Polaris 2004 Sportsman 6x6 Owner's Manual For Maintenance And Safety
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. 2004 Sportsman 6x6
  6. Owner's manual for maintenance and safety
Polaris 2004 Sportsman 6x6 Owner's Manual For Maintenance And Safety

Polaris 2004 Sportsman 6x6 Owner's Manual For Maintenance And Safety

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Polaris 2004 Sportsman 6x6

Summary of Contents for Polaris 2004 Sportsman 6x6

  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 We’ve created a web site just for YOU! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 5 Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Welcome

    S Personal Task Vehiclet (PTV) S All-Surface Loader (ASL) 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 7: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.

  • Page 8: Table Of Contents

    ......POLARIS PRODUCTS .....

  • Page 9: Safety

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV 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. A helmet can prevent a severe head injury.

  • Page 10: Operator Safety

    You should review this information on a regular basis. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.
  • Page 11 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 12 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 13 S Never operate the Sportsman 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 14 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 15 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 Sportsman 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 16: Safety Decals And Locations

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 17 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 18 AWD. See Own- er’s Manual. This vehicle is equipped with a 7079780 Polaris Electronic Throttle Control 7079604 (ETC) to reduce the risk of a stuck or “frozen” throttle. Please refer to your owner’s manual for details. DPassengers can be thrown off.
  • Page 19 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 20 Sportsman 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 Sportsman 6x6.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on a Sportsman 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 22 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 Sportsman 6x6 on any public street, road or highway, including dirt and gravel roads.
  • Page 23 Turn the vehicle around and remount, following the procedure described in the owner’s manual. See page 65. 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 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the Sportsman 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 25 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 26 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 27 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 28 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. Practice turning at slow speeds before attempting to turn at faster speeds.
  • Page 29 SAFETY Operator Safety WARNING 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 30 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 31 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 Sportsman 6x6 around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 32 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 33 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 34 Never modify the Sportsman 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 35 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. WARNING POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs.
  • Page 36 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING Operating a damaged ATV can result in an accident with serious injury or death.
  • Page 37 - NOTES -...

  • Page 38: Features And Controls

    FEATURES AND CONTROLS 1. Service Brake Lever 2. Middle Axle Auxiliary Brake Lever 3. Throttle Lever 4. Box Dump Latch Release 5. Gear Selector 6. Floorboards 7. Backrest 8. Cargo Box 9. Front Rack...
  • Page 39 FEATURES AND CONTROLS Electrical Switches and Indicators 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main switch is on. 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.
  • Page 40 FEATURES AND CONTROLS Electrical Switches and Indicators 4. Main Switch - To start the engine, slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts. The taillight is on whenever the main switch is on.

  • Page 41: Throttle Lever

    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

    FEATURES AND CONTROLS Brakes The braking system is controlled by the two brake levers located on the handlebars, directly in front of each handgrip. Service Brakes The service brake lever (1) is located on the left handlebar. This lever controls both front and rear wheel braking action. Use this lever for normal braking.

  • Page 43: Master Cylinders

    If the fluid level is low, add DOT 3 brake fluid. DO NOT OVERFILL. See page 118 for the part numbers of Polaris products. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.

  • Page 44: Setting The Parking Brake

    FEATURES AND 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.

  • Page 45: Fuel Tank

    FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. There’s about a 7 to 10 mile (11.2 to 16 km) range on the reserve supply.

  • Page 46: Gear Selector

    FEATURES AND CONTROLS Gear Selector The transmission gear selector (1) 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: Recoil Starter

    The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.

  • Page 48: All Wheel Drive (Awd) System

    FEATURES AND CONTROLS All Wheel Drive (AWD) System The Polaris Sportsman 6x6 is equipped with a unique AWD system activated by the AWD switch (1) on the right handlebar. When the switch is off, the vehicle is in rear wheel drive at all times. When the switch is on, the vehicle is in AWD and the front wheels will automatically engage any time the rear wheels lose traction.

  • Page 49: Disengaging Wheel Hubs

    FEATURES AND CONTROLS 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 50: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph.

  • Page 51: Rider Information Center

    If this occurs take the ATV to your Polaris dealer for proper diagnosis. NOTE: All segments of the rider information center will light up for...
  • Page 52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Trip meter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button on the left handlebar is also the mode button.
  • Page 53 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is turned off.

  • Page 54: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2.

  • Page 55: Operation

    OPERATION 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 56 OPERATION Vehicle Break-in Period The break-in period for your new Polaris Sportsman 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 57 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 58: 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 59: Starting A Warm Engine

    OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke. Excessive use of 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 60: Hauling Cargo

    OPERATION Hauling Cargo Your Sportsman 6x6 has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings on the warning labels. Never exceed the specified weights. WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability.

  • Page 61: Dumping Cargo

    OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. 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 box release lever forward. 5.

  • Page 62: Driving Safely

    OPERATION Driving Safely Load Distribution 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 57. 2. Always load the cargo box with the load (1) as far forward as possible.

  • Page 63: Driving Procedures

    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 64: Making Turns

    OPERATION Driving Safely Making Turns Practice making turns at slow speeds. The Sportsman 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 65 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 66: 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 67: 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 68: Turning Around On A Hill

    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 69: 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 70: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your Sportsman 6X6 can operate through water with a maximum recommended depth equal to the footrests (1). 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 71: 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 72: Parking On An Incline

    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 73: 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 74: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
  • Page 75 - NOTES -...

  • Page 76: 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 77: 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 78 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 79 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Frequency Remarks Miles J Brake pads 10 hrs./ Monthly Inspect for wear periodically 100 mi. Breather filter 20 hrs. Monthly Inspect; replace annually " and as needed Battery 20 hrs. Monthly Inspect and clean terminals; check fluid level "...
  • Page 80 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Frequency Remarks Miles " Engine oil 100 hrs./ 6 months Check level daily; break-in 1000 mi. service at one month; change oil more often in cold weather use Oil filter 100 hrs./ 6 months Replace with oil change 1000 mi.

  • Page 81: Lubrication Recommendations

    Maintenance Chart Key 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 82 MAINTENANCE AND LUBRICATION Lubrication Recommendations (Loc. 1) Inner Tie Rod End (Loc. 6) (Loc. 5) (Loc. 2) (Loc. 7) (Loc. 4) (Loc. 3) (Loc. 8)

  • Page 83: Transmission Lubrication

    We recommend the use of AGL Synthetic Gearcase Lubricant. See page 118 for the part numbers of Polaris products. 1. Position the ATV on a level surface and remove the propshaft shield from the right side of the vehicle.

  • Page 84: Front Gearcase Lubrication

    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. We recommend the use of Angle Drive Fluid (see page 118).

  • 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’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

  • Page 86: Oil And Filter Change

    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. If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage.
  • Page 87 Premium 4 All Season synthetic oil or API certified SH oil, 0-40W. Never substitute or mix oil brands. 12. Remove the dipstick (2) and add two quarts (1.9 l) of Polaris Premium 4 synthetic oil (see page 118). Reinstall the dipstick.
  • Page 88 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 89: Engine Cooling System

    Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water (see page 118). 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 90: Recovery Bottle Coolant Level

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water (see page 118). 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 91: Filter Systems

    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 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. Empty the drain tube if necessary. Breather Filter Inspect the filter monthly or after every 20 hours of operation, whichever comes first.

  • Page 93: Toe Alignment

    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 94: 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 95: Front Wheel And Middle Axle Brake

    ″ whenever the cover is loosened (.1cm) or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid (see page 118). 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel.

  • Page 96: Front Wheel Hub Tightening

    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 97 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 operate the vehicle with the drive chain slack out of specification. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the...
  • Page 98 MAINTENANCE AND LUBRICATION Adjustments Rear Axle Drive Chain Adjustment To adjust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. Total slack for the rear chain should be adjusted to 3/8″-1/2″...

  • Page 99: Oil Pump Priming

    MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.

  • Page 100: Side Panel Removal

    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 101: 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. Place the transmission in gear and lock the parking brake.

  • Page 102: 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 103: Tire Specifications

    MAINTENANCE AND LUBRICATION Tire Specifications Tire Specifications Polaris Sportsman 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 104: 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 105: Pvt System

    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.

  • Page 106: Pvt Drying

    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 107: 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 108: Recoil Housing

    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 109: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

  • Page 110: Battery Storage

    MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharging.

  • Page 111: Battery Charging

    MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Action Charge Time* Charge (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at None required...

  • Page 112: 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 113: High Beam Headlight Adjustment

    MAINTENANCE AND LUBRICATION Lights WARNING Operating the vehicle on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your Sportsman 6x6 is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

  • Page 114: Headlight Housing Replacement

    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 115 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 116: Cleaning And Storage

    Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 117: Storage Tips

    5. Treat the fuel system with Polaris Carbon Clean. 6. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline. Engine Anti-Freeze Test engine coolant strength and change if necessary.

  • Page 118: Transporting The Vehicle

    MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting the Vehicle Follow these procedures before transporting the vehicle with another unit. 1. Turn off the engine and remove the key to avoid loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap and oil cap are installed correctly.

  • Page 119: Specifications

    SPECIFICATIONS SPORTSMAN 6x6 Gross Vehicle Weight 1965 lbs. (891 kg)(machine, driver, cargo) Fuel Capacity 4.25 gallons (16.09 liters) Towing Rating 1500 lbs. (681 kg) Unbraked Trailer Towing Capacity* 1900 lbs. (863 kg) Hitch Tongue Capacity 150 lbs. (68.1 kg) Front Rack Capacity 75 lbs.

  • Page 120: Jetting Chart

    SPECIFICATIONS SPORTSMAN 6x6 Transmission Automatic PVT (H/L/N/R) Gear Reduction - Low 6.69/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - High 3.34/1 Drive Ratio - Front: Drive Ratio - Final 12/38 80P Tire Size - Front 25 x 8 - 12 (5 psi) Tire Size - Center 25 x 11 - 10 (5 psi) Tire Size - Rear...

  • Page 121: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2871567 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (16 gal.)

  • Page 122: 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 123 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 124 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 125: 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 126: Warranty

    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 127: Engine Oil

    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.
  • Page 128 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 129 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...

  • Page 130: Index

    INDEX Accessories ....EMISSION CONTROL SYSTEMS Adjustments ....90-98 Engine Cooling System .
  • Page 131 74-77 Toe Alignment ....POLARIS PRODUCTS ..Tool Kit ..... . .

Table of Contents