Polaris 6X6 Owner's Manual For Maintenance And Safety
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Polaris 6X6 Owner's Manual For Maintenance And Safety

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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 5 Copyright 2005 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.

  • Page 6: Table Of Contents

    EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION SPECIFICATIONS POLARIS PRODUCTS TROUBLESHOOTING WARRANTY ........

  • Page 7: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

  • Page 8: Safety

    Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV 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.

  • Page 9: Safety Training

    You should review this information on a regular basis. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

  • Page 10: Operator 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.
  • Page 11 S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate the Sportsman 6x6 without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 12 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.
  • Page 13 S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con- sumer Product Safety Commission at 1-800-638-2772, or call Polaris at 1-800-342-3764.

  • Page 14: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris Sportsman 6x6 any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 15 Sportsman 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 Sportsman 6x6.
  • Page 16 WHAT CAN HAPPEN Sportsman 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.
  • Page 17 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 Sportsman 6x6 on any public street, road or highway, including dirt and gravel roads. WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet, eye protection and protective clothing.
  • Page 18 Turn the vehicle around and remount, following the procedure described in the owner’s manual. See page 62. In the event of an accident, have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes,...
  • Page 19 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The Sportsman 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.
  • Page 20 SAFETY Operator Safety WARNING 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.
  • Page 21 SAFETY Operator Safety WARNING 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.
  • Page 22 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 Sportsman 6x6 on hills steeper than 15_. Practice on small hills before attempting larger hills.
  • Page 23 SAFETY Operator Safety WARNING 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.
  • Page 24 Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the Sportsman 6x6 around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 62. Use extra caution when turning on any hill.
  • Page 25 SAFETY Operator Safety WARNING 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.
  • Page 26 SAFETY Operator Safety WARNING 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.
  • Page 27 HOW TO AVOID THE HAZARD Never modify the Sportsman 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.
  • Page 28 SAFETY Operator Safety WARNING 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. WARNING POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs.
  • Page 29 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING Operating a damaged ATV can result in an accident with serious injury or death.

  • Page 30: Safety Decals And Locations

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 31 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 WARNING REPLACEMENT. 15°...
  • Page 32 NEVER operate this vehicle if you are under age 16. 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.
  • Page 33 SAFETY Safety Decals and Locations TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG) (on hitch) S Operation of this vehicle without the filter element will severely damage the engine.

  • Page 34: Safe Riding Gear

    Safe Riding Gear Always wear clothing suited to the type of riding. ATV 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.

  • Page 35: Features And Controls

    FEATURES AND CONTROLS 1. Service Brake Lever 2. Middle Axle Auxiliary Brake Lever 3. Throttle Lever 4. Box Dump Latch Release 5. Gear Selector 6. Floorboards 7. Backrest 8. Cargo Box 9. Front Rack...
  • Page 36 Electrical Switches and Indicators 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main switch is on. WARNING 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.

  • Page 37: Throttle Lever

    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.

  • Page 38: Service Brakes

    Brakes The braking system is controlled by the two brake levers located on the handlebars, directly in front of each handgrip. Service Brakes The service brake lever (1) is located on the left handlebar. This lever controls both front and rear wheel braking action. Use this lever for normal braking.

  • Page 39: Master Cylinders

    If the fluid level is low, add DOT 3 brake fluid. DO NOT OVERFILL. See page 116 for the part numbers of Polaris products. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.

  • Page 40: Parking Brake

    Parking Brake WARNING 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. Setting the Parking Brake 1. Squeeze and release the left brake lever two or three times, then squeeze and hold.

  • Page 41: Fuel Tank

    FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. There’s about a 7 to 10 mile (11.2 to 16 km) range on the reserve supply.

  • Page 42: Gear Selector

    Gear Selector The transmission gear selector (1) 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.

  • Page 43: Recoil Starter

    The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.
  • Page 44 Recoil Starter 5. Allow the recoil rope to rewind into the recoil assembly, then pull the rope abruptly and forcefully to start the engine. 6. Repeat steps 4-5 if necessary. CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly.
  • Page 45 FEATURES AND CONTROLS All Wheel Drive (AWD) System The Polaris Sportsman 6x6 is equipped with a unique AWD system activated by the AWD 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.

  • Page 46: Disengaging Wheel Hubs

    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.

  • Page 47: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph.

  • Page 48: Rider Information Center

    If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As the shift lever is moved, this indicates the...
  • Page 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button.

  • Page 50: Diagnostic Mode

    Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.
  • Page 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours.

  • Page 52: Operation

    Fuel Safety WARNING 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 en- gine 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.

  • Page 53: Break-In Period

    OPERATION Break-in Period The break-in period for your new Polaris Sportsman 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.
  • Page 54 Check condition / slack, lubricate as needed Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Check condition and operation of the...

  • Page 55: Starting A Cold Engine

    OPERATION Starting a Cold Engine WARNING Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

  • Page 56: Starting A Warm Engine

    Starting a Warm Engine Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral.

  • Page 57: Hauling Cargo

    OPERATION Hauling Cargo Your Sportsman 6x6 has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings on the warning labels. Never exceed the specified weights. WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability.

  • Page 58: Dumping Cargo

    Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. 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 box release lever forward. 5.

  • Page 59: Driving Safely

    OPERATION Driving Safely Load Distribution 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 54. 2. Always load the cargo box with the load (1) as far forward as possible.

  • Page 60: Driving Procedures

    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.

  • Page 61: Making Turns

    Making Turns Practice making turns at slow speeds. The Sportsman 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.
  • Page 62 Driving Safely Sidehilling WARNING 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. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.

  • Page 63: Driving Downhill

    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 to aid in slowing. WARNING Hard use of the braking system while descending a hill could result in a front-end overturn, causing serious injury or death.

  • Page 64: Driving Uphill

    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.

  • Page 65: Turning Around On A Hill

    OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8’ (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.

  • Page 66: Driving On Slippery Surfaces

    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.

  • Page 67: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your Sportsman 6X6 can operate through water with a maximum recommended depth equal to the footrests (1). 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.

  • Page 68: Driving In Reverse

    Driving Safely Driving in Reverse 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.

  • Page 69: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Place the transmission in gear and set the parking brake. 2. Always block the rear wheels on the downhill side. See illustration.

  • Page 70: Driving Over Obstacles

    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. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 71: Emission Control Systems

    CFR 205.158) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 72: Maintenance And Lubrication

    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.

  • Page 73: Periodic Maintenance Chart

    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. Record maintenance and service in the Maintenance Log beginning on page 130.

  • Page 74: Maintenance Chart Key

    Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death.
  • Page 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Hours Calendar Brake pad wear " Battery Front gearcase oil " (if equipped) Middle gearcase " oil (if equipped) Rear gearcase oil " (if equipped) Transmission oil " Engine breather " filter (if equipped) Engine oil change "...
  • Page 76 Toe adjustment Auxiliary brake " Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 620 (1000) 12 M...

  • Page 77: Lubrication Recommendations

    Maintenance Chart Key More often under severe use, such as wet or dusty conditions " Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2 Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.
  • Page 78 MAINTENANCE AND LUBRICATION Lubrication Recommendations (Loc. 1) (Loc. 9) (Loc. 6) (Loc. 5) (Loc. 2) (Loc. 7) (Loc. 4) (Loc. 3) (Loc. 8)

  • Page 79: Oil Change

    Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill hole threads. Polaris recommends the use of Premium AGL Synthetic Gearcase Lubricant. See page 116 for the part numbers of Polaris products.

  • Page 80: Front Gearcase Lubrication

    Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill plug threads. Polaris recommends the use of Premium ATV Angle Drive Fluid. See page 116 for the part numbers of Polaris products.

  • Page 81: Premium 4 Synthetic Lubricant

    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. See page 116 for the part numbers of Polaris products.

  • Page 82: Oil Level

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil Level 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.

  • Page 83: Oil And Filter Change

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage.
  • Page 84 13. After draining, reinstall the drain plug. 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.

  • Page 85: Engine Cooling System

    Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 116 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations...

  • Page 86: Recovery Bottle Coolant Level

    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 93. Maintain the coolant level between the minimum and maximum marks on the recovery bottle.

  • Page 87: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service Always inspect and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. 1. Remove the seat. 2. Remove the spring clamps securing the air box lid and remove the lid.

  • Page 88: Air Box Drain

    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 Always inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70.

  • Page 89: Toe Alignment

    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. Toe Alignment Use the following procedure to check the toe alignment of the vehicle.

  • Page 90: Steering Inspection

    A gap of up to 1/8” will remain at the rear bolts. Optional Suspension Springs Although the Polaris Sportsman 6x6 suspension has the capability of providing the best ride possible, the following accessory springs are available to better suit individual riding preferences.

  • Page 91: Front Brake

    MAINTENANCE AND LUBRICATION Adjustments Front Brake Front Wheel and Middle Axle Brake The front and middle axle brakes are hydraulic disc brakes and are activated by moving the brake lever toward the handlebar. These brakes are self-adjusting and require no adjustment. The following checks are recommended to keep the brake system in good operating condition.

  • Page 92: Rear Brake

    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 93 MAINTENANCE AND LUBRICATION Adjustments Front Drive Chain Adjustment CAUTION Operating the vehicle with the drive chain slack out of specification could cause serious damage to the transmission and drive components. Never operate the vehicle with the drive chain slack out of specification. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the...
  • Page 94 MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment To adjust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. Total slack for the rear chain should be adjusted to 3/8″-1/2″...

  • Page 95: Oil Pump Priming

    MAINTENANCE AND LUBRICATION Adjustments Carburetor 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.

  • Page 96: Side Panel Removal

    MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 3.

  • Page 97: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. Place the transmission in gear and lock the parking brake.

  • Page 98: Tire Tread Depth

    MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. 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.

  • Page 99: Tire Specifications

    Front Wheel Nuts Center and Rear Axle Nut(s) Center and Rear Wheel Nuts Tire Specifications Polaris Sportsman 6x6 Front - 25 x 8 - 12 Inflation Pressure - 5 PSI Center - 25 x 11 - 12 Inflation Pressure - 5 PSI...

  • Page 100: Spark Plugs

    S Spark plug torque is 14 ft. lbs. (1.9 kg/m) CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. 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.

  • Page 101: Pvt System

    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

  • Page 102: Pvt Drying

    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.

  • Page 103: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor 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.

  • Page 104: Recoil Housing

    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.

  • Page 105: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING 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.

  • Page 106: Battery Charging

    MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging.
  • Page 107 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action charger @ standard amps specified on top of battery)

  • Page 108: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Don’t service the headlamps until they’ve cooled sufficiently.

  • Page 109: High Beam Headlight Adjustment

    Operating the vehicle on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your Sportsman 6x6 is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only.

  • Page 110: Headlight Housing Replacement

    MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the Phillips screws from the bottom of the headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to the left or right and use a very short screwdriver.
  • Page 111 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1). Apply dielectric grease to the socket and install the new lamp.

  • Page 112: Cleaning And Storage

    If warning and safety labels are damaged, contact your a Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 113: Fluid Levels

    5. Treat the fuel system with Polaris Carbon Clean. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.

  • Page 114: Storage Tips

    Test engine coolant strength and change if necessary. Replace coolant every two years. Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the maintenance section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease.
  • Page 115 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. 1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime.

  • Page 116: Transporting The Vehicle

    MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting the Vehicle Follow these procedures before transporting the vehicle with another unit. 1. Turn off the engine and remove the key to avoid loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap and oil cap are installed correctly.

  • Page 117: Specifications

    Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC SPORTSMAN 6x6 1965 lbs. (891 kg)(vehicle, driver, cargo) 4.25 gallons (16.09 liters) 150 lbs. (68.1 kg) 1500 lbs. (681 kg) 1900 lbs. (863 kg) 75 lbs.

  • Page 118: Jetting Chart

    0-1800 (Feet) (0-6000) (PN 5630513) 1800-3700 (6000-12000) (PN 5630710) SPECIFICATIONS SPORTSMAN 6x6 Automatic PVT (H/L/N/R) 6.69/1 5.17/1 3.34/1 12/38 80P 25 x 8 - 12 (5 psi) 25 x 11 - 10 (5 psi) 25 x 11 - 10 (5 psi)

  • Page 119: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (qt.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) Premium ATV Angle Drive Fluid (8 oz.)

  • Page 120: Troubleshooting

    Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline...
  • Page 121 Turn the fuel valve on Replace with new fuel Inspect plug(s), replace if necessary Inspect plug(s), verify stop switch is on Immediately see your Polaris dealer Inspect, clean and/or replace spark plugs Replace the filter Recharge battery to 12.8 VDC...
  • Page 122 TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...

  • Page 123: Engine Overheating

    Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...

  • Page 124: Warranty

    LIMITED WARRANTY on all components of the Polaris Light Utility Vehicle against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.

  • Page 125: Engine Oil

    HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
  • Page 126 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 127 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...

  • Page 128: Limited Warranty

    Manufacturer’s Warranty Coverage: The 2006 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner’s Warranty Responsibilities: S As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Own-...
  • Page 129 During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.

  • Page 130: Maintenance Schedule

    When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
  • Page 131 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed.
  • Page 132 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 133: Maintenance Log

    MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 134 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 135: Index

    INDEX Accessories ....Adjustments ....Age Restrictions .
  • Page 136 Parking on an Incline ... . Periodic Maintenance Chart Polaris Products ....Pre Ride Inspection ....

This manual is also suitable for:

2005 sportsman 6x6

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