Polaris 2004 Sportsman 6x6 Owner's Manual For Maintenance And Safety

A card containing important A TV 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.

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WARNING

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Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.

3

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. Visit our Web site at
www.polarisindustries.com.

Polaris Recreational Vehicles

S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Watercraft
S Victory motorcycles

Polaris Professional Series (PPS) Workmobilest

S Utility Task Vehiclet (UTV)
S Personal Task Vehiclet (PTV)
S All-Surface Loader (ASL)

We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest vehicle we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Polaris Professional Series are
registered trademarks of Polaris Industries Inc.

4

VEHICLE IDENTIFICATION NUMBERS

The vehicle frame vehicle identification number (VIN)(1) and engine
serial number (2) are important for model identification when
registering your vehicle, when obtaining insurance, and when ordering
replacement parts. In the event your vehicle is stolen, these numbers
are essential to the recovery and identification of your vehicle.

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. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer .

NOTE: Record your vehicle’s ID numbers and key number (3) in the
spaces provided.

2

1

31XX

3

Frame VIN:

Engine Serial Number:

Vehicle Model Number:

Key Number:

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TABLE OF CONTENTS

WELCOME 3.................................

VEHICLE IDENTIFICATION NUMBERS 4........

SAFETY 6...................................

FEATURES AND CONTROLS 35...............

OPERATION 52..............................

EMISSION CONTROL SYSTEMS 71............

MAINTENANCE AND LUBRICATION 73.........

SPECIFICATIONS 116........................

POLARIS PRODUCTS 118.....................

TROUBLESHOOTING 119.....................

WARRANTY 123..............................

INDEX 127...................................

6

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.

1. Helmet

Your helmet is the most important piece
of protective gear for safe riding. A
helmet can prevent a severe head injury.

Select an approved helmet that meets
or exceeds your state’s safety standards
and bears either the Department of
Transportation (DOT) label, the
American National Standards
Institute label (ANSI z90.1), or the
Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for
proper eye protection. A pair of
goggles or a helmet face shield offer
the best protection for your eyes. They
should be kept clean and be of
shatterproof design (bearing the
markings Z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and
protection.

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.

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3

4

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7

SAFETY

Operator Safety

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.

Know Y our Vehicle

As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.

Safety T raining

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 i nformation on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of the ATV in your area.

We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

WARNING

Failure to follow the warnings contained in this manual can
result in severe injury or death.

A Polaris ATV is not a toy and can be hazardous to operate.
This vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills
or over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.

8

SAFETY

Operator Safety

The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.

The safety alert warning indicates a potential hazard that may
result in serious injury or death.

The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.

CAUTION

NOTE:

A note will alert you to important information or instructions.

A caution indicates a situation that may result in damage to the
vehicle.

CAUTION

WARNING

9

SAFETY

Operator Safety

The Sportsman 6x6 is an off-road vehicle. Familiarize yourself with
all laws and regulations concerning the operation of this vehicle in
your area.

We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

All information in this manual is based on the latest product data and
specifications available at the time of printing. Polaris Industries Inc.
reserves the right to make product changes and improvements that may
affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written
permission of Polaris Industries Inc.

10

SAFETY

Operator Safety

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. Contact an authorized Polaris dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this vehicle.
S Never permit a guest to operate the vehicle unless the guest has read

this manual and all product labels and has completed a certified safe­ty training course.

S Always avoid operating this vehicle on paved surfaces, including

sidewalks, driveways, parking lots, and streets.

S Never operate this vehicle on a public street, road or highway, in-

cluding a dirt or gravel road.

S Never operate this vehicle without wearing an approved helmet that

fits properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Never operate at excessive speeds. Travel at speeds appropriate for

the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts.
S Always inspect your vehicle before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the vehicle during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar t errain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose t errain.
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.

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.

11

SAFETY

Operator Safety

S Always have the vehicle inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S Never operate on hills too steep for the vehicle or for your abilities.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascending a hill. Never climb hills with exces­sively slippery or loose surfaces. Shift your weight forward. Never
open the throttle suddenly or make sudden gear changes. Never go
over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos­sible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the vehicle. Never attempt to turn the
vehicle around on any hill until you’ve mastered (on level ground)
the turning technique outlined in this manual. Avoid crossing the
side of a steep hill when possible.

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 t rees.

S Always be alert to the potential for skidding or sliding. On slippery

surfaces (like ice), travel slowly and use extra caution to reduce the
chance of skidding or sliding out of control.

S Avoid operating the vehicle through deep or fast-flowing water. If

it’s unavoidable, travel slowly, balance your weight carefully, avoid
sudden movements, and maintain a slow and steady forward motion.
Do not make sudden turns or stops, and do not make sudden throttle
changes.

12

SAFETY

Operator Safety

S Wet brakes may have reduced stopping ability. Test your brakes af-

ter l eaving water. If necessary, apply them lightly several times to
allow friction to dry out the pads.

S Always check for obstacles or people behind the vehicle before oper-

ating in reverse. When it’s safe to proceed in reverse, move slowly
and avoid turning at sharp angles.

S Always use the size and type of tires specified for your vehicle, and

always maintain proper tire pressure.

S Never modify this vehicle through improper installation or use of

accessories.

S Never exceed the stated load capacity for your vehicle. Cargo must

be properly distributed and securely attached. Reduce speed and
follow the instructions in this manual for hauling cargo or towing.
Allow a greater distance for braking.

S Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call the Consum­er Product Safety Commission at 1-800-638-2772, or call Po ­laris at 1-800-342-3764.

Additional Important Information

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.

The warranty on your Polaris Sportsman 6x6 is terminated if any
equipment has been added to the vehicle, or if any modifications have
been made to the vehicle, that increase its speed or power.

We also advise you to strictly follow the recommended maintenance
program outlined in this manual. This preventive maintenance
program is designed to ensure that all critical components on the
vehicle are thoroughly inspected by your dealer at various mileage
intervals.

NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may change the
handling characteristics of the vehicle. Use only Polaris-approved
accessories, and familiarize yourself with their function and effect on
the vehicle.

13

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully . If any
of the decals depicted in this manual differ from the decals on your
ATV, always read and follow the instructions of the decals on the ATV.

If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.

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2

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.

IMPROPER TIRE PRESSURE OR OVERLOADING can cause
loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (Kpa): FRONT 5 (34,5) CENTER 5 (34,5)

REAR 5 (34,5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight

INCLUDING MACHINE, DRIVER AND CARGO IS 1965 LBS.)

Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase
your risk of losing control. Loads should be centered, carried as low as
possible in bed, and firmly secured to the rack.
For stability on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack or box.

Read Owner’s Manual for more detailed loading information.

WARNING

WARNING

7079295

7079293

1

2

14

SAFETY

Safety Decals and Locations

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°.

DTo prevent flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

DUse an approved HELMET AND PROTECTIVE GEAR.

DAvoid paved surfaces. Pavement may seriously affect handling and

control.

DUse proper RIDING TECHNIQUES to avoid vehicle overturns on

hills and rough terrain and in turns.

DUse OVERRIDE for reverse speed limiter with caution. To prevent

loss of control, never activate override button with open throttle.

DREVERSE operation can be dangerous, even at low speeds. Steer-

ing becomes difficult. To prevent flipover, avoid sharp turns.
PARKING BRAKE may relax when used for more than 5 minutes.
When parking on grades, leave shift in forward.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL

INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS

MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT.

3

WARNING

3

15

SAFETY

Safety Decals and Locations

4

5

6

8

ETC

This vehicle is equipped with a
Polaris Electronic Throttle Control
(ETC) to reduce the risk of astuck or
“frozen” throttle. Please refer to your
owner’s manual for details.

4

5

Operating this vehicle if you are under the
age of 16 increas es your chance of severe
injury or death.

NEVER operate this vehicle if you are under
age 16.

7078254

Remove flammable containers from before refueling.

Maximum Box Load 800 lbs.

DPassengers can be thrown off.

This can cause serious injury
or death.

DNever carry passengers.

ALL WHEEL

DRIVE

SWITCH

Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your owner’s
manual.

7079780

7079604

WARNING

Pushing reverse
override button
may cause
sudden in­creases in pow­er and traction if
too much
throttle is ap­plied. Loss of
control or for­ward flipover
may result, es­pecially in
AWD. See Own-
er’s Manual .

6

78

7

16

SAFETY

Safety Decals and Locations

Moving parts hazard under belt-clutc h guard. To
prevent serious injury, do not operate vehicle with
guard r emov ed.

Do not modify engine or clutch. Doing so can cause
part failure, possible imbalance, and excessive
engine RPM which can result in serious injury or
death.

NO STEP

7078689

WARNING

(on hitch)

ATTENTION

S Operation of this vehicle without the

filter element will severely damage
the engine.

S Clean air filter often, more frequent

cleaning required in dusty condi­tions.

S Operation of this vehicle without en-

gine breather filter(s) can cause en­gine damage. Consult owner’s
manual for details.

S Specific carburetor jetting and adjust-

ments are required depending on tem­perature and altitude. See your owner’s
manual.

Factory setting:

40_ to 80_ F . at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7079902

(under seat)

7170509

TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

17

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this vehicle without proper instruction.

WHAT CAN

HAPPEN

The risk of an accident is greatly increased if the operator
does not know how to operate the vehicle properly in different
situations and on different types of terrain.

HOW TO AVOID THE

HAZARD

Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.

For more information about the training course, contact an
authorized Polaris dealer or call Polaris at 1-800-342-3764.

POTENTIAL

HAZARD

Failure to follow the age recommendations for this vehicle.

WHAT CAN

HAPPEN

Severe injury and/or death could occur if a person under the age
of 16 operates the Sportsman 6x6.

Even though a child may be within the recommended age group
for operating some vehicles, he/she may not have the skills,
abilities, or judgment needed to operate the Sportsman 6x6
safely and could be susceptible to accident or injury.

HOW TO AVOID THE

HAZARD

No one under the age of 16 should operate a Polaris Sportsman
6x6.

WARNING

WARNING

18

SAFETY

Operator Safety

Safe operation of this rider active vehicle requires good judgement
and physical skills. Persons with cognitive or physical disabilities
who operate this vehicle have an increased risk of overturns and
loss of control, which could result in serious injury or death.

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.

POTENTIAL

HAZARD

Operating a Sportsman 6x6 on paved surfaces, including
sidewalks, paths, parking lots, and driveways.

WHAT CAN

HAPPEN

Sportsman 6x6 tires are designed for off-road use. Operating on
paved surfaces may seriously affect the handling and control of the
vehicle and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE

HAZARD

Avoid operating the Sportsman 6x6 on pavement. If it’s
unavoidable, travel slowly and avoid sudden turns or stops.

WARNING

WARNING

WARNING

19

SAFETY

Operator Safety

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.

POTENTIAL

HAZARD

Operating this vehicle without wearing an approved helmet,
eye protection and protective clothing.

WHAT CAN

HAPPEN

Operating a Sportsman 6x6 without an approved helmet
increases the risk of a severe head injury or death in the
event of an accident.

Operating without eye protection could result in an accident
and could increase the chance of a severe injury in the event
of an accident.

HOW TO AVOID THE

HAZARD

Always wear an approved helmet that fits properly.

Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.

WARNING

WARNING

20

SAFETY

Operator Safety

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.

Ifyouloseallforwardspeed:

Keep your body weight toward the front of the vehicle (uphill).

Apply the brakes. After the vehicle has completely stopped, lock
the parking brake.

If you begin rolling

backwards:

Keep your body weight toward the front of the vehicle (uphill).

Do not apply engine power.

Do not apply the rear brakes.

Gradually apply the service brake. When fully stopped, apply the
auxiliary brake as well, and then lock the parking brake.

Dismount on the uphill side, or to either side if the vehicle is
pointed straight uphill.

Turn the vehicle around and remount, following the procedure
described in the owner’s manual. See page 65. In the event of
an accident, have an authorized Polaris dealer inspect the entire
vehicle for possible damage, including (but not limited to) brakes,
throttle and steering.

WARNING

21

SAFETY

Operator Safety

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.

POTENTIAL

HAZARD

Improperly operating in reverse.

WHAT CAN

HAPPEN

The Sportsman 6x6 could collide with an obstacle or person,
resulting in severe injury.

HOW TO AVOID THE

HAZARD

Before shifting into reverse gear, always check for obstacles or
people behind the vehicle. When it’s safe to proceed, back
slowly .

WARNING

WARNING

22

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to inspect the vehicle before operating.

Failure to properly maintain the vehicle.

WHAT CAN

HAPPEN

Poor maintenance increases the possibility of an accident or
equipment damage.

HOW TO AVOID THE

HAZARD

Always inspect your vehicle before each use to make sure it’s
in safe operating condition.

Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.

POTENTIAL

HAZARD

Removing hands from the handlebars or feet from the
footrests during operation.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce ability to
control the vehicle or could cause loss of balance and
ejection from the vehicle.

If the operator’s foot is not firmly planted on the footrest, it
could come into contact with the rear wheels and lead to
accident or injury.

HOW TO AVOID THE

HAZARD

Always keep both hands on the handlebars and both feet
on the footrests of the vehicle during operation.

WARNING

WARNING

23

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to use extra caution when operating the vehicle on
unfamiliar terrain.

WHAT CAN

HAPPEN

Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.

HOW TO AVOID THE

HAZARD

Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.

POTENTIAL

HAZARD

Skidding or sliding.

WHAT CAN

HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly , the vehicle could overturn.

HOW TO AVOID THE

HAZARD

On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.

WARNING

WARNING

24

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to use extra caution when operating on excessively
rough, slippery or loose terrain.

WHAT CAN

HAPPEN

Operating on excessively rough, slippery or loose terrain could
cause loss of traction or loss of control, which could result in an
accident or overturn.

HOW TO AVOID THE

HAZARD

Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to
control the vehicle on such terrain.

Always use extra caution on rough, slippery or loose terrain.

WARNING

25

SAFETY

Operator Safety

POTENTIAL HAZARD

Turning improperly.

WHAT CAN

HAPPEN

Improper turns could cause loss of control and lead to a
collision or overturn.

HOW TO AVOID THE

HAZARD

Always follow proper procedures for turning as described in
the owner’s manual.

Practice turning at slow speeds before attempting to turn at
faster speeds.

Never turn at excessive speed.

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

WARNING

26

SAFETY

Operator Safety

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN

HAPPEN

Improper hill climbing could cause loss of control or overturn.

HOW TO AVOID THE

HAZARD

Always follow proper procedures for climbing hills as described
in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The
vehicle could flip over backwards.

Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.

WARNING

27

SAFETY

Operator Safety

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. Travel straight down the
hill when possible.

WARNING

28

SAFETY

Operator Safety

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 65. Use extra
caution when turning on any hill.

Avoid crossing the side of a steep hill. If it’s unavoidable, always
follow proper procedures as described in the owner’s manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the vehicle.

WARNING

29

SAFETY

Operator Safety

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.

POTENTIAL

HAZARD

Overloading the vehicle or carrying/towing cargo improperly.

WHAT CAN

HAPPEN

Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or an accident.

HOW TO AVOID THE

HAZARD

Never exceed the stated load capacity for this vehicle.

Cargo should be properly distributed and securely attached.

Reduce speed when hauling cargo or pulling a trailer. Allow a
greater distance for braking.

Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See pages 57-58.

WARNING

WARNING

30

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating the vehicle through deep or fast-flowing water.

WHAT CAN

HAPPEN

Tires may float, causing loss of traction and loss of control,
which could lead to an accident or overturn.

HOW TO AVOID THE

HAZARD

Avoid operating the vehicle through deep or fast-flowing
water. If it’s unavoidable to enter water that exceeds the
recommended maximum depth (see page 67), travel slowly,
balance your weight carefully, avoid sudden movements, and
maintain a slow and steady forward motion. Do not make
sudden turns or stops, and do not make sudden throttle
changes.

Wet brakes may have reduced stopping ability . Always test
the brakes after leaving water. If necessary, apply them
several times to let friction dry out the pads.

POTENTIAL

HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN

HAPPEN

Attempting stunts increases the chance of an accident, including
an overturn.

HOW TO AVOID THE

HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition
driving.

WARNING

WARNING

31

SAFETY

Operator Safety

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.

POTENTIAL

HAZARD

Operating the vehicle with improper modifications.

WHAT CAN

HAPPEN

Improper installation of accessories or modification of the
vehicle may cause changes in handling, which could lead to
an accident.

HOW TO AVOID THE

HAZARD

Never modify the Sportsman 6x6 through improper installation
or use of accessories. All parts and accessories added to the
vehicle must be genuine Polaris Industries Inc. or equivalent
components designed for use on this vehicle and should be
installed and used according to approved instructions. See
your authorized Polaris dealer for more information.

WARNING

WARNING

32

SAFETY

Operator Safety

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.

POTENTIAL

HAZARD

Operating the vehicle after consuming alcohol or drugs.

WHAT CAN

HAPPEN

Consumption of alcohol and/or drugs could seriously affect operator
judgment. Reaction time may be slower and operator balance and
perception could be affected.

Consuming alcohol and/or drugs before or while operating the
vehicle could result in an accident and cause severe injury or death.

HOW TO AVOID THE

HAZARD

Never consume alcohol or drugs before or while operating the
vehicle.

WARNING

WARNING

33

SAFETY

Operator Safety

Operating a damaged ATV can result in an accident with serious
injury or death. After any overturn or accident, have a qualified
service dealer inspect the entire machine for possible damage,
including (but not limited to) brakes, throttle and steering
systems.

CAUTION

Exposure to hot components could result in a fire. Always
keep combustible materials away from the exhaust system.

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

34

-NOTES-

35

FEATURES AND CONTROLS

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. Front Rack

1

2

3

4

4

5

6

7

8

9

36

FEATURES AND CONTROLS
Electrical Switches and Indicators

1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on
unless the main switch is on.

2. Override Switch (Reverse Speed Limiter) - This vehicle is
equipped with a reverse speed limiter system. To obtain additional
power while backing, depress the override button. The override switch
also allows activation of All Wheel Drive (AWD) in reverse if the
AWD switch is on.

3. Engine Stop Switch - The engine will not
start or run when the switch is off. Its purpose is
to provide the operator with a quick means of
engine shutdown in case of stuck throttle or other
emergency. NOTE: Both the main switch and
the emergency engine stop switch shut off all
electrical power to the entire vehicle, including lights. To stop the
engine, slide the stop switch either right or left to the OFF position.

1

2

4

3

5

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.

WARNING

3

37

FEATURES AND CONTROLS

Electrical Switches and Indicators

4. Main Switch - To start the engine, slide the stop switch to the
center RUN position and turn the main key switch clockwise past the
ON position. Release the key when the engine starts.

The taillight is on whenever the main switch is on. Turn the key off to
prevent battery drain.

5. All Wheel Drive (AWD) Switch

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

38

FEATURES AND CONTROLS
Throttle Lever

Engine speed and vehicle
movement are controlled by
pressing the throttle lever
(1). The throttle lever is
spring loaded, and engine
speed returns to idle when
the lever is released.

This vehicle is equipped with
Polaris Electronic Throttle
Control (ETC), which is
designed t o reduce the risk of a frozen or stuck t hrottle. If the throttle
should stick i n an open position, engine RPM will diminish and power
to the rear wheels will cease.

The Electronic Throttle Control (ETC) stops the engine in the
event of a throttle system malfunction and is provided for your
safety. Do not attempt to modify the ETC system or replace it
with any after market throttle mechanisms.

WARNING

Do not start or operate a vehicle with sticking or improperly
operating throttle controls. Doing so could cause an accident
and lead to severe injury or death.

Always contact your dealer for service repairs if throttle
problems arise.

Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks
during operation.

Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.

WARNING

1

39

FEATURES AND CONTROLS

Brakes

The braking system is controlled by the two brake levers located on the
handlebars, directly in front of each handgrip.

Service Brakes

The service brake lever (1) is located on the left handlebar. This lever
controls both front and rear wheel braking action. Use this lever for
normal braking.

Apply the service brakes by squeezing the left brake lever toward the
handlebar. These brakes are hydraulically activated disc brakes.

Always test brake lever travel and check the reservoir fluid level before
riding. The lever should feel firm when squeezed. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before operating. See your dealer for proper
diagnosis and repairs.

Auxiliary Brakes

The auxiliary brake lever (2) is l ocated on the right handlebar. It
controls braking action for the middle axle (rear brake) only. Use the
auxiliary brakes for additional braking or if the service brake system
fails.

1

2

Operating the vehicle with a spongy brake lever can result
in loss of brakes, which could cause an accident and lead to
serious injury or death. Never operate the vehicle with a
spongy-feeling brake lever.

WARNING

40

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 i s
full. When fluid is l ow, the eye will
be clear . NOTE: When checking the fluid level, position the ATV on
level ground with the handlebars turned so the top of the reservoir is
level. If the fluid level is low, add DOT 3 brake fluid. DO NOT
OVERFILL. See page 118 for the part numbers of Polaris products.

2

1

An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid
to drop, which can lead to early brake fade and the possibility of
accident or severe injury. After opening a bottle of brake fluid,
always discard any unused portion.

WARNING

41

FEATURES AND CONTROLS

Parking Brake

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. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the vehicle if leav-

ing it parked on a hill. Another option is to park the vehicle in a
sidehill position.

S Never depend on the parking brake alone for more than five minutes

if the vehicle is parked on a hill. Always block t he wheels to pre­vent rolling.

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.

WARNING

1

42

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.

Fuel Tank

The fuel tank filler cap (2) is located directly
below the handlebar. Use either leaded or
unleaded gasoline with a minimum pump
octane number of 87=(R+ M/2).

RES

ON

OFF

2

1

43

FEATURES AND CONTROLS

Gear Selector

The transmission gear selector (1)
is located on the right side of
the vehicle directly above and
forward of the engine recoil
starter.

To change gears, stop the
vehicle, and with the engine
idling, move the lever to the
desired gear. Do not attempt to
shift gears with engine speed
above idle or while the vehicle
is moving.

Always place the transmission
in gear with the parking brake locked whenever the vehicle is left
unattended.

Maintaining shift linkage adjustment is important to assure proper
transmission function. See your dealer if you experience any shifting
problems.

Belt Life

To extend belt life, use low forward gea r in heav y pulling situations and
when operating at less than seven miles per hour for extended per iods of
time.

L

N

R

H

1

Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear. Depress the auxiliary brake if
shifting into HIGH or PARK.

CAUTION

44

FEATURES AND CONTROLS
Recoil Starter

If the battery has been drained or
damaged and cannot start the
engine, use of the recoil starter (1)
will allow vehicle operation until
repairs can be made. The recoil
starter is located on the right side of
the machine.

Polaris 4-cycle engines are
equipped with automatic
decompressors. This makes recoil
starting possible by reducing the amount of compression during
starting. The decompressor senses when the engine is spinning fast
enough to start and restores compression when running.

1. Position the vehicle on a level surface and lock the parking brake
(see page 41).

2. Shift the transmission into neutral.

3. Make sure the engine stop switch is set to RUN and the main key
switch is in the ON position. NOTE: If the engine is cold, use the
choke as outlined on page 55.

4. Grasp the recoil starter rope handle (2) firmly and pull slowly so
you can feel the engine strokes. NOTE: Every other stroke will
be a “compression stroke” and will make the rope harder to pull.
When a compression stroke is found, continue pulling the rope just
until the engine rolls past the stroke, then stop pulling immediately.

5. Allow the recoil rope to rewind into the recoil assembly, t hen pull
the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

1

2

Extending the recoil starter rope until it stops can cause
damage to the recoil assembly. Do not extend the starter rope
so far that it stops.

If the starter rope handle is not seated properly, water may enter
the recoil housing and damage components. Make sure the
handle is fully seated on the recoil housing, especially when
traveling in wet areas.

CAUTION

45

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The Polaris Sportsman 6x6 is equipped with a unique AWD system
activated by the AWD switch (1) on the right handlebar. When the
switch i s off, the vehicle is in rear wheel drive at all times. When the
switch i s 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. NOTE: The override switch (2) allows activation of AWD
in reverse if the AWD switch is on.

There is no limit to the length of time the vehicle may remain in AWD.
The AWD switch may be turned on or off while the vehicle is moving.

If the switch is turned off when the front hubs are driving, they will not
release until the rear wheels regain traction.

2

1

Switching to AWD while the rear wheels are spinning may
cause severe drive shaft and hub damage. Always switch to
AWD while the rear wheels have traction or are at rest.

CAUTION

46

FEATURES AND CONTROLS
All Wheel Drive (AWD) System

Disengaging Wheel Hubs

The hubs normally disengage when operating in reverse. However, one
or both hubs may occasionally remain engaged. If the handlebars pull
to one side, one front hub is engaged. If both hubs are engaged,
steering effort increases but remains balanced from left to right, and
vehicle speed is somewhat restricted.

Disengage the hubs by stopping, shifting to reverse, and backing for a
short distance. Then proceed in forward again.

NOTE: If the hubs remain engaged after following this procedure,
return the vehicle to your dealer for service.

To continue using AWD while operating in reverse, activate both the
override switch and the AWD switch. See page 37.

Operating with only one front hub engaged could result in
loss of control, accident, and severe injury or death. When
hub engagement symptoms are present, use the disengaging
procedure before proceeding.

WARNING

47

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 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 36 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to depicting vehicle speed, this
needle will flash to signal a fault condition.

3. Speedometer

2

3

1

CAUTION

Washing the ATV with a high pressure washer may cause water to
enter the instrument cluster and cause damage to the electronic
components. Wash the A TV by hand or with a garden hose using
mild soap. Do not use alcohol to clean the instrument cluster.
Immediately clean off any gasoline that splashes on the instrument
cluster.

48

FEATURES AND CONTROLS
Instrument Cluster

Rider Information Center

The rider information center is located in the l ower portion of t he
instrument cluster.

1. Gear Indicator - As the
shift lever is moved, this
will indicate the gear the
machine is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

Eorblank=Error-The

error message usually means
the gear selector is in between
gears. It can, however, also
indicate that the transmission
switch needs repair .

2. High Engine Coolant Temperature - Do not continue to operate the
ATV is this warning appears or serious engine damage could result.

3. Hour Meter

4. Service Interval/Miscellaneous Service Warnings

5. Low Battery and Over Voltage - This warning usually indicates
that the ATV is being operated at an RPM too low to keep the
battery charged. A low battery warning may also occur under normal
operation if the machine is at idle and high electrical load (lights,
cooling fan, accessories) is applied. Driving at a higher RPM or
connecting a battery charger will usually clear the warning.

NOTE: If the instrument cluster no longer illuminates, it’s possible
that a battery over voltage occurred and the instrument cluster has shut
off to protect the electrical system. If this occurs take the ATV to your
Polaris dealer for proper diagnosis.

NOTE: All segments of the rider information center will light up for

2.5 seconds at start-up.

2

5

4

3

1

49

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes:
Mode 1 - Odometer
Mode 2 - Trip meter
Mode 3 - Total Service Hours
Mode 4 - Programmable service interval
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 t he miles traveled by the ATV.

Mode 2 -Trip Meter

The trip meter records the miles t raveled by the ATV on each trip if it’s
reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the total
changes t o 0 . NOTE: In the Rider Information Center, the trip meter
display contains a decimal point, but the odometer displays without a
decimal point.

Mode 3 - Hour Meter

This mode logs the total hours the engine has been in operation.

50

FEATURES AND CONTROLS
Instrument Cluster

Rider Information Center

Mode 4 - 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
turned off. You must enable the programmable service interval before
it can be used.

Once the service interval mode is set with the hours when service is
due, the hours of actual engine operation are subtracted from the set
hours until 0 is reached. When the counter reaches 0, the wrench icon
will flash quickly for 5 seconds each time the vehicle is started as a
reminder that the periodic m aintenance is due.

To set t he hours, press and hold the mode/override button until the
wrench icon flashes. When it begins to flash, release the button. The
setting will increase by one hour each time the button is pressed.
Pressing and holding the button will allow the numbers to escalate
much faster. When the desired time increment is displayed, release the
button and wait for the wrench to stop flashing. When the wrench
stops blinking, your service hours are set. NOTE: If you scroll past
the intended number, hold the button down until the count turns over to

0. You can then reset the number.

If the service interval is enabled on your ATV and you wish to turn it
off, toggle to the service interval mode. Press and hold the mode
button for approximately 7 seconds until the word OFF appears in the
Rider Information Center.

51

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return
your ATV to your dealer for all major repairs.

To enter the diagnostics m ode:

1. Turn the key switch off and wait 20 seconds.

2. Set the park brake and shift the transmission to neutral.

3. Hold the mode/reverse override button and turn the key switch on.
The initial screen displayed looks

similar t o the top illustration and
refers to the software version
installed in your ATV. This
information is displayed briefly.

Use the mode/reverse override
button to toggle through the
diagnostic screens. The first
screen (1) displays battery
voltage.

Screen two (2) is the tachometer
for setting idle speed. If this
needs adjustment, please contact
your dealer.

As long as the center 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.

1

2

52

OPERATION

Fuel Safety

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.
S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area.

Gasoline powered engine exhaust fumes are poisonous and
can cause loss of consciousness and death in a short time.

S Turn the fuel valve off whenever the vehicle is stored or

parked.

The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

WARNING

WARNING

53

OPERATION

Vehicle 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.

1. Fill the fuel tank with either unleaded or leaded fuel that has a
minimum pump octane number of 87= (R+ M)/2.

2. Check the oil reservoir
level indicated on the
dipstick. Add oil if
necessary to bring the
level within the normal
range (1)(see page 118).

3. Drive slowly at first. Select an open area that will allow room to
familiarize yourself with vehicle operation and handling.

4. Vary the t hrottle positions.

5. Perform regular checks on fluid levels, controls, and areas outlined
on the daily pre-ride inspection checklist. See page 54.

6. Pull only light loads during the break-in period.

7. Break in the oil and t he filter. Change both at 20 hours or 200
miles.

CAUTION

Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.

Use of any oils other than those recommended by Polaris may
cause serious engine damage. We recommend the use of
Polaris oil for your vehicle

(see page 118).

Lack of proper lubrication will cause serious engine damage.
Always check the oil level when refueling the vehicle.

ADD 8 OZ. NORMAL FULL

1

54

OPERATION

Pre-Ride Inspection

Use the following checklist to verify that your vehicle is in proper
working condition before each use.

Item/Inspection Procedure

1. Tires - check condition and pressures.

2. Fuel and oil tanks - fill both t anks to their proper levels.

3. All brakes - check operation, adjustment and fluid level (includes
auxiliary brake).

4. Throttle - check for free operation and closing.

5. Headlight/Taillight/Brakelight - check operation of all indicator
lights and switches.

6. Engine stop switch - check for proper function.

7. Wheels - check for tightness of wheel nuts and axle nuts; check
that axle nuts are secured by cotter pins.

8. Drive chain - check condition and slack; refer to drive chain
adjustment procedure.

9. Air cleaner element - check for dirt; clean or replace.

10. Steering - check for free operation, noting any unusual looseness in
any area.

11. Loose parts - visually inspect vehicle for any damaged components
or loose nuts, bolts or fasteners.

12. Ri ding gear - wear a helmet, goggles and protective clothing.

13. Engine coolant - check for proper level at the recovery bottle.

14. Dump box latch - check condition and operation of the mechanism.

If a proper inspection is not performed before each use of the
vehicle, severe injury or death could result. Inspect the vehicle
before each use to ensure it’s in proper working condition.

WARNING

55

OPERATION

Starting a Cold Engine

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. NOTE: If
the knob doesn’t stay where
positioned, increase the tension by
rotating the tension adjusting nut (2)
clockwise.

NOTE: The variable choke is fully on when the
knob is pulled completely out. The choke is off
when the knob is pushed completely in. The
choke can be adjusted gradually, depending on
how much choke is needed for starting. Be sure
the choke is off during operation, as excess fuel
washing into the engine oil will increase wear on engine components.

3. Turn the engine stop switch to RUN. NOTE: Do not press the
throttle while starting the engine.

4. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
switch when the vehicle starts. If the engine does not start, release
the starter and wait five seconds. Then activate the starter for
another five seconds. Repeat this procedure until the engine starts.

5. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up.

6. Vary the engine RPM slightly with the throttle to aid in warm-up.
When the engine idles smoothly, push the choke completely in.

Carbon monoxide exhaust gas is poisonous and can cause
severe injury or death. Never run an engine in an enclosed area.

WARNING

Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several
minutes before operating the vehicle.

CAUTION

1

2

56

OPERATION

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Excessive
use of the choke can cause the spark plug to become wet fouled.

1. 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.

4. If the engine is over-choked when warm, depress the throttle lever
fully while cranking to aid in starting.

5. Release the throttle lever immediately after the engine starts. If the
engine does not start and all conditions are favorable, change the
sparkplugandtryagain.

57

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.

Maximum Cargo Capacities (Level Ground)

Total Cargo 875 lbs. (397 kg)

Front Rack Cargo 75 lbs. (34 kg)

Cargo Box 800 lbs. (363 kg)

Maximum Towing Capacities

Towed Load (level ground) 1500 lbs. (681 kg)

Towed Load (up to 15° incline)

850 lbs. (386 kg)

Vertical Hitch Weight 150 lbs. (68.1 kg)

Towing Grade

15°

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.
S Cargo should be properly distributed and carried as low and

forward in the cargo box as possible.

S Reduce speed and allow a greater distance for braking.
S Use extreme caution when applying brakes with a loaded

vehicle. Avoid terrain or situations that may require backing
downhill.

S Always attach the tow load to the hitch point.
S Do not tow any trailer on a grade steeper than 15

°.

S V ehicle should never exceed 10 mph (16 kph) while towing a

load on a level surface. Vehicle speed should never exceed 5
mph (8 kph) when towing loads in rough terrain, while corner­ing, or while ascending or descending a hill.

WARNING

58

OPERATION

Hauling Cargo

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.

If the weight distribution in the box is located toward the rear of
the box when the release lever is pulled forward, the box may
dump on its own, which could cause serious injury. Never
operate the dump lever without checking the position of the
load. This will prevent unexpected dumping of the cargo box.
Never carry passengers in the cargo box.

WARNING

59

OPERATION

Driving Safely

Load Distribution

1. Never exceed the maximum capacities for hauling cargo as stated
on the load distribution warning labels and on page 57.

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. Unintentional box tilting will result if weight is
placed in the rear of the box and the latch is not secured.

1

WARNING

Operating with the cargo box in the raised position can cause
serious injury and damage to the vehicle. The cargo box could
close unexpectedly and injure the driver. The rear tires will also
catch the rear of the box, damaging the vehicle and creating
hazardous driving conditions.

Never operate this vehicle with the cargo box in the raised
position.

60

OPERATION

Driving Safely

Driving Procedures

1. Sit upright with both feet on the footrests and both hands on the
handlebars.

2. After starting the engine and allowing it to warm up, shift the
transmission into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin
driving. Vehicle speed is controlled by the amount of throttle
opening. PVT shifting is automatic.

6. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.

61

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. This technique alters the balance of traction between the rear
wheels, allowing the turn to be made smoothly. The same learning
technique should be used for turning in reverse.

WARNING

Turning at sharp angles in reverse can result in tipover and
serious injury. Avoid turning at sharp angles while operating
in reverse.

62

OPERATION

Driving Safely

Sidehilling

Sidehilling can be a dangerous type of driving and should be avoided if
at all possible. If you do enter into a situation where sidehilling is
necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle direction.

NOTE: If the vehicle begins to tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side immediately!

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.

WARNING

63

OPERATION

Driving Safely

Driving Do w nhill

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 toaidinslowing.

Hard use of the braking system while descending a hill could
result in a front-end overturn, causing serious injury or death.
Always operate the brakes slightly when descending a hill.

Excessive speed can cause loss of control and lead to serious
injury or death. Always operate slowly when traveling downhill.

WARNING

64

OPERATION

Driving Safely

Driving Up hill

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.

15° Maximum

WARNING

Braking and handling are greatly affected when operating in hilly
terrain. Improper procedure could cause loss of control or
overturn and result in serious injury or death.

Avoid climbing steep hills (15_ maximum).

Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.

65

OPERATION

Driving Safely

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill!
One maneuver that can be used when it’s necessary to turn around
while climbing a hill is the K-turn:

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 left (always uphill) side of the vehicle.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the service brake, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it’s
pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill
side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed
with the service brake, until the vehicle is on more level ground.

WARNING

Improper hill climbing procedures could cause loss of control or
overturn and result in serious injury or death.

Avoid climbing steep hills (15_ maximum).

Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.

8’

Uphill

66

OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever operating on slippery surfaces, such as wet trails or loose
gravel, or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids. NOTE: Correct a skid
by turning t he handlebars in t he direction of the skid and shifting
your body weight forward. Never brake during a skid.

3. Drive with AWD engaged to assist in controlling the vehicle in
slippery areas.

Severe damage to the drive train may occur if the A WD is
engaged while the wheels are spinning. Activate the A WD
switch only when the rear wheels have traction.

CAUTION

WARNING

Failure to exercise care when operating on slippery surfaces can
result in loss of tire traction and cause loss of control, accident,
and serious injury or death.

Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution when operating
on slippery surfaces.

67

OPERATION

Driving Safely

Driving Through Water

Your Sportsman 6X6 can operate through water with a maximum
recommended depth equal to the footrests (1). Follow these procedures
when operating through water :

1. Determine water depths and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal.

NOTE: 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.

IMPORTANT: After running the vehicle in water, it’s critical to have
it serviced as outlined in the maintenance schedule beginning on page

74. The following areas need special attention: engine oil,

transmission oil, front and rear gearcases, and all grease fittings.

1

Major engine damage can result if the vehicle is not thoroughly
inspected after becoming immersed. If your vehicle becomes
immersed or is operated in water that exceeds the footrest
level, take it to your dealer for service before starting the
engine.

CAUTION

68

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

6. Never activate the override button while the throttle is open. Loss
of control may result.

NOTE: This vehicle is equipped with a reverse speed limiter. The
override button should be used with caution as rearward vehicle speed
is greatly increased. Do not operate at wide open throttle. Open the
throttle just enough to maintain a desired speed.

Opening the throttle more than required may cause fuel to build in
the exhaust, resulting in engine popping and/or engine damage.

CAUTION

69

OPERATION

Driving Safely

Driving in Reverse

ParkingOnAnIncline

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.

WARNING

Failure to use caution when operating in reverse can result in
serious injury or death. Before shifting into reverse gear,
always check for obstacles or people behind the vehicle. When
it’s safe to proceed, back slowly.

Do not use the override switch unless additional power is
required for vehicle movement.

Avoid backing on inclines.

Avoid turning at sharp angles in reverse.

70

OPERATION

Driving Safely

Driving Over Obstacles

Keep alert! Look ahead and learn to read the terrain you’re traveling
on. Be constantly alert for hazards such as logs, rocks and low hanging
branches.

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.

WARNING

71

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was tested and approved
in accordance with the USDA Forest Service Standard 5100-1C.
Federal law requires t hat this spark arrestor be installed and functional
when the vehicle is operated on public lands.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by
gases are forced back to the combustion chamber by the intake system.
The system does not allow the blow-by gases to enter the atmosphere.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set carburetion and ignition. The engine and
related components must be maintained at Polaris specifications to
achieve optimal performance.

Adjustment to engine idle is
the only adjustment Polaris
recommends that the
operator perform. Any other
adjustments should be
performed by an authorized
Polaris dealer.

The emissions label (1) is
located on the recoil cover.

1

72

-NOTES-

73

MAINTENANCE AND LUBRICATION

Tool Kit

To help you perform routine maintenance, a tool kit is provided in the
storage compartment under the seat. Items included in the kit are:

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.

The addition of certain accessories, including (but not limited to)
mowers, blades, tires, sprayers, or large racks may change the handling
characteristics of the vehicle. Be sure any accessories added to the
vehicle have been approved by Polaris. Familiarize yourself with their
function and effect on the vehicle.

74

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

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
schedule on the following pages. See page 118 for a list of
Polaris-recommended products.

Maintenance intervals are based upon average riding conditions and an
average vehicle speed of approximately 10 miles per hour. Vehicles
subjected to severe use, such as operation in wet or dusty areas, should
be inspected and serviced more frequently. If you are not familiar with
safe service and adjustment procedures, have a qualified dealer perform
these operations.

Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a qualified dealer
perform these operations.

Maintenance Chart Key

" Perform these operations more often under severe use, such as in
dirty or wet conditions, to purge water or dirt contamination from
grease fittings and other critical components.

J Dealer service item.

L Emission Control System Service (California)

75

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at
20 hours, the equivalent odometer reading would be 200 miles.
Perform all services at whichever reading is reached first.

NOTE: When inspection reveals the need for replacement parts, use
genuine Polaris parts available from your Polaris dealer.

Item Hours/

Miles

Frequency Remarks

Headlamp Pre-ride Pre-ride Check operation daily;

apply Polaris dielectric
grease to connector
when replaced

Taillamp Pre-ride Pre-ride Check operation daily;

apply Polaris dielectric
grease to socket when
replaced

Tires / Air pressure Pre-ride Pre-ride Inspect daily and before

each use

Brake system Pre-ride Pre-ride Inspect

Wheels Pre-ride Pre-ride Inspect

Frame nuts, bolts,
fasteners

Pre-ride Pre-ride Inspect; tighten when

needed

Fuel and oil tanks Pre-ride Pre-ride Fill to proper level

" Air box sediment

tube

Daily Daily Inspect; drain deposits

whenever visible

" Air filter

(pre-cleaner)

Daily Daily Inspect and clean

Coolant level Daily Daily Replace engine coolant

every two years

" Air Filter

(main element)

Weekly Weekly Inspect; replace if neces-

sary

Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

WARNING

76

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

J Brake pads 10 hrs./

100 mi.

Monthly Inspect for wear periodically

"

L

Breather filter 20 hrs. Monthly Inspect; replace annually

and as needed

Battery 20 hrs. Monthly Inspect and clean terminals;

check fluid level

" Transmission

oil level

25 hrs. Monthly Inspect monthly; change

annually

" General lubrica-

tion

50 hrs. 3 months Lubricate all fittings, pivots,

cables, etc.

J Throttlecable/

ETC switch

50 hrs. 6 months Inspect before each use; ad-

just, lubricate, replace if nec­essary

Choke (enrich­er) cable

50 hrs. 6 months Inspect; adjust, lubricate, re-

place if necessary

Carburetor float
bowl

50 hrs. 6 months Drain bowl periodically and

prior to storage

" Rear suspen-

sion

50 hrs. 6 months Inspect; tighten fasteners

" Drive chains 50 hrs. 6 months Inspect daily; adjust and lu-

bricate if needed

J Drive belt 50 hrs. 6 months Inspect; adjust; replace if

necessary

Shift linkage 50 hrs. 6 months Inspect; lubricate, adjust

J Steering 50 hrs. 6 months Inspect before each use; lu-

bricate

" Rear axle /

Center axle

50 hrs. 6 months Inspect bearings; lubricate

" Front suspen-

sion

50 hrs. 6 months Inspect; lubricate; tighten

fasteners

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

77

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

" Engine oil 100 hrs./

1000 mi.

6 months Check level daily; break-in

service at one month;
change oil more often in cold
weather use

Oil filter 100 hrs./

1000 mi.

6 months Replace with oil change

Coolant 100 hrs. 6 months Inspect strength seasonally;

pressure test annually

Breather hose 100 hrs. 6 months Inspect

J Valve clearance 100 hrs. 12 months Inspect; adjust

J Fuel system 100 hrs. 12 months Check for leaks at tank cap,

lines, fuel valve, filter, pump
and carburetor; replace lines
every two years.

J Fuel filter 100 hrs. 12 months Replace annually

Radiator 100 hrs. 12 months Inspect; clean surface

Cooling system 100 hrs. 12 months Inspect hoses

Engine mounts 100 hrs. 12 months Inspect

Spark plug 100 hrs. 12 months Inspect; replace if necessary

" Front hubs 100 hrs. 12 months Change fluid annually

J Clutches (drive

and driven)

100 hrs. 12 months Inspect; clean

J Shift selector

box

200 hrs. 24 months Change oil every two years

J Brake fluid 200 hrs. 24 months Change fluid every two years

Spark arrestor 300 hrs. 36 months Clean out

Headlight aim As required As required Adjust if necessary

J Toe adjustment As required As required Periodic inspection; adjust

when parts are replaced

Recoil housing As required As required Drain moisture after operat-

inginwater

Idle speed As required As required Adjust

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

78

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

NOTE: Hours are based on 10 mph average.

Maintenance Chart Key

" More often under severe use, such as wet or dusty conditions

L Use Polaris Premium All Season Grease or grease conforming to

NLGI No. 2

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Rec. Method Frequency*

Brake Fluid DOT 3 only Maintain proper level.

See page 40.

As required;
change ev­ery two
years or 200
hrs.

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 Oil Premium 4

Synthetic 0W--40

Maintain oil level at the center
of the shift rail. Do not over­fill.

Change ev­ery 2 years
or 200 hrs.

Transmission
Oil

Polaris Premium
Synthetic Gearcase
Lube

Fill to bottom of the filler hole. Change

annually or
at 100 hrs.

Front Prop Shaft
Yoke (Loc. 1)

FGrease Locate Fittings and Grease Every 3 mos.

or 50 hrs.

AWD Hubs
(Loc. 2)

Premium Hub Lube Remove set screw in hubs.

Rotate wheels to 4:00 posi­tion (A). If lubricant is not vis­ible add more. Reinstall set
screw.

Annually or
at 100 hrs.

Ball Joint (Loc. 3) LGrease Locate zerk on back side of

struts and grease with grease
gun.

Every 3 mos.
or at 50 hrs.

Rear Axle Bearing
(Loc. 4)

LGrease

Locate fitting on eccentric
and grease with grease gun.

Every 3 mos.
or 50 hrs.

Swing Arm Bush­ings (Loc. 5)

LGrease

Locate fitting on swing arm
and grease with grease gun.

Monthly or at
20 hrs.

Middle Axle Bear­ings (Loc. 6)

"Grease Locate fitting on eccentric

and grease with grease gun.

Every 3 mos.
or 50 hrs.

Center Swing Arm
Housing (Loc. 7)

"Grease Locate fitting on swing arm

housing and grease with
grease gun.

Every 3 mos.
or 50 hrs.

Rear Strut
(Loc. 8)

"Grease Locate fitting on rear strut and

grease with grease gun.

Every 3 mos.
or 50 hrs.

79

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Inner Tie Rod End

A

(Loc. 1)

(Loc. 2)

(Loc. 3)

(Loc. 4)

(Loc. 5)

(Loc. 6)

(Loc. 7)

(Loc. 8)

80

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Lubrication

The transmission lubricant level should
be checked every six months or
1000 miles (1600 km),
whichever comes first. Maintain
the oil level at the bottom of the
fill hole t hreads. Change
transmission oil annually. We
recommend the use of AGL
Synthetic Gearcase Lubricant.
See page 118 for the part numbers
of Polaris products.

1. Position the ATV on a level surface
and remove the propshaft shield
from the right side of the vehicle.

2. Remove the fill plug (1) and add
the recommended lubricant as
needed to maintain the oil level at
the bottom of the fill hole (2).
The proper level is 1 5/8” from
the top of the fill hole. NOTE: Do not
fill to the bottom of the fill hole threads.

3. Reinstall the fill plug and propshaft shield.

Transmission Oil Change

1. Position the ATV on a level surface and remove the propshaft
shield from the right side of the vehicle.

2. Remove the transmission drain plug l ocated on the bottom
left-hand side and drain the oil into an appropriate container.
Discard used oil properly.

3. Clean and reinstall the drain plug with a new sealing washer.
Torque to 14 ft. lbs. (19 Nm).

4. Remove the fill plug and add the recommended lubricant. Refer to
the specifications section beginning on page 116 for capacities.

5. Reinstall the fill plug and check for leaks.

6. Reinstall the propshaft shield.

1

Front
View

15/8″

2

81

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Lubrication

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. We recommend the use
of Angle Drive Fluid (see page

118).

1. With the vehicle on a level
surface, remove fill plug (1).

2. View the oil level and add the
recommended oil as needed.
Oil should be kept at the
bottom of the fill plug thread.

3. Replace the fill plug.

Gearcase Oil Change

1. Remove the fill plug.

2. Remove gearcase drain plug located on the bottom right-hand side
and drain the oil.

3. Clean and reinstall the drain plug and tighten securely (14 ft.
lbs./1.93 kg m).

4. Add Angle Drive Fluid to the bottom thread of the fill hole.

5. Reinstall the fill plug.

6. Check for leaks.

1

82

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.

Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
breakdown in ambient temperatures from -40° F. to 120° F. Its
exceptional frictional properties result in more efficient operation, more
power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in
this engine, use of any API certified SH oil is allowable as long as it’s
0-40W. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.

Oil System

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. NOTE: The
dipstick must be screwed all the way in to keep the angle and depth
consistent.

5. Add oil (see page 118) as
needed to bring the level
to the normal range (1).
Do not overfill.

NOTE: If oil level rises above the full mark, water and/or fuel may be
collecting in the tank and t he oil should be changed.

CAUTION

Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 All Season synthetic oil or API certified SH oil, 0-40W.
Never mix brands.

ADD 8 OZ. NORMAL FULL

1

83

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

The recommended oil change interval is 100 hours, 1000 miles, or
every six months, whichever comes first. Suggested break-in oil
change is at 20 hours, 200 miles, or one month, whichever comes first.
Severe use requires more frequent service. Severe use includes
continuous duty in dusty or wet conditions and cold weather operation.
Severe use cold weather operation is all operation below 10° F. and
operation between 10° F. and 30° F. when most trips are at a slow
speed. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level
surface. Clean the area around the
drain plug at the bottom of the oil
tank and the bottom of the engine.

2. Run the engine for two to three
minutes, then turn it off.

3. Place a drain pan beneath the
oil tank and remove the drain
plug (1). Allow the oil to
drain completely.

4. Install a new sealing
washer (2) on the oil drain
plug. NOTE: The sealing
surfaces on the drain plug and
the oil tank should be clean and free
of burrs, nicks or scratches.

5. Reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm).

6. Disconnect the lower oil delivery hose and remove the screen
fitting (3) from the oil tank. Clean and reinstall the fitting,
torquing to 25 ft. lbs. (34 Nm). Reattach the oil line.
NOTE: The fitting threads must be sealed with Loctitet PST
505 or PTFE seal tape. The fitting must also line up with the
mark (4) on the rear side of the oil tank.

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.

1

2

3

4

84

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

7. Place shop towels beneath
the oil filter. Using an oil
filter wrench, turn the filter
(1) counterclockwise and
remove.

8. Lubricate the gasket on the
new filter with a film of
new engine oil. Check to
make sure the gasket is in
good condition. Also make
sure the gasket from the old
filter is not still on the engine.

9. Install the new filter and tighten by hand 1/2 to 3/4 turn after
gasket contacts the engine.

10. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the
crankcase. NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or scratches.

11. After draining, reinstall the drain plug.

12. Remove the dipstick (2) and add two quarts (1.9 l) of Polaris
Premium 4 synthetic oil (see page 118). R einstall the dipstick.
NOTE: If the sump is not drained, add about 1 3/4 quarts initially.

13. P lace the gear selector in neutral and set the parking brake.

14. IMPORTANT: Prime the oil pump using the procedure on page
96, then stop the engine and inspect for leaks.

15. Recheck the oil level on the dipstick and add oil as necessary to
bring the level to the upper (full) mark on the dipstick.

16. Dispose of used filter and oil properly.

2

1

CAUTION

Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 All Season synthetic oil or API certified SH oil, 0-40W.
Never substitute or mix oil brands.

85

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

10 hrs.

20 hrs.

50 hrs.

100 hrs.

86

MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level

NOTE: If the cooling system has been drained for maintenance or
repair, replace the coolant. If the recovery bottle has run dry, the level
in the radiator should be inspected. Add coolant as needed (see page

118).

1. Access the radiator pressure cap
by removing the four screws
securing front rack (1). Remove
the front cover (2) by placing
your fingers under the front of
the cover and pulling upward.

2. Remove the pressure cap.

3. Using a funnel, slowly add
coolant as necessary through the
radiator filler neck.

4. Replace the pressure cap and
secure the front cover and rack.

NOTE: Use of a non-standard pressure cap will not allow the
recovery system to function properly. Contact your dealer for the
correct replacement part.

NOTE: T o 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 (see page

118). Polaris Premium 60/40 is already premixed and ready to use. Do

not dilute with water. NOTE: Always follow the manufacturer’s
mixing recommendations for the freeze protection required in your
area.

WARNING

Escaping steam can cause severe burns. Never remove the
pressure cap while the engine is warm or hot. Always allow the
engine to cool before removing the pressure cap.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Recovery Bottle Coolant Level

The recovery bottle (1) is located on
the left side of the vehicle. T o access
the recovery bottle, remove the left
side panel as outlined on page 97.

The coolant level must be maintained
between the minimum and maximum
marks on the recovery bottle. Add
coolant as needed.

NOTE: 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 (see page 118). Polaris Premium 60/40 is already premixed and
ready to use. Do not dilute with water. Always follow the
manufacturer’s mixing recommendations for the freeze protection
required in your area.

Cooling System Operation

The engine coolant level is controlled, or maintained, by the recovery
system. The recovery system components are the recovery bottle, the
radiator filler neck, the radiator pressure cap and the connecting hose.

As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and
into the recovery bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the bottle, past the
pressure cap, and into the radiator.

NOTE: Some coolant level drop on new vehicles is normal as the
system is purging itself of trapped air. Observe coolant levels and
maintain as recommended by adding coolant to the recovery bottle.

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88

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

Polaris recommends that the air filter be replaced annually. When
riding in extremely dusty conditions, replace it more often.

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 t ype pre-filter (1) from the main filter (2). Wash
the pre-filter in soapy water, rinse and allow to dry thoroughly.

5. Reinstall the pre-filter over the main filter. (Replace the main filter
if necessary.)

6. Reinstall the filter into the air box and tighten the clamp. Do not
over-tighten the clamp or filter damage may occur.

CAUTION

Operating the vehicle without a pre-filter can cause engine
damage. Always reinstall the pre-filter before operating.

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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

Inspect the filter monthly or after every 20 hours of operation,
whichever comes first. Replace the filter annually, more often if
needed. Inspect the breather filter hoses every six months and replace
as needed.

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.
Blow gently through the filter in
the direction of the arrow to
check for clogging. Replace if
necessary.

3. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.

4. Reinstall the filter and clamps with the arrow pointing toward the
air box.

NOTE: The breather filter is intended to be used with the air box
pre-filter in place. Without the pre-filter, the breather filter can clog
quickly.

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CAUTION

Operating the vehicle without both the pre-filter and breather filter
can cause engine damage. Always reinstall both filters when
they’ve been removed for service.

90

MAINTENANCE AND LUBRICATION

Adjustments

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. NOTE:
The steering frog can be used as
an indicator of whether the
handlebars are straight. The frog
should always point straight back
from the steering post.

2. Place stands (1) in front of the
vehicle, perpendicular to the rear
tires. See illustration.

3. Tie an elastic string around the
stands, making sure the string just
touches the side surface of the rear
tires on each side of the vehicle
and goes around the stands in
front of the vehicle (2).

4. Measure the distance from the
string to the rim at the front and
rear of the front rim (3). The rear
measurement should be 1/16″ -
1/8″ (.2 to .3 cm) more than the
front measurement.

NOTE: If you discover improper
alignment, see your Polaris dealer for
service.

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.

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MAINTENANCE AND LUBRICATION

Adjustments

Steering Inspectio n

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.

1. Locate handlebar bolts (1) by
removing the upper headlight pod.

2. Loosen the four bolts.

3. Adjust the handlebar to the desired
height. Be sure the handlebars do not
contact the gas tank or any other part of
the machine when turned fully to the left or right.

4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque
the rear two bolts. A gap of up to 1/8” will remain at the rear bolts.

Optional Suspension Springs

Although the P olaris Sportsman 6x6 suspension has the capability of
providing the best ride possible, the following accessory springs are
available to better suit individual riding preferences. NOTE: Optional
springs may be a different color than standard springs. Springs may be
painted to a desired color using Polaris touch up paint, available
through Polaris dealers.

Front Strut Spring 7041375-067

OPTION
64/113 lb/in

7041450-067

STANDARD
101 lb/in

N/A

Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control and
possible serious personal injury or death. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.

WARNING

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SOFT FIRM

92

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 40).
Under normal functioning the
diaphragm extends into the
reservoir as fluid level drops. If
the fluid level is low and t he
diaphragm is not extended, a
leak is likely and the diaphragm
should be replaced. Always fill
the reservoir as needed
whenever the cover is loosened
or removed to ensure proper
diaphragm operation. Use
Polaris DOT 3 brake fluid (see
page 118).

2. Check the brake system for fluid
leaks.

3. Check the brakes for excessive
travel or spongy feel.

4. Check the friction pads for wear,
damage and looseness.

5. Check the security and surface
condition of the disc.

NOTE: Pads should be changed
when worn to 3/64″ (.1 cm), or about
the thickness of a dime.

3/64″
(.1cm)

MiddleAxleBrake

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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.

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.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the handlebar.

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster locknut (3).

2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the
thumb lever. Flip the throttle lever several times to confirm
adjustment.

3. Tighten the locknut and slide the boots over the cable adjuster until
they touch at the middle point of the adjuster.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical
component operations. Service must be performed by your authorized
Polaris dealer.

3/64″ (.1 cm)

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94

MAINTENANCE AND LUBRICATION

Adjustments

Front Drive Chain Adjustment

Check the amount of chain slack by
moving the vehicle slightly forward
to gain slack at the top side of the
front chain. Then pull up and down
on the chain. At this point the chain
should have 3/8″-1/2″ (.95-.1.3 cm)
deflection. If the chain needs
adjustment, use the following
procedure.

NOTE: See the proper splicelink
clip opening position (1).

1. Remove the chain guard
and loosen the chain guide.

2. Loosen the two eccentric
locking bolts (2).

3. Loosen the caliper mount
bolts.

4. Insert a pin punch (3) through the sprocket hub and into the
eccentric axle housing.

5. Roll the vehicle ahead or back to adjust chain slack to the proper
dimension.

6. Tighten the caliper mount bolts to 10-12 ft. lbs. (13.5-16.3 Nm).

7. Tighten the eccentric locking bolts to 60 ft. lbs. (80 Nm).

8. Confirm correct tension by rolling the vehicle forward, checking
chain tension in several places around the chain.

9. Reinstall the chain guard.

NOTE: Reposition the chain guide to allow 1/8″ (.3 cm) clearance
between the sprocket and guide.

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.

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95

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.

Carburetor/Engine Idle RPM Adjustment

Recommended engine idle RPM is 1200 +/- 200. If the engine idle
speed is unsatisfactory and all other conditions are favorable, the
carburetor can be adjusted as follows:

1. Start the engine and allow it to warm up for
approximately five minutes.

2. Place the transmission in gear with the
parking brake applied.

3. Adjust the carburetor idle screw (1) in or
out until the desired idle RPM is reached.
Turning the screw in (clockwise) will raise
RPM. Turning the screw out
(counterclockwise) will lower RP M .

3/8″-1/2″ (.95-.1.3 cm)

3/8″-1/2″ (.95-.1.3 cm)

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96

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. Although this power cannot be
regained, adjustments to the carburetor and drive system can be made
to allow more efficient operation. Optional jets, available from your
Polaris dealer, are required for operation above 6,000 feet and
temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting
when required can cause poor performance, overheating or PVT or
engine damage. See your Polaris dealer for more information about
jetting the ATV for conditions in your area.

NOTE: Pilot screws are sealed with metal plugs and are serviceable
only by Polaris dealers.

Oil Pump Priming

This priming procedure must be performed whenever the oil hose
connection between the oil tank and pump inlet has been disconnected.

1. Clamp or pinch off the vent

line (1) approximately 2I
from the oil tank (2), between
the end of the oil tank vent
fitting and the vent line’s
pressure relief slit (3).

2. Run the engine for 45-60
seconds.

3. Remove the vent line clamp.
The oil pump will now be
properly primed and ready for
operation.

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97

MAINTENANCE AND LUBRICATION

Adjustments

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side
panel near the rear cab. W ith
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
twotabs. Thenpulluponside
panel to disengage front upper
and lower tabs.

4. To reinstall the side panel,
align the panel tabs with the
slots on the front cab. Push
the panel upward and forward
until the tabs lock. Bend the
rear of the side panel and
insert the two tabs into the rear
cab.

Step 2

Step 3

Step 4