Polaris Sportsman Big Boss 6X6 Owner's Manual For Maintenance And Safety
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Polaris Sportsman Big Boss 6X6 Owner's Manual For Maintenance And Safety

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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 Big Boss 6X6

  • Page 1 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 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. 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 PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 POLARIS, SPORTSMAN and BIG BOSS are registered trademarks of POLARIS Industries Inc. Copyright 2012 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 discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

  • Page 7: Table Of Contents

    Specifications ......122 POLARIS Products..... 124 Warranty .

  • Page 8: Introduction

    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. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 9 WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

  • 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

    ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members.

  • Page 12: Safe Riding Gear

    Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 13: Equipment Modifications

    Equipment Modifications We strongly recommend that consumers do not install on a POLARIS vehicle any equipment that may increase the speed or power of the vehi- cle, or make any other modifications to the vehicle for these purposes.

  • 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 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 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: Improper Tire Maintenance

    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 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 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 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: Reverse Override Warning

    SAFETY Safety Labels and Locations Reverse Override Warning General Tire Pressure/Load Warning 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. •...
  • 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 Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7172588 Clutch Cover Warning WARNING •...

  • 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 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: Throttle Lever

    FEATURES AND CONTROLS Throttle Lever WARNING Operating this vehicle with sticking or improperly operating throttle controls could cause an accident. Never start or operate the vehicle if it has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.

  • Page 33: Brake Systems

    FEATURES AND CONTROLS Brake Systems WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. 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 FEATURES AND CONTROLS 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: Fuel Tank Cap

    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 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: All Wheel Drive System

    FEATURES AND CONTROLS 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

    FEATURES AND CONTROLS 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 diagnosis. 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 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 FEATURES AND CONTROLS 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description 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 20 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and lon- ger life for these components.
  • Page 51 OPERATION 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 Ensure proper operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced...

  • Page 53: Safe Operation Practices

    OPERATION 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.

  • Page 56: Driving Procedures

    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 Turn in Sideways direction of skid skid 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.

  • Page 59: Driving Uphill

    OPERATION Driving Uphill 25° Maximum 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

    OPERATION Driving Downhill 25° Maximum 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.
  • 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

    OPERATION 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 Maximum Depth...

  • Page 64: Driving Over Obstacles

    OPERATION 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

    OPERATION 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

    OPERATION 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.

  • Page 68: Dumping Cargo

    OPERATION 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, Latch 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

    Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accor- dance with the USFS standard 5100-1c. Federal law requires that this spark arrester 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 132.

  • Page 72: Periodic Maintenance Chart

    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 “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
  • Page 73 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Air filter, main Weekly Inspect; replace as needed element Brake pad wear 10 H Monthly 60 (100) Inspect periodically Battery 20 H Monthly 125 (200) Check terminals;...
  • Page 74 Inspect periodically; adjust when parts are replaced Auxiliary brake Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

  • Page 75: Lubrication Recommendations

    See page 78. gear lube) ADC Fluid Demand Drive PLUS Fluid See page 80. Front Prop Shaft Yoke POLARIS Premium U-Joint Grease fittings (3 pumps maxi- Lube mum) every 500 miles, before long periods of storage, or after pres- sure washing or submerging...
  • Page 76 POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 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 temperature operation.

  • Page 77: Oil And Filter Change

    7. Reinstall the drain plug. Torque to 14-18 ft. lbs. (19-24 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 MAINTENANCE 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. POLARIS recommends the use of Fill Level Drain Plug POLARIS AGL PLUS Transmis- sion Fluid for this transmission.
  • 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 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 Drain Plug 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 products.
  • Page 83 Periodic Mainte- nance 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.
  • 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: Fluid Change

    MAINTENANCE 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

    Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of 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.

  • 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 MAINTENANCE 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 service.

  • Page 90: Steering Assembly

    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: Tire Tread Depth

    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

    MAINTENANCE Air Filter 1. Remove the seat. Pre-Filter 2. Release the air box cover clips, and remove the air box cover. Main Filter 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 Feature Supported Speedometer Electronic Fuel Injection (Main Fuse) Ignition, Lighting Accessories, 12V Power Receptacle 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.
  • Page 95 MAINTENANCE 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. 25 ft.
  • Page 97 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 down- ward. 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

    MAINTENANCE 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. Harness 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 Torque Specification New Spark Plug 9-11 ft.
  • 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 MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester 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

    • 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: Pvt Operation

    MAINTENANCE PVT System PVT Operation 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 fly- weights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

  • Page 106: Pvt Drying

    MAINTENANCE PVT System PVT Operation The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the tempera- ture inside the clutch cover greatly extends the life of the PVT compo- nents (belt, cover, etc.).
  • Page 107 MAINTENANCE 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

    MAINTENANCE 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

    MAINTENANCE 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

    POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 111 MAINTENANCE 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. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.

  • 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 gar- den 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 MAINTENANCE 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 recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 117 5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protec- tive film of fresh oil. 6. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
  • Page 118 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 materials. They do not allow enough ventilation to prevent condensa- tion, and may promote corrosion and oxidation.

  • Page 119: Transporting The Vehicle

    MAINTENANCE 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 Cable Freeplay

    ADJUSTMENTS 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

    PVT system Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Slippage from failure to...
  • Page 123 Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...
  • Page 124 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...

  • Page 125: Engine Overheating

    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug...

  • Page 126: Specifications

    SPECIFICATIONS SPORTSMAN BIG BOSS 6X6 800 EFI Maximum Weight Capacity 1115 lbs. (507 kg) (includes operator, cargo, accessories) Dry Weight 1047 lbs. (475 kg) Fuel Capacity 4.1 gal. (15.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts. (3.4 l) Demand Drive Fluid Capacity 9.3 oz.
  • Page 127 SPECIFICATIONS SPORTSMAN BIG BOSS 6X6 800 EFI Transmission Automatic PVT with E-Z Shift H/L/N/R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5.11:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 Tires/Pressure, Front 25x8-12 / 7 psi (48.3 kPa) Tires/Pressure, Center 25x11-12 / 10 psi (68.9 kPa)

  • Page 128: Polaris Products

    Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...

  • Page 129: Warranty

    Warranty period will vary regionally. POLARIS also gives a one year limited warranty on the final drive chain (if equipped) 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 130 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 131 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 materi- als, 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 132 WARRANTY 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. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 133 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 134 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 135 POLARIS dealer to perform any service that may be necessary for your vehi- cle. 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 136: 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 137 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 138 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 139: Index

    INDEX 4X4 (AWD) Switch ..26, 34 Clothing ..... . . 9 Clutching.
  • Page 140 INDEX Fluid Lights ..... 91-95 ADC....80-81 Headlight Housing.
  • Page 141 Headlight Switch ... 27 Polaris Product List... . . 124 Main Key Switch ... 27 Polishing the Vehicle .

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