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Polaris Sportsman 6x6 Owner's Manual

Polaris 2002 atv owner's manual
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Summary of Contents for Polaris Sportsman 6x6

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm.
  • Page 3 WARNING Indicates a potential hazard that could result in serious injury or death.
  • Page 4 We’ve created a web site, just for YOU!! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
  • Page 5 Your Owner’s Manual contains instructions for minor maintenance. Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician. Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction.

  • Page 6: Safety Training

    You should review this information on a regular basis. In the event you purchased a used Polaris vehicle from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer.

  • Page 7: Table Of Contents

    Vehicle Identification Numbers Safety ....... . . Understanding Warnings Key Safety Issues Decals and Locations Operator Safety Controls and Features...
  • Page 8 TABLE OF CONTENTS Maintenance and Lubrication Tools ......... Periodic Maintenance Schedule Lubrication Recommendations Maintenance Record...

  • Page 9: Vehicle Identification Numbers

    2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key.

  • Page 10: Safety

    SAFETY Understanding Warnings The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

  • Page 11: Key Safety Issues

    All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.
  • Page 12 S Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. S Always have the vehicle checked by an authorized Polaris dealer if it has been involved in an accident.
  • Page 13 Key Safety Issues S Never operate the vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill.
  • Page 14 Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris 6x6 any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes.

  • Page 15: Safe Riding Gear

    Safe Riding Gear Always wear clothing suited to the type of riding you are doing. Riding this vehicle requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding.

  • Page 16: Decals And Locations

    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. The addition of certain accessories including, but not limited to: mowers, blades, tires, sprayers, or large racks may change the handling characteristics of this vehicle.

  • Page 17: Safety Decals And Locations

    Safety Decals and Locations DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch Maximum Front Rack Load 75 lbs. IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
  • Page 18 SAFETY Safety Decals and Locations...
  • Page 19 PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A WARNING REPLACEMENT. SAFETY...
  • Page 20 SAFETY Safety Decals and Locations...
  • Page 21 AWD. See Own- er’s Manual. AWD Models This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) to reduce the risk of a stuck or “frozen” throttle. Please refer to your Owner’s Manual for details. 7078254 WARNING...
  • Page 22 SAFETY Safety Decals and Locations 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 23: Safety

    Safety Decals and Locations TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (368 KG) UP TO 15 GRADE HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16 KG) (On Hitch) D Operation of this vehicle without the filter element will severely damage the engine.

  • Page 24: Operator Safety

    HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris wheeled vehicle. WARNING WARNING...
  • Page 25 Operator Safety POTENTIAL HAZARD Carrying a passenger on this vehicle. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 26 SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate vehicles of this type on public streets, roads and highways.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in vehicle overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 28 SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions;...
  • Page 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your 6x6 each time you use it to make sure it is in safe operating condition.
  • Page 30 SAFETY Operator Safety POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the vehicle. You may also regain traction unexpectedly, which may cause the vehicle to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
  • Page 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills...
  • Page 32 SAFETY Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. See page 61. Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 33 SAFETY Operator Safety WARNING 15° Maximum POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 62 through Always check the terrain carefully before you start up any hill.
  • Page 34 SAFETY Operator Safety POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 65. NOTE: A special technique is required when braking as you go downhill.
  • Page 35 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the vehicle around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground.
  • Page 36 SAFETY Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 37 Operator Safety POTENTIAL HAZARD Operating this 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. HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 38 Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this vehicle; and should be installed and used according to instructions.
  • Page 39 Operator Safety POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your 6x6 on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle.

  • Page 40: Controls And Features

    CONTROLS AND FEATURES Controls Sportsman 6x6 Vehicle Nomenclature 1. Service Brake Lever 2. Middle Axle Auxiliary Brake 3. Throttle Lever 4. Bed Dump Latch Release(s) 5. Gearbox Shift Lever 6. Floor Boards 7. Back Rest 8. Bed 9. Front Rack...

  • Page 41: Main Switch

    Controls Engine Electrical Switches RUN OFF Activating the override button while throttle is open can cause loss of control resulting in severe injury or death. 1. Override Switch (Reverse Speed Limiter) This vehicle is equipped with a reverse speed limiter system. To obtain additional power while backing up, depress the override button.

  • Page 42: Throttle Lever

    This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle should stick in an open position, engine RPM will diminish and power to the rear wheels will cease.

  • Page 43: Front And Rear Brakes

    Controls Front and Rear Brakes The master cylinders, which are located on the left and right handlebars, should be checked before each ride. The fluid level can be seen through an indicator window (3) on the top of the master cylinder. This “eye”...

  • Page 44: Controls And Features

    CONTROLS AND FEATURES Controls Brakes/Rear Auxiliary Brake The braking system is controlled by two levers located on the handlebars directly in front of the handgrips. 1. Service Brakes (front wheel and transmission) - Left Handlebar Lever This lever controls braking action to all six wheels. It is the normal service brake system to use for braking.

  • Page 45: Parking Brake

    Controls Parking Brake Setting the Parking Brake 1. Squeeze the left hand brake lever two or three times and hold it. 2. Rotate the park brake lock (3) into the notches on the master cylinder body. Release the brake lever. 3.
  • Page 46 CONTROLS AND FEATURES Controls Engine Fuel and Oil System The fuel tank filler cap (1) is located directly behind the handlebar. Its capacity is 4.25 U.S. gallons (16 l) with 1/2 gallon (1.9 l) in reserve. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 (R+ M)/2 octane.
  • Page 47 Controls Engine Fuel and Oil System Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well ventilated area. D Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 48: Transmission Gear Selector Operation

    CONTROLS AND FEATURES Controls Transmission 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. The transmission selector lever has four positions: high forward; reverse; neutral;...

  • Page 49: Recoil Starter

    Controls Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. 1. Be certain the parking brake is set.

  • Page 50: Features

    CONTROLS AND FEATURES Features Light Switches and Indicator Lights 1. Main switch 2. Handlebar light switch and headlight Hi-Lo beam control NOTE: Will not light unless main switch is on. 3. Headlight Hi beam indicator (Blue) 4. Transmission reverse indicator (Yellow) 5.
  • Page 51 Reverse Speed Limiter Override Button The Polaris 6x6 is equipped with a unique Polaris exclusive AWD (All Wheel Drive) system which is activated by a switch on the right handlebar. When the switch is “off” the 6x6 is in rear wheel drive at all times.

  • Page 52: Disengaging Wheel Hubs

    CONTROLS AND FEATURES Features A red AWD light on the switch indicates when the vehicle is in AWD. There is no limit to the length of time the vehicle may remain in AWD. The AWD switch may be turned on or off while the vehicle is moving. If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction.

  • Page 53: Operation

    Vehicle Break-in Period The break-in period for your new Polaris 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 a proper break-in period.

  • Page 54: Vehicle Break-In Period

    OPERATION Daily Pre-Ride Inspection Inspect your 6x6 each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. If a proper inspection is not performed serious injury or death can result.

  • Page 55: Starting The Engine

    Starting a Cold Engine 1. Place the transmission in neutral and reset the parking brake. 2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Pull the choke button (A) all the way out. 5. Set the engine stop switch to “run”. 6.

  • Page 56: Starting A Warm Engine

    OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke since the spark plug can easily become wet fouled. 1. Place the transmission in neutral and push the vehicle to a level sur- face. 2.

  • Page 57: Carrying Loads

    Maximum Capacities Front Rack Cargo Bed (Level Ground) Cargo Sportsman 6x6 - 875 75 lbs. (34 kg) 800 lbs. (363 kg) lbs. (397 kg) Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo.
  • Page 58 OPERATION Carrying Loads Overloading the vehicle or carrying or towing cargo improperly can be dangerous. Improper loading can drastically alter 6x6 handling and braking stability. D Never exceed the stated load capacity for this vehicle. D Do not obstruct the headlight when loading the front rack. D Cargo should be properly distributed and carried as low and forward in the cargo bed as possible.

  • Page 59: Operation

    Carrying Loads Dumping the Cargo Bed 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 mechanism lever forward and lift the front of the cargo bed to dump.

  • Page 60: 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 61: Riding

    Daily Pre-Ride Inspection Inspect your 6x6 each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. If a proper inspection is not performed serious injury or death can result.

  • Page 62: Riding Safely

    RIDING Riding Safely Load Distribution Maximum Cargo Bed Sportsman 6x6 800 lbs. (363 kg) 1. Always load the cargo bed placing the load as far forward as possible. 2. Always operate the vehicle with extreme care whenever hauling or towing loads as balance, handling, and control may be affected.
  • Page 63 Riding Safely 1. Sit upright with both feet on the footrests and both hands on the handle- bars. 2. After starting the engine and allowing it to warm up, shift the transmis- sion into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 64: Making Turns

    Making Turns Practice making turns at slow speeds. Polaris 6x6s are equipped with solid rear axles which 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 65 Riding Safely Sidehilling Sidehilling your 6x6 is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests.

  • Page 66: Riding On Slippery Surfaces

    RIDING Riding Safely Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2.
  • Page 67 Riding Safely Riding On Slippery Surfaces Failure to exercise care when operating on slippery surfaces can be dangerous. Loss of tire traction and vehicle control can result in an accident, including an overturn. S Never apply brakes during a skid. Complete loss of control can result.

  • Page 68: Traveling Downhill

    RIDING Riding Safely Traveling Downhill Whenever descending a hill always: 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. Loss of vehicle control due to excessive speed can occur. Loss of control may result in serious injury or death.

  • Page 69: Traveling Uphill

    Riding Safely Traveling Uphill Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills. 2. Keep both feet on the footrests. 3. Transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5. Remain alert and be prepared to take emergency action. This may in- clude quick dismounting of the vehicle.

  • Page 70: Turning Around On A Hill

    RIDING Riding Safely Turning Around On A Hill If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1.

  • Page 71: Crossing Streams

    Riding Safely Crossing Streams Your Polaris 6X6 can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible.
  • Page 72 RIDING Riding Safely Backing Up Backing Up 1. When backing up, 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 73 Riding Safely Backing Up Backing your 6x6 can be dangerous! You could hit an obstacle or person behind you; or the vehicle could tip over on a steep incline causing severe injury or death. Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power is required for vehicle movement.

  • Page 74: Trail Obstacles

    RIDING Riding Safely Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Hidden or unseen hazards on the trail can be dangerous.

  • Page 75: Riding

    Riding Safely Parking On An Incline Whenever the Vehicle is Parked 1. Place the transmission in gear. 2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 4.

  • Page 76: Maintenance And Lubrication

    MAINTENANCE AND LUBRICATION Tool Kit To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kit are: S screwdriver S open end wrench (8-10 mm) S open end wrench (12-14 mm) S box end wrench S tire pressure gauge S spark plug wrench and handle...

  • Page 77: Periodic Maintenance Schedule

    Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. Due to the nature of the adjustments marked with a recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions NOTE: Inspection may reveal the need for replacement parts.
  • Page 78 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule (Cont.) Due to the nature of the adjustments marked with a recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.
  • Page 79 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Valve Clearance Fuel System Fuel Filter Radiator Cooling System hoses Engine Mounts Spark arrestor Spark Plug Front hubs/fluid change " Clutches (drive and driven) Shift selector box Brake fluid Headlight Aim Toe adjustment Recoil housing Idle Speed Hours or...

  • Page 80: Lubrication Recommendations

    Lube Rec. Brake Fluid DOT 3 Only Drive Chains O-Ring chain lube or SAE 80/90 Gear Selector 10 W Non-detergent Oil Transmission Oil Polaris Premium Synthetic gearcase lube Front Prop Shaft Grease+ U-joints Front Drive Axle Grease+ (U Joint) (AWD Models)
  • Page 81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Steering Post Bushings Upper Front A-Arm Pivot Shaft Demand 6 Premium Hubs - All Hub Lube Wheel Drive Ball Joint Grease** Front A Arm Grease** Pivot Shaft Steering Post Grease** Bushings Inner Tie Rod End Ball Joint Remove set screw in hubs.
  • Page 82 * 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 NOTE: Hours are based on 10 mph average. Center Swing Arm...

  • Page 83: Transmission Lubrication

    Catch and discard used oil properly. 4. Clean and reinstall the drain plug. 5. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) until oil reaches the bottom of the filler hole. 6. Check for leaks.

  • Page 84: Front Gearcase Lubrication

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Lubrication The front gearcase fill plug (3) is located as shown. 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.

  • Page 85: Premium 4 Synthetic Lubricant

    Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.
  • Page 86 Severe use cold weather riding is all riding below 10°F, and riding between 10°F and 30° F when most trips are slow speed. Be sure to change the oil filter whenever changing oil (Polaris PN 3084963) 1. Place vehicle on a level surface.
  • Page 87 13. Reinstall drain plug. 14. Remove dipstick and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially.

  • Page 88: Maintenance Record

    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Interval Performed First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs. Servicing Date Dealer or Person Remarks...

  • Page 89: Cooling System

    Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: 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 area.

  • Page 90: Coolant Level

    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. NOTE: 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 area.

  • Page 91: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service It is recommended that the air filter be replaced yearly. When riding in extremely dusty conditions replacement will be required more often. 1. Remove seat. 2. Remove spring clamps securing the airbox lid and remove lid. 3.

  • Page 92: Air Box Drain

    MAINTENANCE AND LUBRICATION Filter Systems Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box and empty if necessary. Breather Filter and Hoses: Operation of your vehicle without a breather filter can cause engine damage. 1.

  • Page 93: Adjustments

    MAINTENANCE AND LUBRICATION Adjustments Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your Polaris dealer. He/she has the training and tools to make these adjustments. Toe Alignment You can check the toe alignment of the vehicle using the following method.

  • Page 94: Steering Inspection

    NOTE: Optional springs may be a different color than standard springs. Owner may paint springs to desired color using Polaris touch up paint, available through your dealer. SOFT...

  • Page 95: Front Brake

    Use Polaris DOT 3 brake fluid (PN 2870990). S Check brake system for fluid leaks. S Check brake for excessive travel or spongy feel. S Check friction pads for wear, damage and looseness.
  • Page 96 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The transmission brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The transmission brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear.
  • Page 97 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar. 1. Slide the bolts off inline cable adjuster sleeve. Loosen adjuster locknut. 2. Turn adjuster until 1/16″ to 1/8″ freeplay is achieved at thumb lever. Flip throttle lever several times to confirm adjustment.

  • Page 98: Wheel Installation

    MAINTENANCE AND LUBRICATION Adjustments Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

  • Page 99: Tire Inspection

    MAINTENANCE AND LUBRICATION Adjustments Tire Inspection Maintain proper tire pressure according to charts below. Improper tire inflation may affect vehicle maneuverability. When replacing a tire always use original equipment size and type. The use of non-standard size or type tires may affect vehicle handling.

  • Page 100: Tire Specifications

    Center and Rear Wheel Nuts Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. Service work must be performed by your authorized Polaris dealer. Tire Specifications Sportsman 6x6 Front - 25 x 8.00 -12 Inflation Pressure - 5 PSI Center - 25 x 11.00 - 10...

  • Page 101: Front Drive Chain Adjustment

    MAINTENANCE AND LUBRICATION Adjustments Front Drive Chain Adjustment Never adjust or operate the vehicle with the drive chain slack out of the 3/16″-3/8″ (.48 cm - .95 cm) specification. Severe damage to the transmission and drive components can result. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain.
  • Page 102 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 103 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1.

  • Page 104: Carburetor Adjustments

    Contact your dealer for altitude adjustments. They have the training and special tools required to perform all necessary modifications for you. Pilot screws are sealed with metal plugs and are serviceable only by dealers. Jetting Chart 2002 Sportsman 6x6 Altitude Meters Meters (Feet) AMBIENT TEMPERATURE...

  • Page 105: Side Panel Removal

    MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal 1. Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 2. Remove seat. Grasp rear of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage...

  • Page 106: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs S Use NGK BKR5ES spark plugs. S Proper electrode gap is .025″ (.06 cm). S Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs (1.52 kg/m) for a new spark plug. Spark plug condition is indicative of engine operation.

  • Page 107: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor S Because exhaust system temperatures can reach 1000°F, do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. S Because of the increased fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.
  • Page 108 MAINTENANCE AND LUBRICATION Spark Arrestor (Cont.) The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the cleanout plug (A) located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the en- gine.

  • Page 109: Recoil Housing

    MAINTENANCE AND LUBRICATION Recoil Housing Drain the recoil housing after operating the vehicle in very wet conditions. This should also be done before storing the vehicle. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench.

  • Page 110: Pvt

    D Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your deal- D This PVT system is intended for use on Polaris products only. D The PVT housing must be securely in place during operation.

  • Page 111: Battery

    MAINTENANCE AND LUBRICATION Battery Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

  • Page 112: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4.
  • Page 113 MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and se- curely 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 114: Lights

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement Due to the nature of these vehicles and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Poor lighting while riding can result in severe injury or death Position knob in...

  • Page 115: High Beam Headlight Adjustment

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement 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’...

  • Page 116: Headlight Housing Replacement

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Housing Replacement 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also allow easier access.

  • Page 117: Indicator Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight assembly by removing the two screws securing it to the vehicle. 2. Twist the lamp harness 1/4 turn to release the lock.

  • Page 118: Cleaning And Storage

    MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning the 6x6 Keeping your 6x6 clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your 6x6 can be cleaned much like an automobile. Washing the 6x6 If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the drive chain, wheel bearings,...

  • Page 119: Storage Of The 6X

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storage of the 6x6 If your 6x6 is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the ve- hicle.

  • Page 120: Maintenance And Lubrication

    3. Always tie the vehicle to the transporting unit securely using suitable straps and/or rope. 4. Always place the transmission in gear and lock the parking brake. Accessories Polaris has a wide variety of accessories for your 6x6. Contact your Polaris dealer for a complete list.

  • Page 121: Specifications

    Height ..........Width .

  • Page 122: Specifications

    ..........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 123: Wiring Diagram

    WIRING DIAGRAM...

  • Page 124: Troubleshooting

    TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Loading the 6x6 into a pick- up or tall trailer when in high range. Starting out going up a steep incline. Driving at low RPM or low ground speed (at approxi- mately 3--7 MPH).

  • Page 125: Troubleshooting

    Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact you dealer for further service informa- tion.

  • Page 126: Trouble Shooting

    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 you may have. ENGINE CRANKS BUT FAILS TO START Stop Switch Off...

  • Page 127: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE A SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE.
  • Page 128 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 129 Accessories ..... . . Adjustments ....Air Box Drain .
  • Page 130 INDEX Welcome ......Wheel Installation ....Wheel Removal .

This manual is also suitable for:

2002 sportsman 6x6

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