Polaris PTV 6x6 SERIES 10 Owner's Manual

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Page 2

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

Page 3

Page 4

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.

Page 5

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

Polaris Recreational and Utility Vehicles

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

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)

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 t he 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 C ertified Master Service Dealer (MSD) Technician.

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

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

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

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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 i gnition switch replacement.

Frame VIN:

Engine Serial Number:

Vehicle Model Number:

Key Number:

Page 7

TABLE OF CONTENTS

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

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

TABLE OF CONTENTS 5.............................

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

FEATURES 34.......................................

CONTROLS 37......................................

OPERATION 46.....................................

NOISE EMISSION CONTROL SYSTEM 65.............

MAINTENANCE AND LUBRICATION 66................

SPECIFICATIONS 106................................

POLARIS RECOMMENDED PRODUCTS 108...........

TROUBLESHOOTING 109............................

W A RRANTY 113.....................................

INDEX 115..........................................

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

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SAFETY

Operator Safety

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.

The PTV 6x6 is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of t his 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.

Safety Training

When you purchased your new PTV 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 PTV 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 PTV 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 PTV 6x6.

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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

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

procedures described.

S Never operate the PTV 6x6 without proper instruction. Take a trai n-

ing 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. B e alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain.

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 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.

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

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SAFETY

Operator Safety

Equipment Modifications

We are concerned for the safety of our customers and for t he general public. Therefore, we strongly recommend that consumers do not install on a Polaris PTV 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 P olaris PTV 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.

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 P olaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

WARNING

Make sure your PTV 6x6 is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.

Your Polaris PTV 6x6 is designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The PTV 6x6 may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury .

Do not make any modifications to your PTV 6x6.

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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 PTV 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 PTV 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 PTV 6x6.

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 a PTV 6x6.

WHAT CAN

HAPPEN

Carrying a passenger greatly reduces the operator’s ability to balance and control the vehicle, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE

HAZARD

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

POTENTIAL

HAZARD

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

WHAT CAN

HAPPEN

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

WARNING

Page 16

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 PTV 6x6 on any public street, road or highway, including dirt and gravel roads.

POTENTIAL

HAZARD

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

WHAT CAN

HAPPEN

Operating a PTV 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

Page 17

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 59. 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 PTV 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 PTV 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

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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

Page 20

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

Page 21

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 PTV 6x6 on hills steeper than 15_.

Practice on small hills before attempting larger hills.

WARNING

Page 23

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 beginning on page 57.

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

Page 25

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 PTV 6x6 around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 59. 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

Page 26

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 50-51.

WARNING

Page 27

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 60), 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

Page 28

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 PTV 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

Page 29

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

Page 30

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.

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. (34 kg)

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

Page 31

SAFETY

Safety Decals and Locations

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

DOperate on public roads. A collision can occur with another vehicle.

DCarry passengers. Passengers affect balance and steering and in-

crease risk of losing control.

DUSE ALCOHOL or DRUGS before or while operating this vehicle.

DOperate at speeds too fast for your skills or the conditions.

DOperate this vehicle on HILLS steeper than 15 degrees 15°.

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

ALWAYS:

DUse an approved HELMET AND PROTECTIVE GEAR.

DAvoid paved surfaces. Pavement may seriously affect handling and

control.

DUse proper RIDING TECHNIQUES to avoid vehicle overturns on hills

and rough terrain and in turns.

DUse OVERRIDE for reverse speed limiter with caution. To prevent loss

of control, never activate override button with open throttle.

DREVERSE operation can be dangerous, even at low speeds. Steering

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.

WARNING

Page 32

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.

Operating this vehicle if you are under the age of 16 increases your chance of s ev ere 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 c an cause serious injury or death.

DNever carry passengers.

ALL WHEEL

DRIVE

SWITCH

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

7079780

7079604

AWD Models

WARNING

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

This v ehicle is equipped with 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

Page 33

SAFETY

Safety Decals and Locations

Moving par ts hazard under belt-c lut c h guard. To prevent serious injury, do not oper ate vehicle with guard remov ed.

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

NO STEP

7078689

WARNING

(On Hitch)

TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LB S. (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

Page 34

SAFETY

Fuel Safety

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well ventilated area with the

engine stopped.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

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

Page 35

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. PTV 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.

Page 36

FEATURES

Component Locations

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

Page 37

FEATURES

All Wheel Drive (AWD) System

The Polaris PTV 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 i ndicates when the vehicle is in AWD. There is no limit to the length of time the vehicle may remain in AWD.

The AWD switch may be turned on or off while the vehicle is moving. If the switch is turned off when the front hubs are driving, they will not release until the rear wheels regain traction.

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 38

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 37.

Operating with only one front hub engaged could result in loss of control, accident, and severe injury or death.

When hub engagement symptoms are present, use the disengaging procedure before proceeding.

WARNING

Page 39

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 t o 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.

5 Demand 6 (AWD) Switch

Page 40

CONTROLS

Electrical Switches and Indicators

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

1 Light Switch/Hi-Lo Beam Control

The lights won’t turn on unless both the main switch and the engine stop switch are on.

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

The high temp indicator will light only i f the engine overheats.

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

Your PTV 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 41

CONTROLS

Throttle Lever

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

This vehicle is equipped with Polaris Electronic Throttle Control (ETC), which is designed 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

Page 42

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.

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 43

CONTROLS

Brakes

Master Cylinders

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.

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 44

CONTROLS

Parking Brake

Setting the Parking Brake

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

2. Push the park brake lock (2) forward to engage the brake. Release the brake lever.

3. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Important Safeguards

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

ways block the wheels to prevent rolling.

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

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

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

if the vehicle is parked on a hill. Always block 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

Page 45

CONTROLS

Engine Fuel and Oil System

The fuel tank filler cap (1) is 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 main supply is

exhausted. NOTE: There’s a 7 to 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 the fuel valve back to the ON position for normal operation.

OFF

RES

Page 46

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 to shift gears with engine speed above idle or while the vehicle is moving.

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

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

Belt Life

To extend belt life, refrain from continuous operation of the vehicle at the point of engagement (the point at which the vehicle begins to move). C ontinuous operation in this manner increases belt wear.

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 47

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 42.

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.

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 48

OPERATION

Break-in Period

The break-in period for your new Polaris PTV 6x6 is defined as the first ten hours of operation or the time it takes to use the first two tanks of gasoline. No single action on your part is as important as following procedures for a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

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

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

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 throttle positions.

5. Perform regular checks on fluid levels, controls, and areas outlined on the daily pre-ride inspection checklist. See page 47.

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

7. During the break-in period, change the oil and oil filter 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 lubricants for your vehicle.

See page 108 for the part numbers

of Polaris-recommended products

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

ADD 8 OZ. NORMAL FULL

Page 49

OPERATION

Pre-Ride Inspection

Use the following checklist to verify t hat 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 50

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

Page 51

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

Page 52

OPERATION

Hauling Cargo

Your PTV 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

PTV 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 t owing load weight is 1225 lbs. (556 kg) on level ground only and 850 lbs. (386 kg) on a grade up to 15°.

Maximum vertical hitch weight is 35 lbs. (16 kg).

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 53

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 54

OPERATION

Driving Safely

Load Distribution

1. Always load the cargo bed with the l oad 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 75 lbs. (34 kg)

Maximum Cargo Bed PTV 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.

Page 55

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 m aneuvering and using the throttle and brakes on level surfaces.

Page 56

OPERATION

Driving Safely

Making Turns

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

wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.

To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same learning technique should be used for turning in reverse.

WARNING

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

Page 57

OPERATION

Driving Safely

Driving Across Hills

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 58

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.

Page 59

OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Drive directly downhill.

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

3. Slow down.

4. Apply the brakes slightly 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

Page 60

OPERATION

Driving Safely

Driving 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.

Page 61

OPERATION

Driving Safely

Turning Around on a Hill

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

1. Stop and lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the left (always uphill) side of the vehicle.

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

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

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

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

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

WARNING

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

Avoid climbing steep hills (15_ maximum).

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

8’

Uphill

Page 62

OPERATION

Driving Safely

Driving Through Water

Your PTV 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 maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

IMPORTANT: After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See pages 67-69. 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

Page 63

OPERATION

Driving Safely

ParkingOnAnIncline

Avoid parking on an incline if 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.

Page 64

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

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

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

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

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

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

CAUTION

Page 65

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.

Page 66

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

Page 67

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 the 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 inoperative 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 Service 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 68

MAINTENANCE AND LUBRICATION

Tool Kit

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

S Screwdriver S Open end wrench (8-10 mm) S Open end wrench (12-14 mm) S Box end wrench S Tire pressure gauge S Spark plug wrench and handle S Torx wrench (rack removal)

Accessories

Polaris has a wide variety of accessories for your vehicle. Contact your Polaris dealer for a complete list.

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

Page 69

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 108 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.

Page 70

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 dielec-

tric grease to c onnector when replaced

Taillamp Pre-ride Pre-ride Check operation daily; apply Polaris dielec-

tric grease to s ocket when replac ed

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, fas teners Pre-ride Pre-ride Inspect; tighten when needed

Fuel and oil tanks Pre-ride Pre-ride Fill to proper lev el

" Air box sediment tube Daily Daily Inspect; drain deposits whenever vis ible

" Air filter (pre-cleaner) Daily Daily Inspect and clean

Coolant level Daily Daily Replace engine coolant every two years

" Air Filter (main element) Weekly Weekly Inspect; replace if necess ary

J Brake pads 10 hrs/100

miles

Monthly Inspect for wear periodi cally

" Breather filter 20 hrs Monthly Inspect; replace annually and as needed

Battery 20 hrs Monthly Inspect and clean terminals; check fluid level

" Transmission oil level 25 hrs Monthly Inspect monthly; change annually

" General lubrication 50 hrs 3 months Lubricate all fittings, pivots, cables, etc.

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

replace if necessary

Choke (enricher) cable 50 hrs 6 months Inspect; adjust, lubric ate, replac e i f 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

Page 71

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 s ervice 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 sus pension 50 hrs 6 months Inspect; tighten fasteners

" Drive chains 50 hrs 6 months Inspect daily; adj ust and lubric ate i f 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 axl e / 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, li nes, fuel v alve,

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

J Fuel filter 100 hrs 12 months Replace annually

Radiator 100 hrs 12 months Inspect; clean 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 necessary

" Front hubs 100 hrs 12 months Change fluid annually

J Clutches (drive and driven) 100 hrs 12 months Inspect; clean

J Shift selector box 200 hrs 24 months Change 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 moi sture 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

Page 72

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

NOTE: Hours are based on 10 mph average.

Maintenance Chart Key

" More often under severe use, such as wet or dusty conditions L Use Polaris Premium All Season Grease or grease conforming to

NLGI No. 2

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

periods of storage, or after pressure washing or submerging.

Item Lube Rec. Method Frequency*

Brake Fluid DOT 3 only Maintain proper level.

See page 41.

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

Page 73

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

" More often under severe use, such as wet or dusty conditions L Use Polaris Premium All Season Grease or grease conforming to

NLGI No. 2

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

storage, or after pressure washing or submerging.

Page 74

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 Use Polaris Premium All Season Grease or grease conforming to

NLGI No. 2

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

storage, or after pressure washing or submerging.

Page 75

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 S ynthetic Gearcase Lubricant in the transmission. See page 108 for a list of Polaris-recommended products.

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 Polaris Premium Synthetic Gearcase Lubricant until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall the propshaft shield.

Page 76

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Lubrication

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

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. Add Premium Front Gearcase Fluid if needed. See page 108 for a list of Polaris-recommended products.

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 Premium Front Gearcase Fluid to the bottom thread of the fill hole.

5. Reinstall the fill plug.

6. Check for leaks.

Page 77

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

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

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

See page 108 for the part numbers of Polaris-recommended products.

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 t o keep the angle and depth consistent.

5. Add oil 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

Page 78

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 the engine.

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

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

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

5. Reinstall the drain plug and torque to 14-17 ft. lbs. (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. lbs. 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.

Page 79

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 in good condition. Also make sure the gasket from the old filter is not still on the engine.

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

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

11. After draining, reinstall the drain plug.

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

13. Place the gear selector in neutral and set the parking brake.

14. Start 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.

CAUTION

Page 80

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.

Page 81

MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant 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 level in the radiator should be inspected. Add recommended coolant as needed.

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

108). 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.

Page 82

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 90.

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

NOTE: Polaris recommends the use of P olaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water (see page 108). 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 t emperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.

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

Page 83

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.

Page 84

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. Replace if necessary.

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

4. Reinstall the filter and clamps with the arrow pointing toward the engine.

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

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.

Page 85

MAINTENANCE AND LUBRICATION

Adjustments

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a straight-ahead position and hold them in this position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

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

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

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

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

WARNING

Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer.

Page 86

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 PTV 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 P olaris dealers.

PTV 6x6 - Front Strut Spring

7041375-067 OPTION 64/113 lb./in.

7041450-195 STANDARD 101 lb./in.

N/A

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

Page 87

MAINTENANCE AND LUBRICATION

Adjustments

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 41). Under normal functioning the diaphragm extends into the reservoir as fluid level drops. If the fluid level is 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.

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

Page 88

MAINTENANCE AND LUBRICATION

Adjustments

Rear Brake

The transmission brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The transmission brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.

Pads should be changed when worn to 3/64″ (.1 cm) which is about the thickness of a dime.

Inspect the brake disc spline and pad wear surface for excessive wear.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the handlebar.

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

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

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

Front Wheel Hub Tightening

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

3/64″ (.1 cm)

Page 89

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.

Page 90

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, t he 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)

Page 91

MAINTENANCE AND LUBRICATION

Adjustments

Carburetor Adjustments

IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments t o the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

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

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

Page 92

MAINTENANCE AND LUBRICATION

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.

3. Place your hand on top of the side panel behind the fuel tank. With a quick and firm motion, push down on the side panel to disengage the top rear twotabs. Thenpulluponside panel to disengage front upper and lower tabs.

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

Step 2

Step 3

Step 4

Page 93

MAINTENANCE AND LUBRICATION

Wheel Removal

1. Stop the engine, place the transmission in gear and l ock 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 to 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

Rear Wheel Assembly

Page 94

MAINTENANCE AND LUBRICATION

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

Page 95

MAINTENANCE AND LUBRICATION

Tire Specifications

Polaris PTV 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 Specifications

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.

Page 96

MAINTENANCE AND LUBRICATION

Spark Plugs

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

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

1. Normal

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

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

2. Wet Fouled

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

Spark Plug Removal and 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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MAINTENANCE AND LUBRICATION

Spark Arrestor

Use the following procedure to periodically purge accumulated carbon from the 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.

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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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MAINTENANCE AND LUBRICATION

Recoil Housing

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

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

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

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

Battery

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

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

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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MAINTENANCE AND LUBRICATION

Battery

Replenishing Battery Fluid

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

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

Battery Removal

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

2. Remove the battery vent tube from the battery.

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

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

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

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