Polaris Light Utility Hauler 6x6 Owner's Manual

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

1

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 Professional Series (PPS) Workmobilest

Available through Polaris Professional Series dealers.

S Utility Task Vehiclet (UTV)
S Light Utility Hauler (LUH)
S All-Surface Loader (ASL)
S AT V P ro

Polaris Recreational Vehicles

Available through Polaris dealers.

S Snowmobiles
S All-terrain vehicles (ATVs)
S Personal watercraft
S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest 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 W a y Out, and Polaris Professional Series are
registered trademarks of Polaris Industries Inc.

Copyright 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

2

READ YOUR OWNER’S MANUAL

Age Restrictions

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

Know Your Vehicle

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

Safety Training

When you purchased your new LUH 6x6, your dealer offered a
hands-on safety training course that covers all aspects of vehicle safety .
You were also provided with printed materials that explain safe
operating procedures. You should review this information on a regular
basis.

If you purchased a used Polaris LUH 6x6 from a party other than a
Polaris dealer, you can request this free safety training from any
authorized Polaris dealer.

WARNING

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

A Polaris LUH 6x6 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 LUH 6x6.

3

TABLE OF CONTENTS

WELCOME 1........................................

READ YOUR OWNER’S MANUAL 2...................

TABLE OF CONTENTS 3.............................

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

SAFETY 5..........................................

FEATURES AND CONTROLS IDENTIFICATION 31......

CONTROLS 32......................................

FEATURES 42.......................................

OPERATION 44.....................................

NOISE EMISSION CONTROL SYSTEM 63.............

MAINTENANCE AND LUBRICATION 64................

SPECIFICATIONS 104................................

POLARIS RECOMMENDED PRODUCTS 106...........

WIRING DIAGRAM 107...............................

TROUBLESHOOTING 108............................

W A RRANTY 110.....................................

NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.

4

VEHICLE IDENTIFICATION NUMBERS

The 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. If your vehicle is stolen, these numbers are essential
to its recovery and identification.

NOTE: Record your vehicle’s ID numbers in the spaces provided.
Remove the spare key and store it in a safe place. Your key can be

duplicated only by mating a Polaris key blank with an existing key.
NOTE: If both keys are lost, see your dealer for ignition switch
replacement.

2

1

Frame VIN:

Engine Serial Number:

Vehicle Model Number:

Dealer Imprint:

5

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

6

SAFETY

Operator Safety

The LUH 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.

7

SAFETY

Operator Safety

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate the LUH 6x6 without proper instruction. Ta ke 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 terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain.
S Always follow recommended turning procedures as described in this

manual. Practice turning at low speeds before attempting to turn at
faster speeds. Do not turn at excessive speeds.

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.

8

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 trees.

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.

9

SAFETY

Operator Safety

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

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

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.

FOR MORE INFORMA TION 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 s afety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris LUH 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 LUH 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.

10

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. If any decal
becomes illegible or comes off, contact your Polaris dealer for a
replacement. Any safety decal needing replacement will be provided
by Polaris at no charge. The part number is printed on the decal.

1

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 (PSI): FRONT 5 CENTER 5 REAR 5

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight

INCLUDING MACHINE, DRIVER AND CARGO IS 1970 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 bed.

Read Owner’s Manual for more detailed loading information.

WARNING

WARNING

2

1

11

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. T o 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

12

SAFETY

Safety Decals and Locations

ETC

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

4

5

Operating this vehicle if you are under the
age of 16 increases your c hanc e of severe
injury or death.

NEVER operate this vehicle if you are under
age 16.

7078254

Remove flammable containers from bed before refueling.

Maximum Bed Load 800 lbs.

DPassengers can be thrown off.

This can c ause 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

AWD Models

WARNING

Pushing reverse
override button
may caus e
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

4

5

6

7

8

This vehicle is equipped w ith a
back- up alarm.

ALARM MUST SOUND! when
operating this vehicle in reverse.

Failure to maintain a clear view
in the direction of travel could
result in serious injury or death.

The Operator is responsible for
the safe operation of this vehicle.

7170572

WARNING

9

9

13

SAFETY

Safety Decals and Locations

Moving parts hazard under belt -c lut c h guard. To
prevent serious injury, do not operate vehicle with
guard removed.

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

NO STEP

7078689

WARNING

(On Hitch)

TRAILER MAX WEIGHT:
1225 LBS. (557 KG) ON LEVEL GROUND
850 LBS. (368 KG) UP TO 15 GRADE

HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16 KG)

7078261

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

14

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. LUH 6x6 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

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.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.

1

2

3

4

5

15

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 LUH 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 LUH 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 LUH 6x6.

WARNING

WARNING

16

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 an LUH 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 an LUH 6x6 on paved surfaces, including sidewalks,
paths, parking lots, and driveways.

WHAT CAN

HAPPEN

LUH 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 LUH 6x6 on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.

WARNING

WARNING

WARNING

17

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 LUH 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 an LUH 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

18

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 57. 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

19

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating the LUH 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 LUH 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

20

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

21

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

22

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

23

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 LUH 6x6 on hills steeper than
15_.

Practice on small hills before attempting larger hills.

WARNING

WARNING

24

SAFETY

Operator Safety

15° Maximum

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

25

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

26

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 LUH 6x6 around on any hill until you’ve
mastered the turning technique (on level ground) as described in
the owner’s manual. See page 57. 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

27

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 NO TAG-49.

WARNING

WARNING

28

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 58), 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

29

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 LUH 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

30

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. If it’s
unavoidable, confirm that the ice is thick enough and sound
enough to support the vehicle and its operator, as well as the
force created by a moving vehicle. Exercise extreme caution!

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

31

FEATURES AND CONTROLS IDENTIFICATION

1. Service BrakeLever

2. Middle Axle Auxiliary Brake

3. Throttle Lever

4. Bed Dump Latch Release

5. Gearbox Shift Lever

6. Floorboards

7. Backrest

8. Cargo Bed

9. Front Rack

1

2

3

4

4

5

6

7

8

9

32

CONTROLS

Electrical Switches and Indicators

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

1 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.

2 Engine Stop Switch

The engine will not start or run when the switch is in the “off”
position. Its purpose is to provide the operator with a quick means of
engine shutdown in case of stuck throttle or other emergency. NOTE:
Both the main switch and the emergency engine stop switch shut 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.

3 Horn Switch
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. NOTE: This switch m ust be turned
clockwise to the “on” position to start the engine.

5 Demand 6 (AWD) Switch

1

2

4

3

5

33

CONTROLS

Electrical Switches and Indicators

With the engine running, verify the function of all indicator lights
before every use of the vehicle.

1 Main Switch

The taillight is on whenever the main switch (key) is in the “on”
position. Turn the key off to prevent battery drain.

2 Light Switch/Hi-Lo Beam Control

The lights won’t turn on unless the main switch is on.

3 Headlight Hi Beam Indicator (blue)
4 Transmission Reverse Indicator (yellow)
5 Transmission Neutral Indicator (green)
6 All Wheel Drive Indicator (red)
7 Engine High Temp Warning Indicator (red)

The high temp indicator will light only if the engine overheats.

6

1

4

3

5

7

2

Operating the vehicle on streets or roads, especially in darkness,
could result in an accident and serious injury or death.

Your LUH 6x6 is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use caution
and drive at reduced speeds in conditions of reduced visibility such
as fog, rain and darkness.

WARNING

34

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

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

2

35

CONTROLS

Brakes

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

Service Brakes

The service brake lever (1) (front wheel and transmission) is located on
the left handlebar. This lever controls braking action to all six wheels.
Use this system for normal braking.

The service brakes are
applied by squeezing the left
brake lever toward the
handlebar. These brakes are
hydraulically activated disc
brakes and are activated by
only one lever.

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

Auxiliary Brakes

The auxiliary brake lever (2) is located on the right handlebar. This
lever controls the auxiliary brake for the rear axles. Use the auxiliary
brakes for additional braking or if the normal 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

36

CONTROLS

Brakes

Master Cylind ers

The master cylinders (1) are located
on the left and right handlebars.
Fluid levels should be checked
before each ride. The fluid level can
be seen through the indicator
window (2) on the top of the master
cylinder. This “eye” will appear
dark when the fluid level is full.
When fluid needs to be added, the
eye will be clear. NOTE: When
checking the fluid level, the vehicle
should be 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 (see
page 106).

2

1

After opening a bottle of brake fluid, always discard any
unused portion. Never store or use a partial bottle. 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.

WARNING

37

CONTROLS

Parking Brake

Setting the Parking Brake

1. Squeeze and release the brake
lever two or three times, then
squeeze and hold.

2. Rotate the park brake lock (1)
into the notches on the master
cylinder body. 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 t he 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 the 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

38

CONTROLS

Engine Fuel and Oil System

The fuel tank filler cap (1) i s located directly behind the handlebar.
Tank capacity is 4.25 U.S. gallons (16 liters) with 1/2 gallon (1.9 liters)
in reserve. Use either leaded or unleaded gasoline with a minimum
pump octane number of 87 (R+ M/2) octane.

The fuel tank supply valve (2) is located on the left side of the vehicle
and has three positions:

OFF: For vehicle storage and when
transporting.

ON: For normal operation.
RES: For reserve supply if m ain supply is

exhausted.
NOTE: There’s a 7 t o 10 mile (11.2 to 16

km) range on reserve gas. Always refill the
gas tank as soon as possible after
exhausting the main supply.

After refueling, switch t he fuel valve back to the “on” position for
normal operation.

1

2

ON

OFF

RES

39

CONTROLS

Engine Fuel and Oil System

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. Gaso-

line 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

40

CONTROLS

Gear Selector Operation

The transmission gear selector 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 t o 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, refrain from continuous operation of the vehicle at
the point of engagement (the point at which the vehicle begins to
move). Continuous operation in this m anner increases belt wear.

F

N

R

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.

CAUTION

41

CONTROLS

Recoil Starter

If the battery is weak and cannot start
the engine, use of the recoil starter
(1) will allow vehicle operation until
repairs can be made.

1. Position the vehicle on a level
surface and engage the parking
brake. See page 37.

2. Shift the transmission to neutral.

3. Grasp the recoil starter tightly
and pull slightly until the starter
mechanism engages.

4. Pull the rope abruptly to start the
engine.

1

Extending the starter rope too far will 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

42

FEATURES

All Wheel Drive (AWD) System

The Polaris LUH 6x6 is equipped with a unique Polaris exclusive
Demand 6 Drive (AWD) system that’s activated by a switch (1) on the
right handlebar. When the switch is off, the vehicle is in rear wheel
drive at all times. When the switch is on, the vehicle is in AWD and
the front wheels will automatically engage any time the rear wheels
lose traction. When the rear wheels regain traction, the front wheels
will automatically disengage. NOTE: The override switch (2) allows
activation of AWD in reverse if the AWD switch is on.

A red AWD light on the switch indicates when the vehicle is in AWD.
There is no limit to the length of time the vehicle may remain in AWD.

The AWD switch m ay 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.

CAUTION

43

FEATURES

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 Demand 6 Drive (AWD) switch. See page 32.

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

44

OPERATION

Vehicle Break-in Period

The break-in period for your new Polaris LUH 6x6 is defined as the
first ten hours of operation or the time it takes t o 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 106).

3. Drive slowly at first. S elect 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 45.

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

7. Break in the oil and the 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 106).

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

ADD 8 OZ. NORMAL FULL

1

45

OPERATION

Pre-Ride Inspection

Use the following checklist t o 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 tanks 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. Riding gear - wear a helmet, goggles and protective clothing.

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

14. Dump bed 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

46

OPERATION

Starting a Cold Engine

1. Place the transmission in neutral
and lock the parking brake.

2. Turn the fuel tank valve to “on”.

3. Sit on the vehicle.

4. Pull the choke knob (1) out until
it stops.

NOTE: The variable choke is fully
on when the knob is pulled out all the
way. 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.

5. Turn the engine stop switch to “run”.

NOTE: Do not press the throttle while starting the engine.

6. 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.

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

8. 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

47

OPERATION

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Using 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.

3. Turn the fuel tank valve to “on”.

4. Sit on the vehicle.

5. If the engine has cooled to a point where it does not readily start,
intermittent use of the choke button (pulled half way out) may be
necessary.

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

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

48

OPERATION

Hauling Cargo

Your LUH 6x6 has been designed to carry or tow a certain amount of
load. Always read and understand the load distribution warnings listed
on the warning labels. Never exceed the following weights.

Maximum Capacities

(Level Ground)

Front Rack

Cargo

Cargo Bed

LUH 6x6 - 890 lbs.

(404 kg)

75 lbs. (34 kg) 800 lbs. (363 kg)

Improper loading of the front rack can obstruct the headlight beam,
reducing night visibility. Do not obstruct the headlight beam with
cargo.

Maximum Towing Capacities (Level Ground)

Maximum towing load weight is 1500 lbs. (681 kg) on level ground
only and 850 lbs. (386 kg) on a grade up to 15°.

Maximum vertical hitch weight is 150 lbs. (68 kg).
Maximum grade while trailer towing is 15°. Do not tow any trailer on

a grade steeper than 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 for-

ward in the cargo bed 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 Vehicle should never exceed 10 mph (16 kph) while towing a load

on a level grass 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

49

OPERATION

Hauling Cargo

Dumping Cargo

1. Select a level site to dump the cargo bed. Do not attempt to dump
or unload the vehicle while parked on an incline.

2. Set the parking brake.

3. Dismount the vehicle.

4. Pull the cargo bed release lever forward.

5. Lift the front of the cargo bed and dump the cargo.

If the weight distribution on the bed is located toward the rear of
the bed when the release lever is pulled forward, the bed 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 bed.
Never carry passengers on the bed.

WARNING

50

OPERATION

Driving Safely

Load Distribution

1. Always load the cargo bed with the load as far forward as possible.

2. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.

3. Slow down.

4. The cargo bed dump latch must be securely latched before loading
and operating. Unintentional bed tilting will result if weight is
placed in the rear of the bed and the latch is not secured.

Maximum Front Rack
90 lbs. (41 kg)

Maximum Cargo Bed
LUH 6x6 800 lbs. (363 kg)

WARNING

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

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

51

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.

52

OPERATION

Driving Safely

Making Turns

Practice making turns at slow speeds.
The LUH 6x6 is equipped with a solid rear axle that drives all rear

wheels equally at all times. This means t hat 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.

53

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

54

OPERATION

Driving Safely

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

3. Drive with Demand 6 Drive (All Wheel Drive) engaged to assist in
controlling the vehicle in slippery areas.

Severe damage to the drive train may occur if the AWD is
engaged while the wheels are spinning. Activate the AWD 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.

55

OPERATION

Driving Safely

Traveling Downhill

Whenever descending a hill, follow these precautions:

1. Drive directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly 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

56

OPERATION

Driving Safely

Traveling Uphill

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.

57

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 t he 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 t he 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

58

OPERATION

Driving Safely

Crossing Streams

Your LUH 6X6 can operate through water with a maximum
recommended depth equal to the footrests. 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 m aintain 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 chart. See pages 65-67. The
following areas need special attention: engine oil, transmission oil,
front and rear gearcases, and all grease fittings.

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

59

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 m ay 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

60

OPERATION

Driving Safely

Driving in Reverse

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.

61

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

62

OPERATION

Driving Safely

ParkingOnAnIncline

Avoid parking on an incline i f possible. If it’s unavoidable, follow
these precautions:

1. Place the transmission in gear.

2. Set the parking brake.

3. Always block the rear wheels on the downhill side. See
illustration.

4. Shut off fuel supply.

63

NOISE EMISSION CONTROL SYSTEM

REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!
U.S. Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any person other than for

purposes of maintenance, repair, or replacement of any device or
element of design incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to t he ultimate purchaser or
while it is in use or

(2) the use of the vehicle after such device or element of design has
been removed or rendered i noperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE
TAMPERING ARE THE ACTS LISTED BELOW.”

1. Removal or alteration or the puncturing of the muffler or any
engine component which conducts removal of engine exhaust
gases.

2. Removal or alteration or the puncturing of any part of the engine
air induction system.

3. Replacement of any vehicle parts with parts not in compliance with
federal regulations.

4. Lack of proper maintenance.

USFS Approved Spark Arrestor

The muffler on this vehicle was tested and approved in accordance with
the USFS Forest S ervice Standard 5100-1A.

CAUTION

Exhaust system components are very hot during and after use of
the vehicle. Hot components can cause serious burns and can
causeafiretoignite.

Do not touch hot exhaust system components.

Use caution when traveling through tall grass, especially dry
grass.

64

MAINTENANCE AND LUBRICATION

Tool Kit

To help you perform routine maintenance, a t ool kit is provided in the
storage compartment under t he 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.

65

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 106 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.

66

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 or

Odometer

Frequency Remarks

Headlamp Pre-ride Pre-ride Check operation daily; apply Polaris diel ec-

tric grease to connector when replac ed

Taillamp Pre-ride Pre-ride Check operation daily; apply Polaris diel ec-

tric 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 oi l 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; replac e if necess ary

J Brake pads 10 hrs/100

miles

Monthly Inspect for wear periodic ally

" 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 Monthl y Ins pect monthly ; change annually

" General lubrication 50 hrs 3 months Lubricate all fittings, pi vots, c ables, etc.

J Throttle cable / ETC switch 50 hrs 6 months Inspect before each use; adjust, lubricate,

replace if necessary

Choke (enricher) cable 50 hrs 6 months Inspect; adjust, lubricate, replace if neces-

sary

Carburetor float bowl 50 hrs 6 months Drain bowl periodically and prior to storage

" More often under severe use, such as dirty or wet conditions
J Dealer service item

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

67

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours or

Odometer

Frequency Remarks

" Engine oil 100

hrs/1000
miles

6 months Check level daily; break-in service at one

month; change oil more often in cold weather
use

Oil filter 100

hrs/1000
miles

6 months Replace with oil change

Coolant 100 hrs 6 months Inspect strength seasonally; pressure test

system annually

Breather hose 100 hrs 6 months Inspect

" Rear suspension 50 hrs 6 months Inspect; tighten fasteners

" Drive chains 50 hrs 6 months Inspect daily; adjust and lubricate if needed

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

" Front hubs 50 hrs 6 months Check fluid monthly

Shift linkage 50 hrs 6 months Inspect; lubricate, adjust

J Steering 50 hrs 6 months Inspect before each use; lubricate

" Rear axle / Center axle 50 hrs 6 months Inspect bearings

" Front suspension 50 hrs 6 months Inspect; lubricate; tighten fasteners

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; replac e lines ev­ery two years.

J Fuel filter 100 hrs 12 months Replace annually

Radiator 100 hrs 12 months Inspect; clean external surface

Cooling system hoses 100 hrs 12 months Inspect

Engine mounts 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

Spark plug 100 hrs 12 months Inspect; replace if nec essary

" 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 lubricant every two years

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

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 operating in water

Idle speed As required As required Adjust

" More often under severe use, such as dirty or wet conditions
J Dealer service item

68

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 Grease conforming to NLGI No. 2, such as Conoco Superlube M

or Mobilegrease Special

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 36.

As required;
change every
two years or 200
hours

Drive Chains O-Ring chain lube

or SAE 80/90

Lubricate as often as re­quired (before each ride in
wet conditions).

As required

Gear Selector Oil
(1)

10 W
Non-detergent Oil

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

Change every 2
years or 200
hours.

Transmission Oil
(2)

Polaris Premium
Synthetic gearcase
lube

Fill to bottom of the filler
hole.

Change annually
or at 100 hours

Front Prop Shaft
U-joints (3)

FGrease Locate Fittings and

Grease

Every 3 months
or 50 hours

Front Drive Axle
(U-Joint)

FGrease Locate grease fitting and

grease with grease gun.

Every 3 months
or 50 hours

3

1

2

69

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Demand 6
Hubs (AWD) (1)

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 (2) LGrease Locate zerk on back side of struts

and grease with grease gun.

Every 3 months
or at 50 hrs

Front A-Arm
Pivot Shaft (3)

LGrease Locate zerk on pivot shaft and

grease with grease gun.

Every 3 months
or at 50 hrs

Steering Post
Bushings (4)

LGrease Locate fitting on steering post and

grease with grease gun.

Every 3 months
or at 50 hrs

" More often under severe use, such as wet or dusty conditions
L Grease conforming to NLGI No. 2, such as Conoco Superlube M or

Mobilegrease Special

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

storage, or after pressure washing or submerging.

4

Inner Tie Rod End

2

3

Upper

A

1

70

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Drive Axle
U Joints (1)

FGrease Locate grease fitting and grease

with grease gun.

Every 3 months
or 50 hrs

Rear Axle Bear­ing (2)

LGrease

Locate fitting on eccentric and
grease with grease gun.

Every 3 months
or 50 hrs

Swing Arm
Bushings (3)

LGrease

Locate fitting on swing arm and
grease with grease gun.

Monthly or at 20
hrs

Middle Axle
Bearings (4)

"Grease Locate fitting on eccentric and

grease with grease gun.

Every 3 months
or 50 hrs

Center Swing
Arm Housing (5)

"Grease Locate fitting on swing arm hous-

ing and grease with grease gun.

Every 3 months
or 50 hrs

Rear Strut (6) "Grease Locate fitting on rear strut and

grease with grease gun.

Every 3 months
or 50 hrs

" More often under severe use, such as wet or dusty conditions
L Grease conforming to NLGI No. 2, such as Conoco Superlube M or

Mobilegrease Special

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

storage, or after pressure washing or submerging.

2

4

3

6

5

1

71

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Lubrication

The transmission fill plug (1) is
located on the right side of the
vehicle behind the propshaft
shield.

The transmission lubricant level
should be checked every six
months or 1000 miles (1600 km),
whichever comes first.
Transmission oil should be
changed annually.

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

2. View the oil level and add oil
if needed. Oil should be kept
at the bottom of the fill plug thread. NOTE: Use Polaris
Premium Synthetic Gearcase Lubricant in the transmission (see
page 106).

3. Replace the fill plug.

Transmission Oil Change

1. Remove the propshaft shield from the right side of the vehicle.

2. Remove the fill plug.

3. Remove the transmission drain plug (2) located on the bottom
left-hand side and drain the oil. Catch and discard the used oil
properly.

4. Clean and reinstall the drain plug.

5. Add P olaris P remium Synthetic Gearcase Lubricant (see page 106)
until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall the propshaft shield.

1

2

72

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. F ront
gearcase oil should be changed
annually.

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

2. View the oil level and add oil
if needed. Oil should be kept
at the bottom of the fill plug
thread. NOTE: Use GL5
80-90 Weight Gear Lube (see
page 106).

3. Replace the fill plug.

Gearcase Oil Changing Procedure

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 GL 80-90 Weight Gear Lube to the bottom thread of the fill
hole.

5. Reinstall the fill plug.

6. Check for leaks.

1

73

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil (see page 106) 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 106) 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 the 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
substitute or mix oil brands. Use only 0-40W.

ADD 8 OZ. NORMAL FULL

1

74

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Ch ange

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 t he
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. (1.93-2.35 kg/m)

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. l bs.
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.

1

2

3

4

75

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Ch ange

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 i n
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 106). Reinstall the dipstick.
NOTE: If the sump is not drained, add about 1 3/4 quarts initially.

13. Pl ace the gear selector in neutral and set the parking brake.

14. St art the engine and let it idle for one to two minutes. 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. Use only 0-40W.

76

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.

77

MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coo lan t Level

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

106).

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: To ensure that the coolant
maintains its ability to protect the engine, we recommend that the
system be completely drained every two years and a fresh mixture of
antifreeze and water added. Polaris recommends the use of Polaris
Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality
aluminum compatible anti-freeze/coolant and distilled water (see page

106). 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.

1

2

78

MAINTENANCE AND LUBRICATION

Engine Cooling System

Recovery Bottle Coolant Level

The recovery bottle (1) is located on
the left side of the vehicle. To access
the recovery bottle, remove the left
side panel as outlined on page 88.

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 106). 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 t he
system is purging itself of trapped air. Observe coolant levels and
maintain as recommended by adding coolant to the recovery bottle.

1

79

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

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

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

CAUTION

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

2

1

80

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 t o
check for clogging. R eplace 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
engine.

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

1

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.

81

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 t he 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.

1

2

3

82

MAINTENANCE AND LUBRICATION

Adjustments

Steering Inspection

The steering assembly of the vehicle should be checked periodically for
loose nuts and bolts. Have your dealer tighten any loose nuts and bolts
before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Handlebar Adjustment

Your vehicle has handlebars that can be adjusted for a personal fit.

1. Remove the handlebar cover and
loosen the block bolts (1).

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

3. Lightly tighten each bolt equally
to prevent uneven gaps in the
block.

4. Torque the handlebar adjuster block bolts to 10-12 ft. lbs.

Optional Suspension Springs

Although the Polaris LUH 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.

LUH 6x6 - Front
Strut Spring

7041375-067
OPTION
64/113 lb/in

7041450-195
STANDARD
101 lb/in

N/A

1

WARNING

Improper adjustment of the handlebars or incorrect torquing of the
adjuster block bolts can cause limited steering or loosening of the
handlebars, resulting in loss of control and possible serious injury or
death. Perform the handlebar adjustment exactly as outlined.

SOFT FIRM

83

MAINTENANCE AND LUBRICATION

Adjustments

Front Brake

Front Wheel and Middle Axle Brake

The front and middle axle brakes are hydraulic disc brakes and are
activated by moving the brake lever toward the handlebar. These
brakes are self-adjusting and require no adjustment.

The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.

1. Always keep brake fluid at an
adequate level (see page 36).
Under normal functioning the
diaphragm extends into the
reservoir as fluid level drops. If
the fluid level i s low and the
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 106).

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

84

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. F lip 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)

1

2

3

1

85

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 3/16″-3/8″ (.48 cm

- .95 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 (3).

4. Insert a pin punch 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. (1.4 - 1.7 kg/m).

7. Tighten the eccentric locking bolts to 45 ft. lbs. (6.2 kg/m).

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 adjust or operate the vehicle with the drive
chain slack out of the 3/16″-3/8″ (.48 cm - .95 cm) specification.

1

2

3

86

MAINTENANCE AND LUBRICATION

Adjustments

Rear Axle Drive Chain Ad justment

All procedures used in adjusting the front chain apply to the rear chain
adjustment. Total slack for t he rear chain, however, should be adjusted
to 1/4″-1/2″ (.6-1.3 cm).

Carburetor/Engine Idle RPM Adjustment

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

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

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

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

1/4″-1/2″ (.6-1.3 cm)

3/16″-3/8″
(.48 cm - .95 cm)

1

87

MAINTENANCE AND LUBRICATION

Adjustments

Carburetor Adjustments

If the vehicle is operated at various altitudes and temperatures, some
adjustments can be made to improve its operation and driveability.

Above 6000 feet (1800 m), the engine air/fuel mixture becomes overly
rich. An engine loses approximately 3% of its power for each
1000-foot (304.8 m) increase in elevation. Although this power cannot
be regained, changes to the carburetor and drive system can be made to
allow efficient operation. These changes include:

1. Carburetor re-jetting to compensate for atmospheric pressure and
oxygen loss.

2. Transmission convertor modification to adjust for engine
horsepower loss.

We recommend that you see your Polaris dealer for altitude
adjustments. Polaris dealers have the proper training and tools
required to perform these modifications.

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

Jetting Chart

2002 LUH 6x6

AMBIENT TEMPERATURE

Below 40_F

Below 5_C

Above 40_F

Above 5_C

Altitude

0-1800

(0-6000)

147.5 142.5

Met

ers

(Feet)

Over 1800

(Over 6000)

140 135

88

MAINTENANCE AND LUBRICATION

Adjustments

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side
panel near the rear cab. With
a quick and firm m otion, pull
the panel forward and outward
to disengage the t wo 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 t abs 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.

89

MAINTENANCE AND LUBRICATION

Adjustments

Wheel Removal

1. Stop the engine, place the transmission in gear and lock the
parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.

4. Remove the wheel nuts and remove the wheel.

Wheel Installation

1. With the transmission in gear and
the parking brake locked, place
the wheel in the correct position
on the wheel hub. Be sure the
valve stem is toward the outside
and the rotation arrows on the tire
point toward forward rotation.

2. Attach the wheel nuts and finger
tighten them. Make sure the
tapered side of the rear wheel nut
fits into the taper on the wheel
(1).

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the following torque:

Torque center and rear wheel nuts to 50 ft. lbs. (6.9 kg/m).
Torque front wheel nuts t o 20 ft. lbs. (2.1 kg/m).

Improper wheel installation could adversely affect vehicle handling
and tire wear and result in serious injury or death.

Make sure the tapered side of the rear wheel nut fits into the taper
on the wheel.

Do not service wheel nuts that have a cotter pin installed. See your
Polaris dealer.

WARNING

1

Rear Wheel Assembly

90

MAINTENANCE AND LUBRICATION

Specifications

Tire Tread Depth

Always replace tires when tread
depth is worn to 1/8″ (.3 cm) or less.
See illustration.

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the possibility of
skidding, which could lead to loss of control and serious injury or
death. Always replace tires when the tread depth measures 1/8″
(.3 cm) or less.

Use of non-standard size or type of tires or improper tire inflation
may adversely affect vehicle maneuverability and cause loss of
control resulting in serious injury or death. Maintain proper tire
pressure as outlined in this owner’s manual. When replacing a tire
always use original equipment size and type.

WARNING

91

MAINTENANCE AND LUBRICATION

Specifications

Tire Specifications

Tire Specifications

Polaris LUH 6x6

Front - 25 x 8.00 -12

Inflation Pressure - 5 PSI

Center - 25 x 11.00 - 10

Inflation Pressure - 5 PSI

Rear-25x11.00-10

Inflation Pressure - 5 PSI

Cargo Bed Load Capacity

800 lbs. (363 kg)

Front Rack Load Capacity

75 lbs. (34 kg)

Gross Vehicle Weight 1970 lbs. (894 kg)

including vehicle, driver and cargo.

Vehicle weighs 895 lbs. (406 kg).

The following items should be checked for tightness occasionally or if
they’ve been loosened for service.

Axle and Wheel Nut Torque Specification s

Item Specification

Front Spindle Nut(s) 100 in. lbs.

Front Wheel Nuts 20 ft. lbs.

Center and Rear Axle Nut(s) 80 ft. lbs.

Center and Rear Wheel Nuts 50 ft. lbs.

92

MAINTENANCE AND LUBRICATION

Spark Plugs

S Use NGK BKR5E spark plugs.
S Proper electrode gap is .036″ (.9 mm)
S Spark plug torque is 14 ft. lbs. (1.9 kg/m)

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.

1. Normal

The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect
carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil,
use of non-recommended oil, improper use of the choke, or incorrect
carburetion adjustments.

Spark Plug Removal an d Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 14 ft.
lbs. (1.9 kg/m).

Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.

CAUTION

WARNING

A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.

93

MAINTENANCE AND LUBRICATION

Spark Arrestor

Use the following procedure to periodically purge accumulated carbon
from t he exhaust pipe/muffler.

1. Remove the arrestor clean-out plug
(1) from the bottom of the muffler.

2. Place the transmission in neutral
and start the engine.

3. Purge carbon from the system by
momentarily revving the engine several times.

4. If carbon is expelled, cover t he exhaust outlet and rap on the pipe
around the cleanout plug while revving the engine several more
times.

5. If particles are still suspected to be in the muffler, back the vehicle
onto an incline so the rear of the vehicle is one foot higher than the
front. Set the parking brake and block the wheels. Make sure the
vehicle is in neutral and repeat steps 3 and 4.

6. If particles are still suspected to be in the muffler, drive the vehicle
onto the incline so the front of the vehicle is one foot higher than
the rear. Set the parking brake and block the wheels. Make sure
the vehicle is in neutral and repeat steps 3 and 4.

7. Repeat steps 3 through 6 until no more particles are expelled when
the engine is revved.

8. Stop the engine and allow the arrestor to cool. Reinstall the
arrestor plug.

WARNING

Failure to heed the following warnings while servicing the spark
arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is
hot. Exhaust system temperatures can reach 1000° F. Allow
components to cool sufficiently before proceeding.

Remove any combustible materials from the area.

Wear eye protection.

Do not stand behind or in front of the vehicle while purging.

Never run the engine in an enclosed area. Exhaust contains
poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

1

94

MAINTENANCE AND LUBRICATION

PVT System

PVT Drying

There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:

1. Remove the drain plug and allow the water to drain. Replace the
drain plug.

2. Start the engine and shift the transmission into neutral. Apply
varying throttle for 10-15 seconds to expel the moisture and air-dry
the belt and clutches. Do not hold the throttle wide open for more
than 10 seconds.

3. Allow the engine RPM to settle to idle speed and shift the
transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

WARNING

Failure to comply with the instructions in this warning can result
in severe injury or death.

Do not modify any component of the PVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The PVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.

The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:

Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do
not install it in any other product.

Always make sure the PVT housing is securely in place during
operation.

95

MAINTENANCE AND LUBRICATION

Recoil Housing

Water will enter the recoil housing if
the starter handle is disengaged from
the rope or if the handle is not
securely seated when under water.

Drain the recoil housing any time the
vehicle has been operated in very wet
conditions and also before storage.

The drain screw (1) is located at the
bottom of the recoil housing, above
the front propshaft. Remove the
screw with a 10 mm wrench. Reinstall the screw after the housing has
been drained.

NOTE: Do not open the crankcase drain (2) unless the engine has
ingested water. On 4-cycle engines, some engine oil will be lost if
crankcase drain is opened.

Battery

Keep the battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean rags. Coat the
terminals with dielectric grease or petroleum jelly.

Be careful not to allow cleaning solution or tap water into the battery.

2

1

Battery electrolyte is poisonous. It contains sulfuric acid. Serious
burns can result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk

of magnesia, beaten egg, or vegetable oil. Call physician
immediately.

Eyes: Flush with water for 15 minutes and get prompt medical
attention.

Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using in an
enclosed space. Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.

WARNING

96

MAINTENANCE AND LUBRICATION

Battery

Replenishing Battery Fluid

A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. The fluid level should
be kept between the upper and lower
level marks (1).

To refill use only distilled water. Tap
water contains minerals that are harmful
to a battery.

Battery Removal

1. Disconnect the hold-down straps holding the electrical box and
battery in position, and remove the battery cover.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable next.

5. Lift the battery out of the vehicle. Be careful not to tip it sidewaysand
spill electrolyte.

1

Improperly connecting or disconnecting battery cables can result
in an explosion and cause serious injury or death. When removing
the battery, always disconnect the negative (black) cable first.
When reinstalling the battery, always connect the negative (black)
cable last.

WARNING

If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to
the vehicle.

CAUTION

97

MAINTENANCE AND LUBRICATION

Battery

Battery Installatio n and Connection s

1. Set the battery in the battery holder.

2. Install the battery vent tube. NOTE: It must be free from
obstructions and securely installed. If not, battery gases could
accumulate and cause an explosion. The tube should be routed
away from the frame and body to prevent corrosion. Avoid skin
contact with electrolyte, which can cause severe burns.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall the battery cover and attach the hold-down strap.

6. Verify that cables are properly routed.

NOTE: When installing a new battery, make sure it’s fully charged
prior to its initial use. Using a new battery that has not been fully
charged can damage the battery and result in a shorter life. It can also
hinder vehicle performance.

Battery Storage

When the vehicle is placed in storage for three months or more, the
battery should be removed, charged to proper l evel, and stored out of
the sun in a cool, dry place. Before reusing, take the battery to your
dealer for testing and recharging.

Power plug leads may need to be bent down so that the battery cover
can be installed.

98

MAINTENANCE AND LUBRICATION

Lights

Headlight Lamp Replacement

1. Using a small flat-blade screwdriver, push in on the lock tabs
through the two small openings at the front of the headlight pod.

2. Lift the pod slightly while depressing the t abs.

3. Remove the three screws in the back of the headlight pod.

4. Lift the pod cover. Disconnect the speedometer harnesses from t he
speedometer. Unplug the indicator light harness and remove the
pod cover.

5. Unplug the headlamp from the wiring harness.

6. Remove the boot and locking collar from the back of the lamp
housing.

7. Grasp the base of the lamp and lift it out.

8. Reverse the previous steps to replace the l amp and reassemble the
pod. Make sure the tab on the lamp locates properly in the
housing.

WARNING

Poor lighting while driving can result in severe injury or death.
Headlight and taillight lenses become dirty during normal operation.
Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Don’t service the
headlamps until they’ve cooled sufficiently.

Snap pins
into tabs

Position
knob in
slot and
secure in
locking
tabs

Slip o-ring
over pin

Adjustment
Knob Stop

Route plug
over handlebar