Polaris Light Utility Hauler 6x6 Owner's Manual

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WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
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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.
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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.
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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.
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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:
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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
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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.
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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.
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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.
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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.
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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.
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2
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch
Maximum Front Rack Load 75 lbs.
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (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
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1
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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.
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WARNING
3
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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.
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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
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9
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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
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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.
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2
3
4
5
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
Page 32
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
Page 33
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
Page 34
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
Page 35
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
Page 36
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
Page 37
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
Page 38
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
Page 39
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
Page 40
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
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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
Page 42
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
Page 43
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
Page 44
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
Page 45
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
Page 46
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
Page 47
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
Page 48
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
Page 49
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.
Page 50
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
Page 51
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
Page 52
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.
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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.
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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.
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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
Page 56
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.
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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
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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.
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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
Page 60
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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
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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
Page 62
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.
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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
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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.
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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.
Page 66
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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.
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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.
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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
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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
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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
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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
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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
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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
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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
Page 75
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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
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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
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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.
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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.
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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
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MAINTENANCE AND LUBRICATION
Engine Cooling System
Recovery Bottle Coolant Level
The recovery bottle (1) is located on the left side of the vehicle. 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
Page 81
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
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MAINTENANCE AND LUBRICATION
Filter Systems
Air Box Drain
Periodically check the air box drain tube located on the bottom rear of the air box. Empty the drain tube if necessary.
Breather Filter
Inspect the filter monthly or after every 20 hours of operation, whichever comes first. Replace the filter annually, more often if needed. Inspect the breather filter hoses every six months and replace as needed.
1. Remove the clamps and pull the breather filter (1) out of the hoses. NOTE: It’s not necessary to remove the lower hose from the engine.
2. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow 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.
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MAINTENANCE AND LUBRICATION
Adjustments
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8to 1/4toe 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
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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
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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
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MAINTENANCE AND LUBRICATION
Adjustments
Rear Brake
The transmission brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The transmission brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.
Pads should be changed when worn to 3/64(.1 cm) which is about the thickness of a dime.
Inspect the brake disc spline and pad wear surface for excessive wear .
Throttle Cable Free Play Adjustment
Throttle cable free play is adjusted at the handlebar.
1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).
2. Turn the adjuster until 1/16to 1/8freeplay 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
Page 87
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
Page 88
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
Page 89
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
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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.
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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
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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
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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.
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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.
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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
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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.
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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
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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
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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.
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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
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