Polaris Light Utility Hauler 6x6 Owner's Manual
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Polaris Light Utility Hauler 6x6 Owner's Manual

Polaris Light Utility Hauler 6x6 Owner's Manual

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Summary of Contents for Polaris Light Utility Hauler 6x6

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

  • Page 3: Welcome

    S All-terrain vehicles (ATVs) S Personal watercraft S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest vehicle we’ve ever produced.

  • Page 4: Read Your Owner's Manual

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris LUH 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 5: Table Of Contents

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

  • 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: Safety

    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 8 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.
  • Page 9 S Never operate the LUH 6x6 without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 10 SAFETY Operator Safety 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. Practice on smaller hills before attempting larger hills.
  • Page 11 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 LUH 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 12 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 13 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 14 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 15 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 16 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. LUH 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 17 LUH 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 LUH 6x6.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an LUH 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 19 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 LUH 6x6 on any public street, road or highway, including dirt and gravel roads.
  • Page 20 Turn the vehicle around and remount, following the procedure described in the owner’s manual. See page 57. 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 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the LUH 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 22 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 23 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 24 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 25 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 26 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. Always check the terrain carefully before ascending any hill.
  • Page 27 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 28 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 LUH 6x6 around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 29 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 30 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 31 Never modify the LUH 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 32 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 33: Features And Controls Identification

    FEATURES AND CONTROLS IDENTIFICATION 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 34: 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 35 CONTROLS Electrical Switches and Indicators With the engine running, verify the function of all indicator lights before every use of the vehicle. 1 Main Switch The taillight is on whenever the main switch (key) is in the “on” position. Turn the key off to prevent battery drain. 2 Light Switch/Hi-Lo Beam Control The lights won’t turn on unless the main switch is on.
  • Page 36 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 37: 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 38 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 39: 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 two or three times, then squeeze and hold.
  • Page 40 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 41 CONTROLS Engine Fuel and Oil System 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 42: 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 43 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 44: Features

    FEATURES All Wheel Drive (AWD) System The Polaris LUH 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 45 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 46: Operation

    OPERATION Vehicle Break-in Period The break-in period for your new Polaris LUH 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 47 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 48: 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 49: 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 50: Hauling Cargo

    OPERATION Hauling Cargo Your LUH 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 51 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 52: Driving Safely

    OPERATION Driving Safely Load Distribution Maximum Cargo Bed LUH 6x6 800 lbs. (363 kg) Maximum Front Rack 90 lbs. (41 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 53 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 54 OPERATION Driving Safely Making Turns Practice making turns at slow speeds. The LUH 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 55 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.

  • Page 56: 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 57 OPERATION Driving Safely Traveling 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 58 OPERATION Driving Safely Traveling 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 59 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 60 OPERATION Driving Safely Crossing Streams Your LUH 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 61: 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 62 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 63: 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 64: 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 65: 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 66: 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 67: 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 68 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 69 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 70: Lubrication Recommendations

    More often under severe use, such as wet or dusty conditions " Grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging. Item Lube Rec.
  • Page 71 More often under severe use, such as wet or dusty conditions " Grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging. Inner Tie Rod End Upper...
  • Page 72 More often under severe use, such as wet or dusty conditions " Grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.

  • Page 73: 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 106).
  • Page 74 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Lubrication The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. 1. With the vehicle on a level surface, remove fill plug (1).
  • Page 75 Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil (see page 106) 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 76 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 77 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 (see page 106). Reinstall the dipstick.
  • Page 78 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 79: 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 106). 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 80 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water (see page 106). 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 81 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 82 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 83 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 84: 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 85: Front Brake

    3/64 ″ or removed to ensure proper (.1cm) diaphragm operation. Use Polaris DOT 3 brake fluid (see page 106). 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel.
  • Page 86 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 87 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 88 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 89 2. Transmission convertor modification to adjust for engine horsepower loss. We recommend that you see your Polaris dealer for altitude adjustments. Polaris dealers have the proper training and tools required to perform these modifications. NOTE: Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers.
  • Page 90 MAINTENANCE AND LUBRICATION Adjustments 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 91: 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 92: Tire Tread Depth

    MAINTENANCE AND LUBRICATION Specifications 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 93 MAINTENANCE AND LUBRICATION Specifications Tire Specifications Tire Specifications Polaris LUH 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 94: 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 95: 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 96: 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 97 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 98: 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 99: 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 100: 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 101 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 102 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 103 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 104: 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 105: Transporting The Vehicle

    MAINTENANCE AND LUBRICATION Cleaning and Storage Vehicle Storage 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 106: Specifications

    SPECIFICATIONS Vehicle Specifications 2002 LUH 6x6 Height ..........48″...
  • Page 107 ..... . . 87 Non-oxygenated or 89 Oxygenated Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

  • Page 108: Polaris Recommended Products

    POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2 Cycle Engine Oil (Quart) 2871281 Engine Oil (Quart) Premium 4 Synthetic 0W--40 (4--Cycle) 2871844 Engine Oil (Gallon) Premium 4 Synthetic 0W--40 (4--Cycle) 2871567...

  • Page 109: Wiring Diagram

    WIRING DIAGRAM...

  • Page 110: Troubleshooting

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact your dealer.
  • Page 111 TROUBLESHOOTING The following information is provided to help you identify probable causes for questions you may have about the operation of your vehicle. See your Polaris dealer with any additional questions. ENGINE CRANKS BUT FAILS TO START Stop Switch Off...

  • Page 112: Warranty

    This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.
  • Page 113 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 115 ......Battery Installation and Connections ..POLARIS RECOMMENDED PRODUCTS ..Battery Maintenance .
  • Page 116 PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. Part No. 9917234 Rev 02 PRINTED IN THE USA...

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