Polaris Sportsman 6x6 User Manual

7VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers and key number in thespaces provided. Remove the spare key and store it in a s

97MAINTENANCE AND LUBRICATIONSpark PlugsS Use NGK BKR5E spark plugs.S Proper electrode gap i s .036″ (.9 mm)S Spark plug torque is 14 ft. lbs. (1.9 kg

98MAINTENANCE AND LUBRICATIONPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As e

99MAINTENANCE AND LUBRICATIONPVT SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or death.Do not modif

100MAINTENANCE AND LUBRICATIONSpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious in

101MAINTENANCE AND LUBRICATIONRecoil Hou singWater will enter the recoil housing ifthe starter handle is disengaged fromthe rope or if the handle is n

102MAINTENANCE AND LUBRICATIONBatteryWARNINGImproperly connecting or disconnecting battery cables can resultin an explosion and cause serious injury o

103MAINTENANCE AND LUBRICATIONBatteryBattery StorageWhen the vehicle is placed in storage for three months or more, thebattery should be removed, stor

104MAINTENANCE AND LUBRICATIONBatteryBattery ChargingNOTE: Always verify battery condition before and 1-2 hours after theend of charging.State ofCharg

105MAINTENANCE AND LUBRICATIONLightsWARNINGPoor lighting while driving can result in severe injury or death.Headlight and taillight lenses become dirt

106MAINTENANCE AND LUBRICATIONLightsWARNINGOperating the vehicle on streets or roads, especially in darkness,could result in an accident and serious i

8SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals on the

107MAINTENANCE AND LUBRICATIONLightsHeadlight Housin g Replacement1. Remove the Phillips screws from the bottom of the headlight podat each front corn

108MAINTENANCE AND LUBRICATIONLightsTaillig ht/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp m ay need to bereplaced.1

109MAINTENANCE AND LUBRICATIONCleaning and StorageSee page 113 for the part numbers of Polaris products.Cleaning the ATVKeeping your ATV clean will no

110MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsIf your vehicle will be placed in extended or off season storage,perform all necessary r

111MAINTENANCE AND LUBRICATIONCleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion,preserve

112MAINTENANCE AND LUBRICATIONPeriodic Maintenance RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingD

113POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)2871844 Premium 4 Synthetic 0W-40 (

114SPECIFICATIONSSPORTSMAN 6x6Gross Vehicle Weight 1965 lbs. (891 kg)(machine, driver, cargo)Fuel Capacity 4.25 gallons (16.09 liters)Hitch Tongue Cap

115SPECIFICATIONSSPORTSMAN 6x6Transmission Automatic PVT (H/L/N/R)Gear Reduc tion - Low 6.69/1Gear Reduc tion - Reverse 5.17/1Gear Reduc tion - High 3

116TROUBLESHOOTINGContact your P olaris dealer for service if you’re unable to identifysolutions using the following charts.Drive Belt and Cover Probl

9SAFETYSafety Decals and LocationsImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER:DOperate on public roads. A collision can occur with

117TROUBLESHOOTINGEngine Doesn’t Turn OverPossible Cause SolutionLow battery voltage Recharge battery to 12.8 VDCLoose battery connections Check all c

118TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

119TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut o f fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line In

120WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTHLIMITED WARRANTY on all components of the Polaris L

121WARRANTYThis warranty does not cover the use of unauthorized lubricants, chemicals, or fuels thatare not compatible with the vehicle. The exclusive

122WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THEREIS NO WARRANTY OR SERVICE BULLETIN COVERAGE ONTHIS VEHICLE IF IT IS SOLD O

123WARRANTYExported VehiclesHow t o Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of t

124WARRANTYCalifornia Emission Control Warranty StatementYour Warranty Rights and ObligationsThe California Air Resources Board and Polaris Industries

125WARRANTYCalifornia Emission Control Warranty StatementWarranty PeriodThis warranty period begins on the date, which the LSI engine is delivered, to

126WARRANTYCalifornia Emission Control Warranty StatementWhat is Not Covered Under This WarrantyThis warranty does not cover any emission-related part

10SAFETYSafety Decals and Locations4568ETCThis vehicle is equipped with aPolaris Electronic Throttle Control(ETC) to reduce the risk of a stuck or“fro

127WARRANTYCalifornia Emission Control Warranty StatementMaintenance ScheduleItem Maintenance Interval(whichever comes first)RemarksHours Calendar Mil

128WARRANTYCalifornia Emission Control Warranty StatementRepair and Replacement of Emission-Related PartsIt is recommended that only LSI engine replac

129INDEXAAccessories 69...Adjustments 86-94...Age Restrictions 13...Air Box Drain 85...Air

130INDEXMMain Switch 34...MAINTENANCE ANDLUBRICATION 69-112...Maintenance Record 112...Making Turns 58...

11SAFETYSafety Decals and Locations(on hitch)ATTENTIONS Operation of this vehicle without thefilter element will severely damagethe engine.S Clean air

12SAFETYSafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce th

13SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy

14SAFETYOperator SafetyThe following signal words and s ymbols appear throughout thismanual and on your vehicle. Your safety is involved when these wo

15SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further

16SAFETYOperator SafetyS Always have the vehicle inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hill

A card containing important ATV safety information should be attachedto the owner’s manual on the next page. If you cannot locate this card,or if it h

17SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test your brakes af-ter leaving water. If necessary, apply t hem lightly severa

18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly incre

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on a Sportsman 6x6.WHAT CANHAPPENCarrying a passenger greatly reduces the operator’

20SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle on public streets, roads or highways.WHAT CANHAPPENThe vehicle could collide with

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling or rolling backwards while climbing a hill.WHAT CANHAPPENStalling or rolling while climbing a h

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the Sportsman 6x6 at excessive speeds.WHAT CANHAPPENExcessive speed increases the operator’s c

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrestsduring operation.WHAT CANHAPPENRemoving eve

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extra caution when operating on excessively rough,slippery or loose terrain.WHAT CANHAPPE

25SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on excessively steep hills.WHAT CANHAPPENThe vehicle may overturn and cause serious injury or

26SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT raveling downhill improperly.WHAT CANHAPPENImproperly descending a hill could cause loss of control or

27SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly crossing or turning on hills.WHAT CANHAPPENImproperly crossing or turning as hills could caus

28SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control or overturn.

29SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the vehicle through deep or fast-flowing water.WHAT CANHAPPENT ires may float, causing loss of

30SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this vehicle with improper tires or with improper oruneven tire pressure.WHAT CANHAPPENUse of

31SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on frozen bodies of water.WHAT CANHAPPENSevere injury or death can result if the vehicle and/o

32SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always

33FEATURES AND CONTROLS1. Service Brake Lever2. Middle Axle Auxiliary Brake Lever3. Throttle Lever4. Box Dump Latch Release5. Gear Selector6. Floorboa

34FEATURES AND CONTROLSElectrical Switches and Indicators1. Light Switch/Hi-Lo Beam Control - The lights won’t t urn onunless the main switch is on.WA

35FEATURES AND CONTROLSThrottle LeverWARNINGDo not start or operate a vehicle with sticking or improperlyoperating throttle controls. Doing so could c

36FEATURES AND CONTROLSBrakesThe braking system is controlled by the two brake levers located on thehandlebars, directly in front of each handgrip.Ser

37FEATURES AND CONTROLSBrakesMaster Cylind ersThe master cylinders (1) are locatedon the left and right handlebars.Check fluid levels before each use

38FEATURES AND CONTROLSParking BrakeWARNINGOperating the vehicle while the parking brake is engaged couldresult in an accident and serious injury or d

39FEATURES AND CONTROLSFuel ValveThe fuel valve (1) is located on the left sidepanel. It has three positions:OFF: F or vehicle storage and when transp

40FEATURES AND CONTROLSGear SelectorThe transmission gear selector (1)is located on the right side ofthe vehicle directly above andforward of the engi

41FEATURES AND CONTROLSRecoil StarterIf the battery has been drained ordamaged and cannot start theengine, use of the recoil starter (1)will allow veh

42FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemThe Polaris S portsman 6x6 is equipped with a unique AWD systemactivated by the AWD switch (1) on t

43FEATURES AND CONTROLSAll Wheel Drive (AWD) SystemDisengaging Wheel HubsThe hubs normally disengage when operating in reverse. However, oneor both hu

44FEATURES AND CONTROLSInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehiclespeed from the right front wheel. The inst

45FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. Allsegments will l

46FEATURES AND CONTROLSInstrument ClusterRider Information CenterThe rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - Tripmeter

2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeThe diagnostic mode is for informational purposes only. Please returny

48FEATURES AND CONTROLSInstrument ClusterRider Information CenterDiagnostic ModeScreen 5: P rogrammable service intervalThe purpose of t he programmab

49OPERATIONFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling ga

50OPERATIONVehicle Break-in PeriodThe break-in period for your new Polaris S portsman 6x6 is defined asthe first ten hours of operation or the time it

51OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

52OPERATIONStarting a Cold EngineWARNINGCarbon monoxide exhaust gas is poisonous and can causesevere injury or death. Never run an engine in an enclos

53OPERATIONStarting a W arm EngineWarm engines do not normally require the use of the choke. Excessiveuse of t he choke can cause the spark plug to be

54OPERATIONHauling CargoYour Sportsman 6x6 has been designed to carry or tow a certainamount of load. Always read and understand the load distribution

55OPERATIONHauling CargoDumping Cargo1. Select a level site to dump the cargo box. Do not attempt to dumpor unload t he vehicle while parked on an inc

56OPERATIONDriving SafelyLoad Distribution1. Never exceed the maximum capacities for hauling cargo as statedon the load distribution warning labels an

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

57OPERATIONDriving SafelyDriving Procedures1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. After starting the engine

58OPERATIONDriving SafelyMaking Tu rnsPractice making turns at slow speeds.The Sportsman 6x6 is equipped with a solid rear axle that drives allrear wh

59OPERATIONDriving SafelySidehillingWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting i

60OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Drive directly downhill.2. Transfer your weight to th

61OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills.3. Ke

62OPERATIONDriving SafelyTurning Around on a HillWARNINGImproper hill climbing procedures could cause loss of control oroverturn and result in serious

63OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever operating on slippery surfaces, such as wet trails or loosegravel, or during freezing we

64OPERATIONDriving SafelyDriving Through WaterYour Sportsman 6X6 can operate through water with a maximumrecommended depth equal to the footrests (1).

65OPERATIONDriving SafelyDriving in ReverseThis vehicle is equipped with a reverse speed limiter. The overridebutton should be used with caution as re

66OPERATIONDriving SafelyParkingOnAnInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Place the transmis

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67OPERATIONDriving SafelyDriving Over ObstaclesKeep alert! Look ahead and learn to read the terrain you’re travelingon. Be constantly alert for hazard

68EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with s

69MAINTENANCE AND LUBRICATIONTool KitTo help you perform routine maintenance, a tool kit is provided in thestorage compartment under t he seat. Items

70MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition.

71MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interv

72MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"EEngine br

73MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)JEFuel system 10

74MAINTENANCE AND LUBRICATIONLubrication RecommendationsLubricate all components at t he intervals outlined in the PeriodicMaintenance Chart beginning

75MAINTENANCE AND LUBRICATIONLubrication RecommendationsA(Loc. 1)(Loc. 2)(Loc. 3)(Loc. 4)(Loc. 5)(Loc. 6)(Loc. 7)(Loc. 8)(Loc. 9)

76MAINTENANCE AND LUBRICATIONLubrication RecommendationsTransmission LubricationAlways check and change thetransmission lubricant at theintervals outl

5TABLE OF CO NTENTSWELCOME 3...VEHICLE IDENTIFICATION NUMBERS 7...SAFETY 8...FEATUR

77MAINTENANCE AND LUBRICATIONLubrication RecommendationsFront Gearcase LubricationAlways check and change thefront gearcase oil at the intervalsoutlin

78MAINTENANCE AND LUBRICATIONLubrication RecommendationsPremium 4 Synthetic LubricantPolaris Premium 4 All Season Synthetic engine oil has been specia

79MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil LevelThe oil tank is located on the left side of the vehicle. To check the oil:1. Position

80MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter ChangeCAUTIONHot oil can cause serious burns to skin. Do not allow hot oil toco

81MAINTENANCE AND LUBRICATIONLubrication RecommendationsOil and Filter Change7. Place shop towels beneaththe oil filter. Using an oilfilter wrench, tu

82MAINTENANCE AND LUBRICATIONEngine Cooling SystemCoolantTo ensure that the coolant maintains its ability to protect the engine, werecommend that the

83MAINTENANCE AND LUBRICATIONEngine Cooling SystemRecovery Bottle Coolant LevelThe recovery bottle (1) is located onthe left side of the vehicle. To a

84MAINTENANCE AND LUBRICATIONFilter SystemsAir Filter ServiceAlways inspect and replace the air filter at the intervals outlined in thePeriodic Mainte

85MAINTENANCE AND LUBRICATIONFilter SystemsAir Box DrainPeriodically check the air box drain tube located on the bottom rear ofthe air box. Empty the

86MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGSevere injury or death can result from improper toe alignment andadjustment. Do not attempt to adjust t

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87MAINTENANCE AND LUBRICATIONAdjustmentsSteering InspectionThe steering assembly of the vehicle should be checked periodically forloose nuts and bolts

88MAINTENANCE AND LUBRICATIONAdjustmentsFront BrakeFront Wheel and Middle Axle BrakeThe front and middle axle brakes are hydraulic disc brakes and are

89MAINTENANCE AND LUBRICATIONAdjustmentsRear BrakeThe transmission brake is a hydraulicdisc brake and is activated by the samelever that activates the

90MAINTENANCE AND LUBRICATIONAdjustmentsFront Drive Chain AdjustmentCAUTIONOperating the vehicle with the drive chain slack out ofspecification could

91MAINTENANCE AND LUBRICATIONAdjustmentsRear Axle Drive Chain AdjustmentTo adjust the rear axle drive chain, loosen the rearmost eccentriclocking bolt

92MAINTENANCE AND LUBRICATIONAdjustmentsCarburetorIMPORTANT: Your Polaris ATV is calibrated at the factory foroptimal performance at altitudes ranging

93MAINTENANCE AND LUBRICATIONAdjustmentsSide Panel Removal1. Remove the seat.2. Grasp the rear of the sidepanel near the rear cab. W itha quick and fi

94MAINTENANCE AND LUBRICATIONAdjustmentsWheel Removal1. Stop the engine, place the transmission in gear and lock theparking brake.2. Loosen the wheel

95MAINTENANCE AND LUBRICATIONT ire Tread DepthAlways replace tires when treaddepth is worn to 1/8″ (.3 cm) or less.WARNINGOperating the vehicle with w

96MAINTENANCE AND LUBRICATIONT ire SpecificationsTire SpecificationsPolaris Sportsman 6x6Front - 25 x 8 - 12Inflation Pressure - 5 PSICenter-25x11-12I