Polaris PTV 6x6 SERIES 10 Owner's Manual
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Polaris PTV 6x6 SERIES 10 Owner's Manual

Polaris PTV 6x6 SERIES 10 Owner's Manual

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Summary of Contents for Polaris PTV 6x6 SERIES 10

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 4 All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

  • Page 5: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) 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 vehicle we’ve ever produced.

  • Page 6: Vehicle Identification Numbers

    NOTE: Record your vehicle’s ID numbers in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with an existing key. NOTE: If both keys are lost, see your dealer for ignition switch replacement.

  • Page 7: Table Of Contents

    ....... . POLARIS RECOMMENDED PRODUCTS ...

  • Page 8: Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris PTV 6x6 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 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 10 S Never operate the PTV 6x6 without proper instruction. Take a train- ing 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 11 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 12 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes af- ter leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the vehicle before oper- ating in reverse.

  • Page 13: 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 PTV 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 14 PTV 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 PTV 6x6.
  • Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on a PTV 6x6. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the vehicle, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD 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 PTV 6x6 on any public street, road or highway, including dirt and gravel roads.
  • Page 17 Turn the vehicle around and remount, following the procedure described in the owner’s manual. See page 59. 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 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the PTV 6x6 at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator’s chance of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the vehicle at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle before each use to make sure it’s in safe operating condition.
  • Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the vehicle could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
  • 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 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual.
  • Page 23 SAFETY Operator Safety WARNING 15° Maximum POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual beginning on page 57. Always check the terrain carefully before ascending any hill.
  • Page 24 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 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing or turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the PTV 6x6 around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 26 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 27 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 28 Never modify the PTV 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. See...
  • Page 29 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. If it’s unavoidable, confirm that the ice is thick enough and sound enough to support the vehicle and its operator, as well as the force created by a moving vehicle.
  • Page 30 Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal. WARNING DO NOT TOW FROM RACK OR BUMPER.
  • 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 REPLACEMENT.
  • Page 32 AWD Models The Operator is responsible for the safe operation of this vehicle. This vehicle is equipped with a Polaris Electronic Throttle Control 7170572 (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 WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
  • Page 34 SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well ventilated area with the engine stopped. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 35 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. PTV 6x6 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.

  • Page 36: Features

    FEATURES Component Locations 1. Service Brake Lever 2. Middle Axle Auxiliary Brake 3. Throttle Lever 4. Bed Dump Latch Release 5. Gearbox Shift Lever 6. Floorboards 7. Backrest 8. Cargo Bed 9. Front Rack...
  • Page 37 FEATURES All Wheel Drive (AWD) System The Polaris PTV 6x6 is equipped with a unique Polaris exclusive Demand 6 Drive (AWD) system that’s activated by a switch (1) on the right handlebar. When the switch is off, the vehicle is in rear wheel drive at all times.
  • Page 38 FEATURES 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 39: Controls

    CONTROLS Electrical Switches and Indicators 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. 1 Override Switch (Reverse Speed Limiter) This vehicle is equipped with a reverse speed limiter system.
  • Page 40 CONTROLS Electrical Switches and Indicators With the engine running, verify the function of all indicator lights before every use of the vehicle. 1 Light Switch/Hi-Lo Beam Control The lights won’t turn on unless both the main switch and the engine stop switch are on.
  • Page 41 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 42: Service Brakes

    CONTROLS Brakes The braking system is controlled by two levers located on the handlebars, directly in front of the handgrips. Service Brakes The service brake lever (1) (front wheel and transmission) is located on the left handlebar. This lever controls braking action to all six wheels. Use this system for normal braking.
  • Page 43 CONTROLS Brakes Master Cylinders The master cylinders (1) are located on the left and right handlebars. Fluid levels should be checked before each ride. The fluid level can be seen through the indicator window (2) on the top of the master cylinder.

  • Page 44: Parking Brake

    CONTROLS 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 brake lever (1) two or three times, then squeeze and hold.
  • Page 45 CONTROLS Engine Fuel and Oil System The fuel tank filler cap (1) is located directly behind the handlebar. Tank capacity is 4.25 U.S. gallons (16 liters) with 1/2 gallon (1.9 liters) in reserve. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 (R+ M/2) octane.

  • Page 46: Belt Life

    CONTROLS Gear Selector Operation The transmission gear selector 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 47 CONTROLS Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. 1. Position the vehicle on a level surface and engage the parking brake.

  • Page 48: Operation

    OPERATION Break-in Period The break-in period for your new Polaris PTV 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 49 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not performed before each use of the vehicle, severe injury or death could result. Inspect the vehicle before each use to ensure it’s in proper working condition. Use the following checklist to verify that your vehicle is in proper working condition before each use.

  • Page 50: 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 51: Starting A Warm Engine

    OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke. Using 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 52: Hauling Cargo

    OPERATION Hauling Cargo Your PTV 6x6 has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following weights. Maximum Capacities Front Rack Cargo Bed (Level Ground) Cargo...
  • Page 53 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo bed. 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 bed release lever forward. 5.

  • Page 54: Driving Safely

    OPERATION Driving Safely Load Distribution Maximum Cargo Bed PTV 6x6 800 lbs. (363 kg) Maximum Front Rack 75 lbs. (34 kg) 1. Always load the cargo bed with the load as far forward as possible. 2. Always operate the vehicle with extreme caution whenever hauling or towing loads.
  • Page 55 OPERATION 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 56 OPERATION Driving Safely Making Turns Practice making turns at slow speeds. The PTV 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 57 OPERATION Driving Safely Driving Across Hills 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 58: Driving On Slippery Surfaces

    OPERATION 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 59: 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 60: Driving Uphill

    OPERATION Driving Safely Driving Uphill 15_ Maximum 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 61 OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (15_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.

  • Page 62: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your PTV 6X6 can operate through water with a maximum recommended depth equal to the footrests. Follow these procedures when operating through water : 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3.

  • Page 63: 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. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration.

  • Page 64: Driving In Reverse

    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6.
  • Page 65 OPERATION Driving Safely Driving in Reverse WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it’s safe to proceed, back slowly. Do not use the override switch unless additional power is required for vehicle movement.

  • Page 66: Driving Over Obstacles

    OPERATION 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 67: Noise Emission Control System

    NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or...

  • Page 68: 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 69: Periodic Maintenance Schedule

    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. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
  • Page 70 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. NOTE: When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.
  • Page 71 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or Frequency Remarks Odometer Engine oil 6 months Check level daily; break-in service at one " hrs/1000 month; change oil more often in cold weather miles Oil filter 6 months Replace with oil change hrs/1000 miles Coolant...

  • Page 72: Lubrication Recommendations

    NOTE: Hours are based on 10 mph average. Maintenance Chart Key " More often under severe use, such as wet or dusty conditions L 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 73 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 74 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 75: Transmission Lubrication

    2. View the oil level and add oil if needed. Oil should be kept at the bottom of the fill plug thread. NOTE: Use Polaris Premium Synthetic Gearcase Lubricant in the transmission. See page 108 for a list of Polaris-recommended products.
  • Page 76 Oil should be kept at the bottom of the fill plug thread. Add Premium Front Gearcase Fluid if needed. See page 108 for a list of Polaris-recommended products. 3. Replace the fill plug. Gearcase Oil Changing Procedure 1. Remove the fill plug.
  • Page 77 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.
  • Page 78 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. The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first.
  • Page 79 Season synthetic oil or API certified “SH” oil, 0-40W. Never substitute or mix oil brands. Use only 0-40W. 12. Remove the dipstick (2) and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil. Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts initially.
  • Page 80 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person 10 hrs. 20 hrs. 50 hrs. 100 hrs.

  • Page 81: Radiator Coolant Level

    Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water (see page 108). Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your...
  • Page 82 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water (see page 108). Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.
  • Page 83 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service Polaris recommends that the air filter be replaced annually. When riding in extremely dusty conditions, replace it more often. 1. Remove the seat. 2. Remove the spring clamps securing the air box lid and remove the lid.
  • Page 84 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 Inspect the filter monthly or after every 20 hours of operation, whichever comes first.
  • Page 85 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 86: Steering Inspection

    NOTE: Optional springs may be a different color than standard springs. Springs may be painted to a desired color using Polaris touch up paint, available through Polaris dealers. SOFT...
  • Page 87 ″ whenever the cover is loosened (.1cm) or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness.
  • Page 88 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.
  • Page 89 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 adjust or operate the vehicle with the drive chain slack out of the 3/16″-3/8″ (.48 cm - .95 cm) specification. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at...
  • Page 90 MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment All procedures used in adjusting the front chain apply to the rear chain adjustment. Total slack for the rear chain, however, should be adjusted to 1/4″-1/2″ (.6-1.3 cm). 3/16″-3/8″ (.48 cm - .95 cm) 1/4″-1/2″...
  • Page 91 NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. NOTE: Pilot screws are sealed with metal plugs and are serviceable...
  • Page 92 MAINTENANCE AND LUBRICATION Side Panel Removal 1. Remove the seat. Step 2 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 93: Wheel Removal

    Make sure the tapered side of the rear wheel nut fits into the taper on the wheel. Do not service wheel nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. With the transmission in gear and...

  • Page 94: Tire Tread Depth

    MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. 1/8I (.3 cm) See illustration. 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 95 MAINTENANCE AND LUBRICATION Tire Specifications Tire Specifications Polaris PTV 6x6 Front - 25 x 8.00 -12 Inflation Pressure - 5 PSI Center - 25 x 11.00 - 10 Inflation Pressure - 5 PSI Rear - 25 x 11.00 - 10...

  • Page 96: 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 97: 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 98: 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 99 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 100: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery.

  • Page 101: Battery Storage

    MAINTENANCE AND LUBRICATION Battery Battery Installation and Connections 1. Set the battery in the battery holder. 2. Install the battery vent tube. NOTE: It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.

  • Page 102: 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 103 MAINTENANCE AND LUBRICATION Lights High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod. 1. Place the vehicle on a level surface with the headlight approximately 25 ft.
  • Page 104 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 105 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) and replace it with the recommended lamp.

  • Page 106: Cleaning And Storage

    MAINTENANCE AND LUBRICATION Cleaning and Storage Keeping your vehicle clean will not only improve its appearance, but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile. Washing the Vehicle The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water.

  • Page 107: Transporting The Vehicle

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storing the Vehicle If your vehicle will be placed in extended or off season storage, follow this procedure to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. 2. Turn the fuel valve to OFF and drain the carburetor.

  • Page 108: Specifications

    SPECIFICATIONS PTV 6x6 Gross Vehicle Weight 1970 lbs. (including machine, driver, cargo) Fuel Capacity 4.25 gallons/16.09 liters Towing Capacity 1500 lbs/681 kgs Hitch Tongue Capacity 150 lbs/68.1 kgs Front Rack Capacity 75 lbs/34 kgs Cargo Box Capacity 800 lbs/362.8 kgs Overall Length 105 in/266.7 cm Overall Width...
  • Page 109 SPECIFICATIONS PTV 6x6 Lubrication System Dry Sump Transmission PVT (Forward, Neutral, Reverse) Tire Size - Front 25 x 8 - 12 (5 psi) Tire Size - Center 25 x 11 - 10 (5 psi) Tire Size - Rear 25 x 11 - 10 (5 psi) Front Brake Fixed disc hydraulic floating caliper Rear Brake...

  • Page 110: Polaris Recommended Products

    POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.)

  • Page 111: Troubleshooting

    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 Solution Starting out going up a steep in- Apply the parking brake, dismount ,and perform cline.
  • Page 112 Inspect plug(s), replace if necessary No spark to spark plug Inspect plug(s), verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect, clean and/or replace spark plugs Clogged fuel filter...
  • Page 113 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer...

  • Page 114: Engine Overheating

    Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...

  • Page 115: Warranty

    ONE YEAR 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 116 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 117: Index

    Engine Cooling System ....79-80 POLARIS RECOMMENDED PRODUCTS . . . Engine Idle RPM Adjustment ....
  • Page 118 INDEX Safe Riding Gear ......Tire Specifications ..... . . SAFETY .

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