Polaris 2002 ATV Sportsman 6X6 User Manual

7SAFETYUnderstanding WarningsThe following two pages identify signal words and symbols that appearin this manual. Your safety is involved when these w

97MAINTENANCE AND LUBRICATIONAdjustmentsTire SpecificationsTire SpecificationsSportsman 6x6Front - 25 x 8.00 -12Inflation Pressure - 5 PSICenter - 25

98MAINTENANCE AND LUBRICATIONAdjustmentsFront Drive Chain AdjustmentCheck the amount of chainslack by moving the vehicleslightly forward to gain slack

99MAINTENANCE AND LUBRICATIONAdjustmentsRear Axle Drive Chain AdjustmentAll procedures used in adjusting the front chain apply to the rear chainadjust

100MAINTENANCE AND LUBRICATIONAdjustmentsCarburetor/Engine Idle RPM AdjustmentRecommended engine idle RPM is 1200+/- 200. If the engine idle speed is

101MAINTENANCE AND LUBRICATIONAdjustmentsCarburetor AdjustmentsIf the vehicle is to be operated at various altitudes and temperatures,certain adjustme

102MAINTENANCE AND LUBRICATIONAdjustmentsSide Panel Removal1. Side panel removal maybe difficult until thelocking tabs andreceivers have beensnapped a

103MAINTENANCE AND LUBRICATIONSpark PlugsS Use NGK BKR5ES spark plugs.S Proper electrode gap is .025″ (.06 cm).S Spark plug torque is 17 ft. l bs.(2.3

104MAINTENANCE AND LUBRICATIONSpark ArrestorWARNINGS Because exhaust system temperatures can reach 1000°F, donot perform this operation immediately af

105MAINTENANCE AND LUBRICATIONSpark Arrestor (Cont.)The exhaust pipe must be periodically purged of accumulated carbon asfollows:1. Remove the cleanou

106MAINTENANCE AND LUBRICATIONRecoil HousingDrain the recoil housingafter operating the vehiclein very wet conditions.This should also be donebefore s

8SAFETYKey Safety IssuesProtect Your SportKnow all local, state/province riding laws;Respect your vehicle;Respect the environment; andYou will gain th

107MAINTENANCE AND LUBRICATIONPVT SystemWARNINGThe PVT system rotates at high speeds, creating large amountsof force on clutch components. Extensive e

108MAINTENANCE AND LUBRICATIONBatteryReplenishing the Battery FluidA poorly maintained battery willdeteriorate rapidly. Check thebattery fluid level o

109MAINTENANCE AND LUBRICATIONBatteryBattery Removal1. Disconnect hold down straps holding the electrical box and battery inposition and remove batter

110MAINTENANCE AND LUBRICATIONBattery1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obstructions and se-curel

111MAINTENANCE AND LUBRICATIONLights - Adjustment - ReplacementHeadlight Lamp Replacement.1. Using a small flat blade screwdriver, push in on the lock

112MAINTENANCE AND LUBRICATIONLights - Adjustment - ReplacementHigh Beam Headlight AdjustmentThe headlight beam can be adjusted to any position desire

113MAINTENANCE AND LUBRICATIONLights - Adjustment - ReplacementHeadlight Housing Replacement1. Remove Phillips screws from bottom of headlight pod at

114MAINTENANCE AND LUBRICATIONLights - Adjustment - ReplacementTaillight/Brakelight Lamp ReplacementIf the taillight/brakelight does notwork the lamp

115MAINTENANCE AND LUBRICATIONCleaning and StorageCleaning the 6x6Keeping your 6x6 clean will not only improve its appearance but it canalso extend th

116MAINTENANCE AND LUBRICATIONCleaning and StorageStorage of the 6x6If your 6x6 is to be placed inextended or of f season storage,the following steps

9SAFETYKey Safety IssuesSERIOUS INJURY OR DEATH can result if you do n otfollow these instructions:S Read this manual and all labels carefully and fol

117MAINTENANCE AND LUBRICATIONCleaning and StorageTransporting the 6x6Whenever the 6x6 is to be transported the following measures shouldbe taken.1. T

118SPECIFICATIONSHeight 48″...Width 46″...Length 105″...

119SPECIFICATIONSEngine Specifications2002 S portsman 6x6Engine EH50PLE-06...Displacement 499 cc...

120WIRING DIAGRAM

121TROUBLESHOOTINGClutch Drive Belt & Cover Related Issues: DiagnosisPossible Causes Solutions/What to doLoading the 6x6 into a pick-up or tall tr

122TROUBLESHOOTINGPossible Causes Solutions/What to doStuck in mud or snow. Shift the transmission to Low Range,carefully use fast, aggressive throttl

123TROUBLESHOOTINGThe following information is provided to help you identify probablecauses for questions you may have about the operation of your veh

124WARRANTYLIMITED WARRANTYPolaris Industries Inc., 1225 Highway 169 North, Minneapolis,Minnesota 55441-5078, gives a SIX M ONTH LIMITED WARRANTYon al

125WARRANTYThis warranty does not cover the use of unauthorized lubricants,chemicals, or fuels that are not compatible with the vehicle. Theexclusive

126INDEXAccessories 117...Adjustments 90-102...Air Box Drain 89...Air Cleaner 88...

10SAFETYKey Safety IssuesS Never operate the vehicle on hills too steep for the vehicle or foryour abilities. Practice on smaller hills before attempt

127INDEXWelco me 2...Wheel Installation 95...Wheel Removal 95...Wiring Diag ram 120...

11SAFETYKey Safety IssuesS Wet brakes may have reduced stopping ability. Test your brakesafter leaving water. If necessary apply them lightly several

12SAFETYSafe Riding GearAlways wear clothing suited to the type of riding you are doing.Riding this vehicle requires special protective clothing which

13SAFETYSafety Decals and LocationsNOTE:Warning decals have been placed on the vehicle for your protection.Read and follow the instructions on each de

14SAFETYSafety Decals and Locations12DO NOT TOW FROM RACK OR BUMPER.Vehicle damage or tipover may result causing severeinjury or death. Tow only from

15SAFETYSafety Decals and Locations3

16SAFETYSafety Decals and Locations3Improper vehicle use can result in SEVERE INJURY or DEATH.NEVER:D Operate on public roads. A collision can occur w

WARNINGThe engine exhaust from thisproduct contains chemicalsknown to cause cancer, birth de-fects or other reproductive harm.

17SAFETYSafety Decals and Locations45678

18SAFETYSafety Decals and LocationsETCThis vehicle is equipped with aPolaris Electronic Throttle Control(ETC) to reduce the risk of a stuck or“frozen”

19SAFETYSafety Decals and LocationsMoving part s hazard under belt-c lutch guard. Toprevent serious injur y, do not operate v ehicle wit hguard remov

20SAFETYSafety Decals and Locations(On Hitch)TRAILER MAX WEIGHT:1225 LBS. (557 KG) ON LEVEL GROUND850 LBS. (368 KG) UP TO 15 GRADEHITCH MAX. VERTICAL

21SAFETYOperator SafetyPOTENTIAL HAZARDOperating this vehicle without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased i

22SAFETYOperator SafetyPOTENTIAL HAZARDCarrying a passenger on this vehicle.WHAT CAN HAPPENGreatly reduces your ability to balance and control this ve

23SAFETYOperator SafetyPOTENTIAL HAZARDOperating this vehicle on public streets, roads orhighways.WHAT CANHAPPENYou can collide with another vehicle.H

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards or improperly dismounting whileclimbing a hill.WHAT CANHAPPENCould result in

25SAFETYOperator SafetyPOTENTIAL HAZARDOperating this vehicle at excessive speeds.WHAT CAN HAPPENIncreases your chances of losing control of the vehic

26SAFETYOperator SafetyPOTENTIAL HAZARDFailure to inspect the vehicle before operating.Failure to properly maintain the vehicle.WHAT CAN HAPPENIncreas

Indicates a potential hazard that could result in seriousinjury or death.WARNING

27SAFETYOperator SafetyPOTENTIAL HAZARDFailure to use extra care when operating this vehicle on unfamiliarterrain.WHAT CANHAPPENYou can come upon hidd

28SAFETYOperator SafetyPOTENTIAL HAZARDFailure to use extra care when operating on excessivelyrough, slippery or loose terrain.WHAT CANHAPPENCould cau

29SAFETYOperator SafetyPOTENTIAL HAZARDT urning improperly.WHAT CAN HAPPENVehicle could go out of control, causing a collision oroverturn.HOW TO AVOID

30SAFETYOperator SafetyPOTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control or cause vehicle to overturn.HOW TO AVOID

31SAFETYOperator SafetyPOTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause vehicle to overturn.HOW TO AVO

32SAFETYOperator SafetyPOTENTIAL HAZARDImproperly crossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause vehicle to ov

33SAFETYOperator SafetyPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENCould cause loss of control or a collision. Could cause vehi

34SAFETYOperator SafetyPOTENTIAL HAZARDOperating this vehicle through deep or fast flowing water.WHAT CAN HAPPENT ires may float, causing loss of trac

35SAFETYOperator SafetyPOTENTIAL HAZARDOperating this vehicle with improper tires, or with improper oruneven tire pressure.WHAT CANHAPPENUse of improp

36SAFETYOperator SafetyWARNINGWARNINGPOTENTIAL HAZARDRiding on frozen lakes and rivers.WHAT CAN HAPPENSevere injury or death can result if the vehicle

1We’ve c reated a web site, just for YOU!!S Technical tipsS New product introductionsS Event schedulesS Parts and Service Manual informationS Exciting

37CONTROLS AND FEATURESControlsSportsman 6x6 Vehicle Nomenclature6. Floor Boards7. Back Rest8. Bed9. Front Rack1. Service Brake Lever2. Middle Axle Au

38CONTROLS AND FEATURESControlsEngine Electrical Switches123RUNOFFOFF1. Override Switch (Reverse Speed Limiter)This vehicle is equipped with a reverse

39CONTROLS AND FEATURESControlsThrottle LeverEngine speed and vehiclemovement are controlled bypressing the t hrottle lever.The t hrottle lever (1) is

40CONTROLS AND FEATURESControlsFront and Rear BrakesThe master cylinders, which arelocated on the left and righthandlebars, should be checkedbefore ea

41CONTROLS AND FEATURESControlsBrakes/Rear Auxiliary BrakeThe braking system is controlled by two levers located on thehandlebars directly in front of

42CONTROLS AND FEATURESControlsParking BrakeSetting the Parking Brake1. Squeeze the left hand brakelever two or three times andhold it.2. Rotate the p

43CONTROLS AND FEATURESControlsEngine Fuel and Oil SystemThe fuel tank filler cap (1) is located directly behind the handlebar. Itscapacity is 4.25 U.

44CONTROLS AND FEATURESControlsEngine Fuel and Oil SystemNOTE: The t aillight is on whenever the main switch (key) is in the onposition. Turn the key

45CONTROLS AND FEATURESControlsTransmission Gear Selector OperationThe transmission gearselector is located on theright side of the vehicledirectly ab

46CONTROLS AND FEATURESControlsRecoil StarterIf the battery is weak andcannot start the engine, use ofthe recoil starter located onthe right side of t

2WELCOMEThank you for choosing Polaris, and welcome to our world-widefamily of Polaris enthusiasts. Polaris proudly produces an exciting lineof recrea

47CONTROLS AND FEATURESFeaturesLight Switches and Indicator Lights1. Main switch2. Handlebar light switch and headlight Hi-Lo beam control NOTE:Will n

48CONTROLS AND FEATURESFeaturesAll Wheel Drive SystemThe Polaris 6x6 is equipped with a unique Polaris exclusive AWD (AllWheel Drive) system which is

49CONTROLS AND FEATURESFeaturesA 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

50OPERATIONVehicle Break-in PeriodThe break-in period for your new Polaris 6x6 is defined as the first tenhours of operation or t he time it takes to

51OPERATIONDaily Pre-Ride InspectionInspect your 6x6 each time before riding to ensure it is in properworking order. If proper inspection is not done,

52OPERATIONStarting a Cold Engine1. Place the t ransmission in neutral andreset the parking brake.2. Turn the fuel tank valve to ON.3. Sit on the vehi

53OPERATIONStarting a Warm EngineWarm engines do not normally require the use of the choke since thespark plug can easily become wet fouled.1. Place t

54OPERATIONCarrying LoadsYour 6x6 has been designed to carry or tow a certain amount of load.Always read and understand the load distribution warnings

55OPERATIONCarrying LoadsWARNINGOverloading the vehicle or carrying or towing cargo improperlycan be dangerous.Improper loading can drastically alter

56OPERATIONCarrying LoadsDumping the Cargo Bed1. Select a level site to dump the cargo bed. Do not attempt to dump orunload the vehicle while parked o

3ATTENTION!This is an ADULT VEHICLE ONLY; not a toy. Operation isprohibited for anyone under 16 years of age. READ ANDUNDERSTAND WARNINGS AND OWNER’S

57NOISE EMISSION CONTROL SYSTEMREGULATIONTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing t

58RIDINGDaily Pre-Ride InspectionInspect your 6x6 each time before riding to ensure it is in properworking order. If proper inspection is not done, se

59RIDINGRiding SafelyLoad Distribution1. Always load the cargo bed placing the load as far forward as possible.2. Always operate the vehicle with extr

60RIDINGRiding Safely1. Sit upright with both feet on the footrests and both hands on the handle-bars.2. After starting t he engineand allowing it to

61RIDINGRiding SafelyMaking TurnsPractice making turns at slow speeds.Polaris 6x6s are equipped with solid rear axles which drives all rearwheels equa

62RIDINGRiding SafelySidehillingSidehilling your 6x6 is one of the most dangerous types of ridingand should be avoided if possible. In the event you d

63RIDINGRiding SafelyRiding On Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loosegravel, or during cold freezing weathe

64RIDINGRiding SafelyRiding On Slippery SurfacesWARNINGFailure to exercise care when operating on slippery surfaces canbe dangerous.Loss of tire tract

65RIDINGRiding SafelyTraveling DownhillWhenever descending a hill always:1. Drive directly downhill.2. Transfer your weight to the rear of the vehicle

66RIDINGRiding SafelyTraveling UphillWhenever traveling uphill always travel straight uphill and:1. Avoid steep hills.2. Keep both feet on the footres

4TABLE OF CONTENTSVehicle Identification Numbers 6...Safety 7 - 20...Understanding Warnings 7...

67RIDINGRiding SafelyTurning Around On A HillIf the vehicle stalls while climbing a hill, never back it down thehill! One maneuver which can be used w

68RIDINGRiding SafelyCrossing StreamsYour Polaris 6X6 can operate through water up to maximumrecommended depths reaching the footrests. Before fording

69RIDINGRiding SafelyBacking UpBacking Up1. When backing up, always avoid backing downhill.2. Back slowly.3. When in reverse, apply the brakes lightly

70RIDINGRiding SafelyBacking UpWARNINGBacking your 6x6 can be dangerous!You could hit an obstacle or person behind you; or the vehiclecould tip over o

71RIDINGRiding SafelyTrail ObstaclesKeep Alert!Look ahead and learn to read the trail as you ride. Stay on the rightside of the trail, if possible, an

72RIDINGRiding SafelyParkingOnAnInclineWhenever the Vehicle is Parked1. Place the transmission in gear.2. Set t he parking brake.3. Avoid parking on a

73MAINTENANCE AND LUBRICATIONTool KitTo help you perform routine m aintenance, a tool kit is provided in thestorage compartment under the seat. Items

74MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleCareful periodic maintenance will help keep your vehicle in the safest,most reliable conditi

75MAINTENANCE AND LUBRICATIONPeriodic Maintenance Schedule (Cont.)" More often under severe use, such as dirty or wet conditionsNOTE: Inspection

76MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours orOdometerFrequency RemarksJ Valve Clearance 100 hrs 12 months Inspect/A djustJ F

5TABLE OF CONTENTSMaintenance and Lubrication 73 - 117...Tools 73...Periodic Maintenance Schedule 74...

77MAINTENANCE AND LUBRICATIONLubrication RecommendationsItem Lube Rec. Method Freque nc y*Brake Fluid DOT 3 Only Maintain proper level.See page 40.As

78MAINTENANCE AND LUBRICATIONLubrication RecommendationsDemand 6Hubs - AllWheel DrivePremiumHub LubeRemove set screw in hubs. Ro-tate wheels to 4:00 p

79MAINTENANCE AND LUBRICATIONLubrication RecommendationsFront DriveAxle U JointsGrease + Locate grease fitting and greasewith grease gun.Every 3 month

80MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission LubricationThe transmission fill plug (1) is located on the right side of themach

81MAINTENANCE AND LUBRICATIONLubrication RecommendationsFront Gearcase LubricationThe front gearcase fill plug (3) islocated as shown.The front gearca

82MAINTENANCE AND LUBRICATIONLubrication RecommendationsPremium 4 Synthetic LubricantPolaris Premium 4 All Season S ynthetic engine oil has been speci

83MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter ChangeThe recommended oil change interval is 100 hours, 1000 miles, orevery six

84MAINTENANCE AND LUBRICATIONLubrication Recommendations8. Place shop towels beneath oil filter. Using an oil filter wrench, turnfilter counterclockwi

85MAINTENANCE AND LUBRICATIONPeriodic Maintenance RecordUse the following chart to record periodic maintenance work:MaintenanceIntervalPerformedServic

86MAINTENANCE AND LUBRICATIONEngine Cooling SystemRadiator Coolant Level In-spectionNOTE: This procedure is onlyrequired if the cooling systemhas been

6VEHICLE IDENTIFICATION NUMBERSImportant: Record these numbers from your vehicle in the spacesprovided.1. Frame VIN2. Engine Serial Number (Right fron

87MAINTENANCE AND LUBRICATIONEngine Cooling SystemCoolant LevelThe recovery bottle, located onthe left side of the machine,must be maintained between

88MAINTENANCE AND LUBRICATIONFilter SystemsAir Filter ServiceIt is recommended that the air filter be replaced yearly. When riding inextremely dusty c

89MAINTENANCE AND LUBRICATIONFilter SystemsAir Box DrainPeriodically check the air box drain tube located on the bottom rear ofthe air box and empty i

90MAINTENANCE AND LUBRICATIONAdjustmentsToe AlignmentYou can check the toe alignment of thevehicle using the following method.The recommended toe alig

91MAINTENANCE AND LUBRICATIONAdjustmentsSteering InspectionThe steering assembly of the machine should be checked periodicallyfor loose nuts and bolts

92MAINTENANCE AND LUBRICATIONAdjustmentsFront BrakeFront Wheel and Middle AxleBrakeThe front and middle axlebrakes are hydraulic disc typebrakes which

93MAINTENANCE AND LUBRICATIONAdjustmentsRear BrakeThe transmission brake is ahydraulic disc type brakewhich is activated by the samelever which activa

94MAINTENANCE AND LUBRICATIONAdjustmentsThrottle Cable Free Play AdjustmentThrottle cable free play is adjusted at the handlebar.1. Slide the bolts of

95MAINTENANCE AND LUBRICATIONAdjustmentsWheel Removal Procedure1. Stop the engine, place the transmission in gear and lock the parkingbrake.2. Loosen

96MAINTENANCE AND LUBRICATIONAdjustmentsTire InspectionTire Tread DepthAlways replace tires when tread depth is worn to 1/8″ (.3 cm) or less.CAUTIONMa