transfer your weight forward. Proceed at a steady rate of speed and throttle opening. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle. WARNING Braking and handling are greatly affected whenever operating in hilly terrain.
RIDING Riding Safely Turning Around On A Hill 8’ Uphill 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 vehicle). 5.
RIDING Riding Safely Crossing Streams Your Polaris 6X6 can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal. S Avoid operating the 6X6 through deep or fast flowing water.
RIDING Riding Safely Backing Up Backing Up 1. 2. 3. 4. 5. 6. 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. 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.
RIDING Riding Safely Backing Up WARNING Backing your 6x6 can be dangerous! You could hit an obstacle or person behind you; or the vehicle could tip over on a steep incline causing severe injury or death. Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power is required for vehicle movement. Avoid backing on steep inclines. Avoid turning at sharp angles in reverse.
RIDING Riding Safely Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen obstacles. D Keep alert and constantly look for obstacles on the trail.
RIDING Riding Safely Parking On An Incline Whenever the Vehicle is Parked 1. Place the transmission in gear. 2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 4. Shut off fuel supply. WARNING 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.
MAINTENANCE AND LUBRICATION Tool Kit To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following 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.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule (Cont.) CAUTION Due to the nature of the adjustments marked with a J, it is recommended that service be performed by an authorized Polaris dealer. " 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.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or Odometer Frequency Remarks J Valve Clearance 100 hrs 12 months Inspect/Adjust J Fuel System 100 hours 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec. Method Frequency* Brake Fluid DOT 3 Only Maintain proper level. See page 40. As required; change every two years or 200 hours Drive Chains O-Ring chain lube or SAE 80/90 Lubricate as often as required (before each ride in wet conditions). As required Gear Selector 10 W Non-detergent Oil Maintain oil level at the center of the shift rail. Do not overfill. Change every 2 years or 200 hours.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Inner Tie Rod End Steering Post Bushings Demand 6 Hubs Upper Front A-Arm Pivot Shaft Ball Joint 4:00 position Demand 6 Hubs - All Wheel Drive Premium Hub Lube Remove set screw in hubs. Rotate wheels to 4:00 position. If lubricant is not visible add more. Reinstall set screw. Annually or at 100 hrs Ball Joint Grease** Locate zerk on back side of struts and grease with grease gun.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Middle Axle Bearings U Joint Swing Arm Bushings Center Swing Arm Housing Rear Axle Bearing Rear Strut Front Drive Axle U Joints Rear Axle Bearing Grease + Locate grease fitting and grease with grease gun. Locate fitting on eccentric and grease with grease gun. Every 3 months or 50 hrs Every 3 months or 50 hrs Swing Arm Bushings Grease** Locate fitting on swing arm and grease with grease gun.
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.
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.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 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.
MAINTENANCE AND LUBRICATION Lubrication Recommendations 8. Place shop towels beneath oil filter. Using an oil filter wrench, turn filter counterclockwise to remove. 9. Using a clean dry cloth, clean filter sealing surface on crankcase. 10. 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. 11.
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.
MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level Inspection 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. Front Cover Rack WARNING 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.
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 The engine coolant level is Bottle controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service It is recommended that the air filter be replaced yearly. When riding in extremely dusty conditions replacement will be required more often. 1. Remove seat. 2. Remove spring clamps securing the airbox lid and remove lid. 3. Loosen clamp and remove filter. 4. Remove fabric type pre-filter from main filter. Wash pre-filter in soapy water and dry it. 5. Reinstall pre-filter over main filter. Replace main filter as required. 6.
MAINTENANCE AND LUBRICATION Filter Systems Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box and empty if necessary. Breather Filter and Hoses: Operation of your vehicle without a breather filter can cause engine damage. 1. Remove the clamps and pull the filter out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine. 2. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging.
MAINTENANCE AND LUBRICATION Adjustments WARNING 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. 1.
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 1 3 2. Adjust handlebar to desired height.
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. 3/64″ The following checks are (.1cm) 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.
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 S S 93 Pads should be changed when worn to 3/64″ (.1 cm) which is about the thickness of a dime. Inspect the brake disc spline and pad wear surface for excessive wear. 3/64″ (.
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 point of adjuster.
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.
MAINTENANCE AND LUBRICATION Adjustments Tire Inspection 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 may affect vehicle handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. Tread Depth 1/8I (.
MAINTENANCE AND LUBRICATION Adjustments Tire Specifications Tire Specifications Sportsman 6x6 Front - 25 x 8.00 -12 Inflation Pressure - 5 PSI Center - 25 x 11.00 - 10 Inflation Pressure - 5 PSI Rear - 25 x 11.00 - 10 Inflation Pressure - 5 PSI Cargo Bed Load Capacity 800 lbs. (363 kg) Front Rack 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 Adjustments Front Drive Chain Adjustment 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.
MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment All procedures used in adjusting the front chain apply to the rear chain adjustment. Total slack for the rear chain, however, should be adjusted to 1/4″-1/2″ (.6-1.3 cm). 3/16″-3/8″ (.48 cm - .95 cm) 1/4″-1/2″ (.6-1.
MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: Idle Screw 1. Warm up the engine by running the vehicle approximately five minutes. 2.
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 3% 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.
MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1. Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 2. Remove seat. Grasp rear of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 3. Place hand on top of 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.
MAINTENANCE AND LUBRICATION Spark Plugs Use NGK BKR5ES spark plugs. Proper electrode gap is .025″ (.06 cm). Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs (1.52 kg/m) for a new spark plug. Spark plug condition is indicative of engine operation. The spark plug 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. S S S 1.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING S S S S S S Because exhaust system temperatures can reach 1000°F, do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. 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.
MAINTENANCE AND LUBRICATION Spark Arrestor (Cont.) The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the cleanout plug (A) located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the enA gine. Purge accumulated carbon from the system by momentarily revving the engine several times. 3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the cleanout plug while revving the engine several more times.
MAINTENANCE AND LUBRICATION Recoil Housing Drain the recoil housing after operating the vehicle Crankcase Drain 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 Recoil Drain (above front is disengaged from the rope propshaft on shaft drive models) guide when under water.
MAINTENANCE AND LUBRICATION PVT System WARNING The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this system remains safe: D Do not 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.
MAINTENANCE AND LUBRICATION Battery WARNING 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. WARNING 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.
MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV, being careful not to tip it sideways and spill electrolyte.
MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely 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. 3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement WARNING 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 knob in slot and secure in locking tabs Slip O-Ring over pin Adjustment Knob Stop Route plug over handlebar 1.
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. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Housing Replacement 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also allow easier access. 2. Remove three Phillips screws at back of headlight pod. 3. Lift pod cover up. Disconnect speedometer harnesses from speedometer.
MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be Lens replaced. 1. Remove the taillight assembly by removing the two screws securing Lamp it to the vehicle. Lamp 2. Twist the lamp harness 1/4 turn to Harness release the lock. Pull the lamp harness out of the back of the assembly. 3. Remove the lamp from the harness and replace it with the recommended lamp. 4.
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.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage of the 6x6 If your 6x6 is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. Drain tube 2. Turn the fuel valve to “off” and attached drain the carburetor. here 3. Remove the spark plug and Drain Screw pour approximately one ounce of Premium 4 oil into the cylinder.
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.
SPECIFICATIONS Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48″ Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46″ Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105″ Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.5″ Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS Engine Specifications 2002 Sportsman 6x6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EH50PLE-06 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499 cc Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cylinder Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 120
TROUBLESHOOTING Clutch Drive Belt & 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 burnrange. ing. Starting out going up a steep incline. When starting out on an incline, use low range, or dismount the 6x6 after first applying the park brake and perform the “K” turn as described on page 67 of this manual.
TROUBLESHOOTING Possible Causes Solutions/What to do Stuck in mud or snow. Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn. Climbing over large objects from a stopped position. Shift the transmission to Low Range, carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.
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.
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.
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.
INDEX Accessories . . . . . . . . . . . . . . . . . . . . . . . 117 Adjustments . . . . . . . . . . . . . . . . . . . 90-102 Air Box Drain . . . . . . . . . . . . . . . . . . . . . 89 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . 88 All Wheel Drive . . . . . . . . . . . . . . . . . . . 48 Backing Up . . . . . . . . . . . . . . . . . . . . . 69-70 Battery Fluid . . . . . . . . . . . . . . . . . . . . . 108 Battery Installation . . . . . . . . . . . . . . . . 109 Battery Maintenance . . . . . . .
INDEX Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wheel Installation . . . . . . . . . . . . . . . . . . 95 Wheel Removal . . . . . . . . . . . . . . . . . . . 95 Wiring Diagram . . . . . . . . . . . . . . . . . . 120 Understanding Warnings . . . . . . . . . . . . . 7 127 Vehicle Break-- in Period . . . . . . . . . . . . . 50 Vehicle Identification Numbers . . . . . . . . 6 Vehicle Nomenclature . . . . . . . . . . . . . . . 37 Warranty . . . . . . . . . . . . . . . . . . . . .
