Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
This is an adult vehicle only.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
Pantone 426 C
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER:
S Operate on public roads. A collision can occur with another
vehicle.
S Carry passengers. Passengers affect balance and steering and
increase risk of losing control.
S USE ALCOHOL or DRUGS before or while operating this
vehicle.
S Operate at speeds too fast for your skills or the conditions.
S Operate this vehicle on HILLS steeper than 25 degrees. To
prevent flipover on hilly terrain, use throttle and brakes
gradually.
ALWAYS:
S Use an approved HELMET AND PROTECTIVE GEAR.
S Avoid paved surfaces. Pavement may seriously affect
handling and control.
S Use proper RIDING TECHNIQUES to avoid vehicle
overturns on hills and rough terrain and in turns.
S Use OVERRIDE for reverse speed limiter with caution. To
prevent loss of control, never activate override button with
open throttle.
REVERSE 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.
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9922233 Rev 03
Printed in USA
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
• Victory Motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational 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 machine we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a factory certified Master Service Dealer
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 complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
®
utility vehicles
®
®
(MSD)
1
POLARIS, THE WAY OUT, SPORTSMAN and BIG BOSS are registered trademarks
of Polaris Industries Inc.
Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2010 SPORTSMAN BIG BOSS 6X6 800 EFI Owner’s Manual
P/N 9922233
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 indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. This Polaris vehicle 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating this vehicle. Keep this manual with the
vehicle.
• Never operate this vehicle without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
5
INTRODUCTION
####
VIN
Engine Serial Number
Key Number
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
ATV safety training is a top priority for Polaris. Polaris strongly
encourages you and any family members who will be riding the ATV to
take a training course.
If you purchased a new Polaris ATV in the United States, your dealer
provided instruction to you about the authorized ATV RiderCourse
that is available to you and your eligible family members. This training
is included in the purchase price of your ATV. 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 ATV in the United States, you can enroll
sm
in the ATV RiderCourse
for a fee. Call ATV Enrollment Express at
(800) 887-2887 or visit www.atvsafety.org.
If you purchased a Polaris ATV outside the United States, please contact
your dealer or local law enforcement agencies for information about
safety training.
This Polaris vehicle is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of this vehicle in your
area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.
sm
7
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris vehicle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris vehicle 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.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
9
SAFETY
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain.
Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.
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.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.
Even though a child may be within the
recommended age group for operating some
Polaris vehicles, he/she may not have the skills,
abilities, or judgment needed to operate this
vehicle safely and could be susceptible to accident
or injury.
10
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
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.
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in
safe operating condition before operating
increases the risk of an accident.
Always inspect the vehicle before each use to
make sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
11
SAFETY
Safety Warnings
Protective Apparel
Riding on this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).
Using Alcohol or Drugs
Operating the vehicle after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.
Never consume alcohol or drugs before
or while operating this vehicle.
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the
vehicle, which may result in an accident or
overturn.
Never carry a passenger on this vehicle.
12
Safety Warnings
Operating on Pavement
Operating this vehicle on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the vehicle and could result in
loss of control and accident or overturn.
Avoid operating the vehicle on pavement.
The tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this vehicle on public streets,
roads or highways could result in a collision
with another vehicle.
Never operate the vehicle on any public
street, road or highway, including dirt and
gravel roads. In many states it's unlawful to
operate this type of vehicle on public
streets, roads and highways.
Operating at Excessive
Speeds
Operating the vehicle at excessive speeds
increases the operator's risk of losing
control.
Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.
SAFETY
13
SAFETY
Safety Warnings
Physical Control of the Vehicle
Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
vehicle. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.
Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or overturn.
Always follow proper procedures for turning
as described in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 55. Always
move the 4X4 switch to ADC 4X4 (if
equipped) before ascending or descending a hill.
14
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or overturn.
• Always follow proper procedures for traveling down hills as described in the owner's
manual. NOTE: A special technique is
required when braking while traveling downhill. See page 57.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral. Always move the
4X4 switch to ADC 4X4 (if equipped) before
ascending or descending a hill. See page 36.
• Always check the terrain carefully before descending a hill.
• Shift your weight rearward.
• 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.
Crossing Hillsides
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or overturn. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow proper procedures as
described in the owner's manual. See page 56.
Never attempt to turn the vehicle around on any hill until you've mastered the
turning technique (on level ground) as described in the owner's manual. See
page 58.
15
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause an
overturn.
• Always maintain a steady speed when climbing
a hill.
• Always move the 4X4 switch to ADC 4X4 (if
equipped) before ascending or descending a
hill. See page 36.
If all forward speed is lost:
• Keep body weight uphill.
• Apply the service brakes.
• Lock the parking brake when fully stopped.
• Dismount on 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 58.
If the vehicle begins rolling downhill:
• Keep body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the service brake
gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on 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 58.
16
Safety Warnings
Operating on Steep Hills
Operating on excessively steep hills could cause
an overturn.
Never operate on hills too steep for the vehicle or
for your abilities. Never operate the vehicle on hills
steeper than 25 degrees.
Operating on Slippery Terrain
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.
Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of control or
overturn.
Travel slowly and use extra caution when operating
on unfamiliar terrain. Always be alert to changing
terrain conditions.
SAFETY
17
SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this vehicle with improper
tires or with improper or uneven tire
pressure could cause loss of control or
accident.
Always use the size and type of tires
specified for your vehicle.
Always maintain proper tire pressure as
described in the owner's manual and
on safety labels.
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 60.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.
18
SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the vehicle or carrying/towing
cargo improperly may cause changes in
handling, which could cause loss of control or
an accident.
• Never exceed the stated load capacity for
this vehicle.
• Cargo should be properly distributed and
securely attached.
• Reduce speed when carrying cargo or pull-
ing a trailer. Allow a greater distance for
braking.
• Always follow the instructions in the owner's manual for carrying cargo or pull-
ing a trailer.
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 61.
Before shifting into reverse gear, always check for obstacles or people behind
the vehicle. When it's safe to proceed, back slowly.
Poor Visibility
Operating the vehicle in darkness or inclement weather could result in a collision
or accident, especially if operating on a road or street. This vehicle is not
equipped with highway-approved lights. Operate this vehicle off-road only. Use
caution and drive at reduced speeds in conditions of reduced visibility such as
fog, rain and darkness. Clean headlights frequently and replace burned out
headlamps promptly.
19
SAFETY
Safety Warnings
Operating Through Deep Water
Operating the vehicle through deep or
fast-flowing water could cause the tires to
float, causing loss of control or overturn.
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
59):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• 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. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result
in serious injury or death if the vehicle and/or
the operator fall through the ice.
Never operate the vehicle on a frozen body of
water.
20
SAFETY
Safety Warnings
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
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 overturn and loss of control.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
21
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.
If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge. The part number is printed
on the label.
General Warning
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER:
• Operate on public roads. A collision can occur with another vehicle.
• Carry passengers. Passengers affect balance and steering and increase risk
of losing control.
• USE ALCOHOL or DRUGS before or while operating this vehicle.
• Operate at speeds too fast for your skills or the conditions.
• Operate this vehicle on HILLS steeper than 25 degrees. To prevent flipover
on hilly terrain, use throttle and brakes gradually.
ALWAYS:
• Use an approved HELMET AND PROTECTIVE GEAR.
• Avoid paved surfaces. Pavement may seriously affect handling and control.
• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and
rough terrain and in turns.
• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of
control, never activate override button with open throttle.
REVERSE 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.
7175784
22
Safety Labels and Locations
+
+
Tire Pressure/Load
Warning
Reverse Override
Warning
+
Front Rack
Warning
+
General
Warning
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• 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.
• Max. Rack Loads: 100 lbs. (45 kg)
Reverse Override Warning
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.
7175662
7175486
23
SAFETY
+
Clutch Cover
Warning
+
Age 16 Warning
+
Container/No Passenger
Warning
Safety Labels and Locations
Container/No Passenger Warning
WARNING
Remove flammable containers from box before refueling.
WARNING
• Passengers can be thrown off. This can cause serious injury or death.
• Never carry passengers.
Maximum Box Load 800 lbs. (363 kg)
7079316
24
SAFETY
Safety Labels and Locations
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this ATV if you are under age 16.
7172588
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
NO STEP
7172563
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
9921509
25
FEATURES AND CONTROLS
Mode/Reverse
Override
Switch
Main Key Switch
Engine
Stop Switch
Headlight
Switch
4X4
Switch
Switches
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system.To gain
additional wheel speed while backing, release the throttle and depress
the override button.
WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.
The override switch also allows activation of 4X4 in reverse, if the 4X4
switch is on. This switch is also used to toggle through the modes of the
rider information center. See page 37.
All Wheel Drive (AWD) Switch
See page 34 for AWD information.
26
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