Polaris Sportsman 9922233 Owner's Manual
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Polaris Sportsman 9922233 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Pantone 426 C
Sportsman
Big Boss 6X6
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.

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Summary of Contents for Polaris Sportsman 9922233

  • Page 1 Pantone 426 C Sportsman Big Boss 6X6 Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • Page 2 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 When parking on grades, leave shift in forward. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. Pantone 426 C 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.
  • Page 5 ® • 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 experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 6 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...

  • Page 7: Table Of Contents

    Specifications ......122 Polaris Products..... . . 124 Declaration of Conformity .

  • Page 8: Introduction

    The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols 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.
  • Page 9 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.

  • Page 10: 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.

  • Page 11: Safety

    You should review this information on a regular basis. If you purchased a used Polaris ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.
  • Page 12 Boots 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.

  • Page 13: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever 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.

  • Page 14: Operating Without Instruction

    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.

  • Page 15: Safety Warnings

    Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • 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 refu- eling is performed or where gasoline is stored.

  • Page 16: Protective Apparel

    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).

  • Page 17: Operating On Pavement

    SAFETY 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.

  • Page 18: Turning Improperly

    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.

  • Page 19: Descending Hills Improperly

    Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill.

  • Page 20: Stalling While Climbing A Hill

    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.

  • Page 21: Operating On Steep Hills

    SAFETY 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...

  • Page 22: Skidding Or Sliding

    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.

  • Page 23: Improper Cargo Loading

    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.

  • Page 24: Operating Through Deep Water

    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): •...

  • Page 25: Operating A Damaged Vehicle

    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.

  • Page 26: General Warning

    If an informational or graphic label becomes illegible or comes off, con- tact 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...

  • Page 27: Tire Pressure/Load Warning

    Safety Labels and Locations General Warning Front Rack 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. • Cold tire pressure: Front: 7.0 psi (48.3 kPa) Center: 10.0 psi (68.9 kPa) Rear: 10.0 psi (68.9 kPa)
  • Page 28 SAFETY Safety Labels and Locations Age 16 Warning Container/No Passenger Warning Clutch Cover Warning 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.

  • Page 29: Age 16 Warning

    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. Clutch Cover Warning WARNING •...

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Switches Headlight Switch Switch Main Key Switch Mode/Reverse Override Engine Switch Stop Switch 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.

  • Page 31: Engine Stop Switch

    FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights.
  • Page 32 Engine speed returns to idle when the lever is released. This vehicle is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 33: Brake Systems

    Brake Systems WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the rear brake. Do not aggressively apply the rear brake when going forward.
  • Page 34 FEATURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti- vated disc brakes. Always test brake lever travel and master cylinder fluid level before riding.
  • Page 35 Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.

  • Page 36: Parking Brake

    FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in park. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4.
  • Page 37 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located Gear on the right side of the vehicle. Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

  • Page 38: All Wheel Drive (Awd) System

    FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the 4X4 (AWD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline.

  • Page 39: Engaging Awd

    All Wheel Drive System Engaging AWD The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable AWD until the engine RPM is below 3100. Once enabled, AWD remains enabled until the 4X4 switch is turned off.

  • Page 40: Engaging Active Descent Control

    FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatically engage when all four of the follow- ing conditions occur:...

  • Page 41: Instrument Cluster

    Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation.

  • Page 42: Rider Information Center

    If this occurs, take the vehicle to your Polaris dealer for proper diag- nosis. 1. Gear Indicator - This indicator displays gear shifter position.
  • Page 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the vehicle.

  • Page 44: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
  • Page 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the all- wheel-drive coil.
  • Page 46 Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference.
  • Page 47 Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 45 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • Page 49 Instrument Cluster Rider Information Center Downloading Codes Blink Code BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Throttle Position Sensor Out of Adjustment Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery...

  • Page 50: Operation

    Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.
  • Page 51 Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3.

  • Page 52: Pre-Ride Checklist

    Ensure proper operation Ensure operation Ensure proper operation 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 53: Safe Operation Practices

    Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle.

  • Page 54: Trail Etiquette

    Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your Polaris dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

  • Page 55: Starting The Engine

    Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. OPERATION...
  • Page 56 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

  • Page 57: Turning The Vehicle

    OPERATION Turning the Vehicle Your vehicle is equipped with a solid rear axle, which drives both 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 turn- ing and the inside tire must slip traction slightly.

  • Page 58: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3.

  • Page 59: Driving Uphill

    Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill.
  • Page 60 OPERATION Driving on a Sidehill (Sidehilling) 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 sidehill is unavoidable, follow these precautions: 1.

  • Page 61: Driving Downhill

    Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. Avoid steep hills (25° maximum). 3. Shift body weight uphill. 4. Drive straight downhill. 5.
  • Page 62 OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.

  • Page 63: Driving Through Water

    Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Fol- low these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines.

  • Page 64: Driving Over Obstacles

    Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3.

  • Page 65: Driving In Reverse

    Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.

  • Page 66: Hauling Cargo

    Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: •...
  • Page 67 Never install a hitch longer than 8.25" (21 cm). Never install automotive accessories on your Polaris vehicle. Always install Polaris- approved (or equivalent) accessories designed for use on this vehicle. OPERATION Load cargo as far...

  • Page 68: Dumping Cargo

    Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check cargo distribution. If cargo has shifted to the rear of the box, exercise caution.

  • Page 69: Parking On An Incline

    OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

  • Page 70: Emission Control Systems

    CFR 205) 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 USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 71: Maintenance

    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 134.

  • Page 72: Periodic Maintenance Chart

    Improperly performing the procedures marked with a component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use.
  • Page 73 Periodic Maintenance Chart Item Hours Calendar Air filter, main element Brake pad wear Engine oil change (break-in) Battery ADC fluid Front gearcase (demand drive) oil Middle gearcase oil (if equipped) Rear gearcase oil (if equipped) Transmission oil Engine breather filter (if equipped) General lubrication Shift linkage...
  • Page 74 Spark arrestor 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) Hours Calendar Miles (Km) 100 H...

  • Page 75: Lubrication Recommendations

    Fluid (or GL5 80-90 weight Rear Gearcase Oil gear lube) ADC Fluid Demand Drive Plus Fluid Front Prop Shaft Yoke Polaris Premium U-Joint Lube = Perform more often for vehicles subjected to severe use Lube See page 72. See page 31.

  • Page 76: Engine Oil

    Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera- ture operation.

  • Page 77: Oil And Filter Change

    7. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counter- clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
  • Page 78 Engine Oil Oil and Filter Change 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 11. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn.

  • Page 79: Transmission Oil

    ATV behind the footwell. The drain plug is located on the bottom left side of the gearcase. We recommend the use of Polaris Fill Level Drain Plug Premium AGL Synthetic Gearcase Lubricant. See page 124 for the part numbers of Polaris products.
  • Page 80 Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Chart beginning on page 67. We rec- ommend the use of Polaris Demand Drive Plus Fluid. Use of other fluids may result in improper operation of components. See page 124 for the part numbers of Polaris products.

  • Page 81: Fluid Change

    MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug. 2. Place a drain pan under the demand drive unit. 3. Remove the drain plug. Allow the fluid to drain completely. 4.

  • Page 82: Rear Gearcase Oil

    The drain plug is located on the bottom of the gearcase. We recommend the use of Polaris ATV Angle Drive Fluid (or GL5 80- 90 weight gear lube). See page 124 for the part numbers of Polaris prod- ucts. Oil Check 1.
  • Page 83 Chart beginning on page 67. We recommend the use of Polaris ATV Angle Drive Fluid (or GL5 80-90 weight gear lube). See page 124 for the part numbers of Polaris products. Drain Plug The middle gearcase fill plug is Check/Fill Plug located on the side of the gearcase.
  • Page 84 Periodic Maintenance Chart beginning on page 67. Maintain the fluid level between the minimum and maximum marks on the reservoir. We recommend the use of Polaris Demand Drive Plus Fluid. See page 124 for the part numbers of Polaris products.
  • Page 85 Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).

  • Page 86: Cooling System

    Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant 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 124 for the part numbers of Polaris products.

  • Page 87: Radiator Coolant

    Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair.
  • Page 88 Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.

  • Page 89: Toe Alignment

    1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for ser- vice. MAINTENANCE Stand String...

  • Page 90: Side Panel Removal

    MAINTENANCE Steering Assembly The steering assembly of the vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.

  • Page 91: Wheel Removal

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. Stop the engine. 2. Place the transmission in park.

  • Page 92: Wheel Installation

    MAINTENANCE Tires Wheel Installation 1. Place the transmission in park. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5.

  • Page 93: Air Filter

    Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 94: Fuse Replacement

    MAINTENANCE Fuse Replacement Fuse If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com- partment on the top of the access door.
  • Page 95 Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Upper Headlight Lamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers.

  • Page 96: High Beam Adjustment

    MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in park. 2.

  • Page 97: Low Beam Adjustment

    MAINTENANCE Lights Low Beam Adjustment Phillips Screw The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw.

  • Page 98: Headlight Housing Replacement

    MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.

  • Page 99: Lower Headlamp Replacement

    Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4.

  • Page 100: Spark Plugs

    Refer to the specifications section beginning on page 122 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.
  • Page 101 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white.

  • Page 102: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1.

  • Page 103: Spark Arrestor

    Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves.

  • Page 104: Pvt System

    • 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 105 MAINTENANCE 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 106: Pvt Drying

    PVT System When To Use Low Range and High Range Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h) PVT Drying There may be some instances when water is accidently ingested into the PVT system.
  • Page 107 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. WARNING Battery electrolyte is poisonous.

  • Page 108: Battery Removal

    Battery Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the vehicle. Be careful not to tip a conven- tional battery sideways, which could spill electrolyte.

  • Page 109: Battery Installation

    Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 107 before installing the battery.

  • Page 110: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Polaris recommends maintaining battery charge by using a Polaris Bat- tery Tender charger or by charging about once a month to make up for normal self-discharge.
  • Page 111 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 104. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 112 MAINTENANCE Battery Battery Charging (Sealed Battery) 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 113: Cleaning And Storage

    Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

  • Page 114: Polishing The Vehicle

    Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 115 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 116: Storage Tips

    See page 109. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 117: Fluid Levels

    6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline. MAINTENANCE...

  • Page 118: Battery Maintenance

    Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated mate- rials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 119: Transporting The Vehicle

    Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope.

  • Page 120: Adjustments

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod.
  • Page 121 Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar.

  • Page 122: Troubleshooting

    Dry out the PVT. See page 102. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).
  • Page 123 Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark plugs...
  • Page 124 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...

  • Page 125: Engine Overheating

    Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter...

  • Page 126: Specifications

    500 Watts @ 3000 rpm 10:1 Electric Electronic Fuel Injection 8 BTDC @ 2000 RPM RC7YC / .035 in. (0.9 mm) Pressurized Wet Sump Automatic PVT (Polaris Variable Transmis- sion) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 6.1" (15.5 cm) travel...
  • Page 127 SPORTSMAN BIG BOSS 6X6 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Final Tires/Pressure, Front Tires/Pressure, Center Tires/Pressure, Rear Brakes, Front Brakes, Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Clutching Altitude...

  • Page 128: Polaris Products

    Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Grease / Specialized Lubricants Additives / Miscellaneous 565 Thread Sealant Charger...

  • Page 129: Declaration Of Conformity

    Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive)

  • Page 130: Warranty

    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED 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 (if equipped) for failure due to defects.
  • Page 131 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 132 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 133 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 Registra- tion form to the dealer.
  • Page 134 How to Get Service 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 135 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 136 This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.
  • Page 137 Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 138: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 139 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 140 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 141: Index

    4X4 (AWD) Switch ..26, 34 Accessories ....114 Active Descent Control Fluid . . . 80-81 Active Descent Control System .

  • Page 142: Index

    INDEX Fluid ADC....80-81 Brake ....31 Demand Drive .
  • Page 143 Parking on an Incline ... . 65 Periodic Maintenance Chart ..67-70 Polaris Product List... . . 124 Polishing the Vehicle ... 110 Pre-Ride Checklist .

This manual is also suitable for:

Sportsman 800 big bossSportsman big boss 6x6Sportsman big boss 6x6 800 efi2010 sportsman big boss 6x6 800 efi

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