Polaris 2002 Sportsman 6x6 Owner's Manual PDF

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Summary of Content for Polaris 2002 Sportsman 6x6 Owner's Manual PDF

WARNING

The engine exhaust from this product contains chemicals

known to cause cancer, birth de- fects or other reproductive harm.

Indicates a potential hazard that could result in serious injury or death.

WARNING

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www.polarisindustries.com/owner

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WELCOME Thank you for choosing Polaris, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles. We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris vehicle the finest machine weve ever produced. Follow the instructions and recommendations in this Owners Manual for safe and enjoyable operation of your vehicle. Your Owners 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. Return to your dealership for all of your service needs during, and after, the warranty period. Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door! Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc.

Copyright 2001 Polaris Industries Inc. All Rights Reserved Printed in the U.S.A.

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ATTENTION! This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 16 years of age. READ AND UNDERSTAND WARNINGS AND OWNERS MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various areas which are being discussed on your machine. Operating this vehicle carries with it responsibilities for your personal safety, the safety of others, and the protection of our environment.

SAFETY TRAINING When you purchased this vehicle your dealer offered a hands-on safety training course covering all aspects of vehicle safety. In addition, you were provided with certain printed material which instructs you on safe operating procedures. 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. Failure to follow the warnings contained in this manual can result in SEVERE INJURY OR DEATH. NOTE: Illustrations used in this manual are for general representation only. Your model may differ.

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TABLE OF CONTENTS

Vehicle Identification Numbers 6. . . . . . . . . . . . . . Safety 7 - 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Warnings 7. . . . . . . . . . . . . . . . . . . . . . . . .

Key Safety Issues 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decals and Locations 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Safety 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls and Features 37 - 49. . . . . . . . . . . . . . . . . Controls 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 50 - 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre Ride 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Break-In Period 51. . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrying Loads 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise Emission Control System 57. . . . . . . . . . . . Riding 58 - 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre Ride Inspection 58. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Riding Safely 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS Maintenance and Lubrication 73 - 117. . . . . . . . . .

Tools 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Periodic Maintenance Schedule 74. . . . . . . . . . . . . . . . . .

Lubrication Recommendations 77. . . . . . . . . . . . . . . . . . .

Maintenance Record 85. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Systems 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plugs 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Arrestor 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recoil Housing 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PVT 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lights 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 115. . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 118 - 119. . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram 120. . . . . . . . . . . . . . . . . . . . . . . . . . Trouble Shooting 121 - 123. . . . . . . . . . . . . . . . . . . . Warranty 124 - 125. . . . . . . . . . . . . . . . . . . . . . . . . . .

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VEHICLE IDENTIFICATION NUMBERS

Important: Record these numbers from your vehicle in the spaces provided.

1. Frame VIN

2. Engine Serial Number (Right front side of engine crankcase)

The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required. In the event your vehicle were stolen these numbers are essential to the recovery and identification of your vehicle.

Dealer Imprint

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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.

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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.

Indicates a potential hazard that could result in serious injury or death.

Indicates a potential hazard that may result in minor personal injury or damage to the machine.

WARNING

CAUTION

NOTE NOTE: will alert you to important information or instructions.

Indicates a situation that may result in damage to the machine.

CAUTION

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SAFETY

Key Safety Issues Protect Your Sport Know all local, state/province riding laws; Respect your vehicle; Respect the environment; and You will gain the respect of others. We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this vehicle are thoroughly inspected at various intervals. 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. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Illustrations included in this manual are general representations of parts having a similar function. Your model may differ. THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This Vehicle handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

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SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions: S Read this manual and all labels carefully and follow the operating

procedures described. S Never operate this vehicle without proper instruction. Take a

training course. Beginners should receive training from a certi- fied instructor. Contact an authorized Polaris dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this vehicle. S Never permit a guest to operate this vehicle unless the guest has

read this manual and all product labels, and has completed a certi- fied training course.

S Always avoid operating this vehicle on any paved surfaces, includ- ing sidewalks, driveways, parking lots and streets.

S Never operate this vehicle on any public street, road or highway, even a dirt or gravel one.

S Never operate this vehicle without wearing an approved helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating this ve- hicle.

S Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your vehicle each time you use it to make sure it is

in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

S Always keep both hands on the handlebars and both feet on the footrests of the vehicle during operation.

S Always go slowly and be extra careful when operating on unfamil- iar terrain. Always be alert to changing terrain conditions when operating the vehicle.

S Never operate on excessively rough, slippery or loose terrain. 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.

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SAFETY 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. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

S Always follow proper procedures for going down hills and for brak- ing on hills as described in this manual. Check the terrain careful- ly before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

S Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the vehicle. Never attempt to turn the vehicle around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

S Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to either side if pointed straight uphill. Turn the ve- hicle around and remount, following the procedure described in this manual.

S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over ob- stacles as described in this manual.

S Always be careful of skidding or sliding. 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.

S Avoid operating the vehicle through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maxi- mum depth (pg. 68), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sud- den throttle changes.

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SAFETY Key Safety Issues S Wet brakes may have reduced stopping ability. Test your brakes

after leaving water. If necessary apply them lightly several times to let friction dry out the pads.

S Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

S Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

S Never modify this vehicle through improper installation or use of accessories.

S Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT vehicle SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764. Additional Important Information... 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. Any modifications to the original equipment of the vehicle substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard. Polaris hereby informs you that the warranty on your vehicle is terminated if any such equipment has been added to the vehicle or any modifications have been made to the vehicle which increase its speed or power. We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the vehicle are thoroughly inspected by your dealer at various mileage intervals. NOTE: 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. Be certain any accessories added to this vehicle have been approved by Polaris. Familiarize yourself with their function and affect on the vehicle.

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SAFETY

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. A helmet can prevent a serious head injury. Select an approved helmet which meets or exceeds your states safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI Z90.1), or the Snell Memorial Foundation label.

2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings Z2.1 or VESC 8).

3. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.

4. Boots The best footwear is a pair of strong over the calf type boots with heels such as moto cross boots.

5. Clothing To protect your body, long sleeves and pants should always be worn. Riding pants with kneepads, a jersey and shoulder pads provide the best protection.

1

2 3

4

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SAFETY Safety Decals and Locations NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your 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. Be certain any accessories added to this vehicle have been approved by Polaris. Familiarize yourself with their function and affect on the vehicle.

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SAFETY

Safety Decals and Locations 1

2

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. TIRE PRESSURE (PSI): FRONT 5 CENTER 5 REAR 5 MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight INCLUDING MACHINE, DRIVER AND CARGO IS 1965 LBS.) Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible in box, and firmly secured to the rack. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack or box. Read Owners Manual for more detailed loading information.

WARNING

WARNING

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SAFETY Safety Decals and Locations

3

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SAFETY

Safety Decals and Locations 3

Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER:

D Operate on public roads. A collision can occur with another vehicle.

D Carry passengers. Passengers affect balance and steering and in- crease risk of losing control.

D USE ALCOHOL or DRUGS before or while operating this vehicle.

D Operate at speeds too fast for your skills or the conditions.

D Operate this vehicle on HILLS steeper than 15 degrees 15.

D To prevent flipover on hilly terrain, use throttle and brakes gradually. ALWAYS:

D Use an approved HELMET AND PROTECTIVE GEAR.

D Avoid paved surfaces. Pavement may seriously affect handling and control.

D UseproperRIDINGTECHNIQUES toavoid vehicle overturns onhills and rough terrain and in turns.

D Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

D REVERSE operation can be dangerous, even at low speeds. Steer- ing becomes difficult. To prevent flipover, avoid sharp turns. PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward.

LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNERS MANUAL IS

MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.

WARNING

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SAFETY Safety Decals and Locations

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5

6

7 8

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SAFETY

Safety Decals and Locations

ETC 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 Owners Manual for details.

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Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this vehicle if you are under age 16.

7078254

Remove flammable containers from box before refueling. Maximum Box Load 800 lbs.

S Passengers can be thrown off. This can cause serious injury or death.

S Never carry passengers.

ALL WHEEL DRIVE SWITCH

Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owners Manual.

7079780 7079604

AWD Models

WARNING Pushing reverse override button may cause sudden in- creases in pow- er and traction if too much throttle is ap- plied. Loss of control or for- ward flipover may result, es- pecially in AWD. See Own- ers Manual.

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7 8

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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.

NO STEP 7078689

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WARNING

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SAFETY

Safety Decals and Locations

(On Hitch)

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)

7078261

ATTENTION D Operation of this vehicle without

the filter element will severely damage the engine.

D Clean air filter often, more frequent cleaning required in dusty conditions

D Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owners manual for details.

D Specific carburetor jetting and

adjustments are required depending on temperature and altitude. See your Owners Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters).

7079902

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SAFETY Operator Safety

POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc. They should then regularly practice the skills learned in the course and the operating techniques described in the Owners Manual. For more information about the training course, contact an authorized Polaris dealer or call Polaris at 1-800-342-3764.

POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle. WHAT CAN HAPPEN Use by children of vehicles that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris wheeled vehicle.

WARNING

WARNING

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SAFETY

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. The operator requires the space of the entire seat to shift position as needed during operation. The seat is not for carrying passengers.

POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN This vehicles tires are designed for off-road use only; not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD

Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.

Safe operation of this rider active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in serious injury or death.

WARNING

WARNING

WARNING

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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.

POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly. You should also wear:

D eye protection (goggles or face shield);

D gloves;

D boots;

D long-sleeved shirt or jacket; and

D long pants.

WARNING

WARNING

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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. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the service brake, gradually. When fully stopped, apply auxiliary brake as well, and then lock parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the vehicle around and remount, following the procedure described in the Owners Manual. See page 67. In the event of an accident, have a qualified service dealer check the complete machine including, but not limited to brakes, throttle and steering for possible damage.

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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; and your experience.

WARNING

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

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SAFETY

Operator Safety

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.

Always follow the inspection and maintenance procedures and schedules described in the Owners Manual.

POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off the vehicle. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your 6x6 during operation.

WARNING

WARNING

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SAFETY Operator Safety

POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning or going out of control. HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the vehicle.

WARNING

WARNING

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.

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SAFETY

Operator Safety

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 necessary to control the vehicle on such terrain. Always be especially cautious on these kinds of terrain.

WARNING

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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 Owners Manual. See page 61.

Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the 6x6 on hills too steep for the vehicle or for your abilities.

Practice on smaller hills before attempting large hills. Never operate vehicle on hills steeper than 15_.

WARNING

WARNING

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SAFETY

Operator Safety

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 Owners Manual. See pages 62 through 67.

Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The vehicle could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

15 Maximum

WARNING

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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 Owners Manual. See page 65. NOTE: A special technique is required when braking as you go downhill.

Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

WARNING

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SAFETY

Operator Safety

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 Owners Manual on level ground. See pages 62 and 67. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the vehicle.

WARNING

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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. If you cannot avoid obstacles, always follow proper procedures as described in the Owners Manual on page 71.

WARNING

WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in the Owners Manual for carrying cargo or pulling a trailer. See pages 54 and 59.

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SAFETY

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 Owners Manual. See page 68. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

WARNING

WARNING POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts such as jumps. Dont try to show off.

35

SAFETY Operator Safety

POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD

Always use the size and type tires specified in the Owners Manual for this vehicle. See page 96. Always maintain proper tire pressure as described in the Owners Manual. See page 96.

POTENTIAL HAZARD Operating this vehicle with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD 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. If you have questions, consult an authorized Polaris dealer.

WARNING

WARNING

36

SAFETY

Operator Safety

WARNING

WARNING

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.

POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this vehicle.

37

CONTROLS AND FEATURES Controls Sportsman 6x6 Vehicle Nomenclature

6. Floor Boards 7. Back Rest 8. Bed 9. Front Rack

1. Service Brake Lever 2. Middle Axle Auxiliary Brake 3. Throttle Lever 4. Bed Dump Latch Release(s) 5. Gearbox Shift Lever

1 2

3

4

4

5

6

7

8

9

38

CONTROLS AND FEATURES

Controls Engine Electrical Switches

1 23

RUN OFFOFF

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.

NOTE: The override switch also allows activation of All Wheel Drive (AWD) in reverse, if AWD switch is on.

2. Main Switch

To start the engine, slide the stop switch (3) to the center run position and turn the main key switch clockwise past the on position. Release the key when the engine starts.

This switch must be turned clockwise to the on position to start the engine.

3. Engine Stop Switch

The engine will not start or run when the switch is in its off position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights. To stop the engine, slide the stop switch right or left to the off position.

WARNING Activating the override button while throttle is open can cause loss of control resulting in severe injury or death.

39

CONTROLS AND FEATURES Controls Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released. 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.

Choke Knob (2) Refer to the engine starting procedure on pages 52 - 53 for correct choke and throttle settings during starting.

12

The Electronic Throttle Control (ETC) limits engine power in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

WARNING

Do not start or operate this vehicle with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident.

Always check the lever for free movement and return before starting the engine and occasionally during riding.

WARNING

40

CONTROLS AND FEATURES

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 will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear. NOTE: When checking the fluid level, the handle bars should be turned so until the top of the reservoir is level. If the fluid level is low add DOT 3 (PN 2870990) only.

The service brakes are applied by squeezing the left side brake lever toward the handlebar. These brakes are hydraulically activated disc type brakes which are activated by one lever only. Always test brake lever travel and reservoir fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

3

Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

WARNING

Improperly operating the vehicle with a spongy brake lever can result in loss of braking. Loss of braking could cause an accident. Never operate the vehicle with a spongy feeling brake lever.

WARNING

41

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. 2. Auxiliary Brakes - Right Handlebar Lever This lever controls the auxiliary brake for the rear axles. It is to be used for additional braking effect, or in the event of failure of the normal service brake system.

1 2

42

CONTROLS AND FEATURES

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. To release the parking brake lock, squeeze the brake lever. It will return to its released position.

The parking brake will slowly relax or lose holding power if left unattended for more than five minutes. Do not depend on parking brake to hold vehicle for more than five minutes.

3

WARNING Always check to be sure that the parking brake has been disengaged before operating the vehicle. An accident could result if the parking brake is left on while the vehicle is operated. The parking brake may relax when left on for a long period of time. This could cause an accident. Do not leave the vehicle on a hill depending on the parking brake for more than five minutes. Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a side hill position.

43

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. The fuel tank supply valve (2) located on the left side of the vehicle has three positions:

OFF: For vehicle storage and whenever transporting. ON: For normal operation. RES: For reserve supply in the event of main supply exhaustion. NOTE: There is about a 7 to 10 mile (11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after having used the reserve supply. Always remember to take the fuel valve off RES after refueling your machine.

1

2

ON

OFF

RES

44

CONTROLS AND FEATURES

Controls Engine Fuel and Oil System

NOTE: The taillight is on whenever the main switch (key) is in the on position. Turn the key off to prevent battery drain.

WARNING Gasoline is highly flammable and explosive under certain conditions.

D Always exercise extreme cautionwhenever handling gasoline.

D Always refuel with the engine stopped and outdoors or in awell 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.

D Do not over fill the tank. Do not fill the tank neck.

D If you should get gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

D Never start the engine or let it run in an enclosed area. Gaso- line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

D Shut off fuel valve whenever the vehicle is stored or parked.

WARNING

The engine exhaust from this product contains chemicals

known to cause cancer, birth de- fects or other reproductive harm.

45

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; and low forward. Use of low forward gear is recommended in heavy pulling situations to extend belt life. To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended. Maintaining shift linkage adjustment is important to assure proper transmission function. Should you experience any shifting problem see your dealer.

H L

N

R

Shift Patterns

WARNING 1. Do not attempt to shift the transmission while the vehicle is mov-

ing or while operating on hilly terrain. 2. Always place the transmission in gear with the parking brake ap-

plied whenever the vehicle is left unattended.

46

CONTROLS AND FEATURES

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. See page 42. 2. Grasp the recoil starter

tightly and pull slightly un- til the starter mechanism engages.

3. Pull the rope abruptly to start the engine.

Recoil Starter

Do not extend the starter rope so far that it stops This will cause damage to the recoil assembly. Make sure the manual start handle is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.

CAUTION

47

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. Transmission neutral indicator (Green) 6. All Wheel Drive indicator (Red) 7. Engine hi temp warning indicator (Red) NOTE: Will light only if

engine overheats. With engine running, verify function of indicator lights each time vehicle is used.

6

1

4

3

5 7

2

This vehicle is not equipped with highway approved lighting. This vehicle is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

WARNING

48

CONTROLS AND FEATURES

Features All Wheel Drive System

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. When the switch is on the 6x6 is in AWD and the front wheels will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage. NOTE: The override switch also allows activation of AWD in reverse, if AWD switch is on.

Reverse Speed Limiter Override Button

AWD Button

49

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.

Disengaging Wheel Hubs When backing uphill while in AWD and then going forward downhill, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again.

You can tell if only one front hub is engaged if the handlebars pull to one side. If both front wheel hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted.

CAUTION Do not switch on AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the AWD switch on.

WARNING If both hubs were engaged and only one released during operation, loss of control could result. If you experience hub engaging symptoms, use the above disengaging technique before proceeding. Failure to disengage front hubs as directed above could result in severe injury or death. If the hubs remain engaged after following these instructions return the vehicle to your dealer for service.

50

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. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

1. Fill fuel tank with either unleaded or leaded fuel which has a mini- mum pump octane number of 87= (R+ M)/2.

2. Check oil reservoir lev- el indicated on dipstick. Add oil if necessary.

3. Drive slowly at first. Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-ride inspec- tion checklist found on page 12.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 200 miles.

CAUTION Use only Polaris Premium 4 All Season synthetic oil, or API certified SH oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CAUTION Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

51

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. Always inspect your 6x6 before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure D Tires - check condition and pressures

D Fuel and oil tanks - fill both tanks to their proper levels

D All brakes - check operation, adjustment and fluid level (in- cludes auxiliary brake)

D Throttle - check for free operation and closing

D Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

D Engine stop switch - check for proper function

D Wheels - check for tightness of wheel nuts andaxle nuts; check that axle nuts are secured by cotter pins

D Drive chain - condition and slack; refer to drive chain adjust- ment

D Air cleaner element - check for dirt; clean or replace

D Steering - check for free operation noting any unusual loose- ness in any area

D Loose parts - visually inspect vehicle for any damaged or loose nuts/bolts or fasteners

D Operators helmet, goggles and clothing

D Engine coolant - check for proper level at the recovery bottle.

D Check condition and operation of the dump box/bed latch mechanism.

WARNING

52

OPERATION

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 theway

out. 5. Set the engine stop switch to run. 6. Turn the ignition key past the ON

position to engage the starter.

NOTE: the choke is on FULL when the knob is pulled out all the way. The choke is OFF when the knob is pushed in. This is a variable choke and can be adjusted gradually, depending on how much choke is needed for starting. 7. Do not press the throttle while starting the engine. 8. Activate the starter for a maximum of five seconds, releasing the key

or button when the vehicle starts. If engine does not start, release the starter and wait five seconds; then activate the starter for another five seconds. Repeat this procedure until engine starts.

NOTE: Do not press the throttle while starting the engine.

After the Engine Starts 1. If the engine slows or stops, pushing the choke button in half way will

allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up until

the engine idles smoothly. Then push the choke button all the way in.

A

CAUTION Proper engine warm up is essential each time before driving to avoid engine damage.

WARNING Carbon monoxide exhaust gas is poisonous! Always start the vehicle outdoors. Never run the engine in an enclosed area.

53

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. Lock the parking brake. 3. Turn the fuel tank valve to ON. 4. Sit on the vehicle. 5. If the engine has cooled to a point where it does not readily start, inter-

mittent use of the choke button pulled half way out is permitted. 6. If the engine is over-choked by mistake when warm, depress the

throttle lever fully while cranking to aid in starting. 7. Release the throttle lever immediately after the engine starts. If the en-

gine does not start and all conditions are favorable, change the spark plug.

54

OPERATION

Carrying Loads Your 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 (Level Ground)

Front Rack Cargo

Cargo Bed

Sportsman 6x6 - 875 lbs. (397 kg)

75 lbs. (34 kg) 800 lbs. (363 kg)

Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo.

Maximum Towing Capacities (Level Ground) Maximum towed load weight - 1250 lbs. (568 kg) on level ground only; 850 lbs. (386 kg) up to 15 grade. Maximum vertical hitch weight - 30 lbs (14 kg). Use of low forward is recommended in heavy pulling situations to extend belt life. Maximum grade while trailer towing - 15; do not tow any trailer on a grade steeper than 15.

55

OPERATION Carrying Loads

WARNING 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.

D Reduce speed and allow greater distance for braking.

D Heavy loads can cause braking and control problems.

D Use extreme caution when applying brakes with a loaded ve- hicle. Generally avoid terrain or situations which may require backing downhill.

D Always attach the tow load to thehitch point designated for your vehicle.

D Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never ex- ceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

56

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.

WARNING Never carry passengers on the bed. If the weight distribution on the bed is located toward the rear of the bed and the release lever is pulled forward, the bed will want to dump on its own. Never operate the dump lever without checking the position of the load. This will prevent unexpected dumping of the cargo bed.

WARNING

In the event of an accident have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle, and steering for possible damage.

57

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 (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. 1. Removal or alteration or the puncturing of the muffler or any engine

component which conducts removal of engine exhaust gases. 2. Removal or alteration or the puncturing of any part of the engine air

induction system. 3. Replacement of any vehicle parts with parts not in compliance with

federal regulations. 4. Lack of proper maintenance.

USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

CAUTION Remember, exhaust system components are very hot during and after use of the vehicle.

D Do not touch hot exhaust system components. Serious burns can result.

D Be especially careful when traveling through tall grass. The po- tential for fire exists.

58

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. Always inspect your 6x6 before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure D Tires - check condition and pressures

D Fuel and oil tanks - fill both tanks to their proper levels

D All brakes - check operation, adjustment and fluid level (in- cludes auxiliary brake)

D Throttle - check for free operation and closing

D Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

D Engine stop switch - check for proper function

D Wheels - check for tightness of wheel nuts andaxle nuts; check that axle nuts are secured by cotter pins

D Drive chain - condition and slack; refer to drive chain adjust- ment

D Air cleaner element - check for dirt; clean or replace

D Steering - check for free operation noting any unusual loose- ness in any area

D Loose parts - visually inspect vehicle for any damaged or loose nuts/bolts or fasteners

D Operators helmet, goggles and clothing

D Engine coolant - check for proper level at the recovery bottle.

D Check condition and operation of the dump box/bed latch mechanism.

WARNING

59

RIDING Riding Safely Load Distribution

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. 3. Slow down and drive in low range only. 4. The cargo bed dump latchmust be securely latched before loading and

operating. Unintentional bed tilting will result if weight is placed in the rear of the bed and the latch is not secured.

Maximum Front Rack 75 lbs. (34 kg)

Maximum Cargo Bed Sportsman 6x6 800 lbs. (363 kg)

WARNING Never operate this vehicle with the cargo bed in the raised position. The cargo bed could close unexpectedly while driving, severely injuring the driver. The rear tires will catch the rear of the bed, damaging the vehicle and creating hazardous driving conditions.

60

RIDING

Riding Safely

1. Sit uprightwith both feet on the footrests and both handson thehandle- bars.

2. After starting the engine and allowing it towarm up, shift the transmis- sion into gear.

3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving.

Vehicle speed is controlled by the amount of throttle opening and PVT shifting is done automatically.

6. Drive slowly, practice maneuvering and using the throttle and brakes on level surfaces.

WARNING Indicates a potential hazard which could result in serious injury or death.

61

RIDING Riding Safely 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. To turn, steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly. The same learning technique should be used for turning in reverse.

WARNING Avoid turning at sharp angles in reverse as tipover and serious injury may result.

62

RIDING

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. 3. Steer slightly into the hill to maintain vehicle directions. If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

WARNING Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the vehicle could occur.

D Avoid crossing the side of a steep hill if possible.

D Use extreme care when operating your 6x6 in hilly terrain.

63

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. Maintain a high level of alertness, reading the trail and avoiding quick,

sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and

shifting your body weight forward. 4. Driving with Demand 6 Drive (All Wheel Drive) engaged can assist

in controlling the vehicle in slippery areas. Before riding your vehicle on a frozen body of water be sure that the ice is thick enough to support the machine and its operator, as well as the force that is created by a moving vehicle. Severe injury or death can result if the vehicle and/or its operator break through the ice.

CAUTION Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur.

64

RIDING

Riding Safely Riding On Slippery Surfaces

WARNING 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. S Do not operate on excessively slippery surfaces if possible. S Always reduce speed and use additional caution.

65

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.

WARNING Loss of vehicle control due to excessive speed can occur. Loss of control may result in serious injury or death.

66

RIDING

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.

15_ Maximum

WARNING Braking and handling are greatly affected whenever operating in hilly terrain. Loss of vehicle control or overturning of the vehicle could occur.

D Avoid climbing steep hills (15_ maximum).

D Use extreme care when operating your vehicle in hilly terrain.

67

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. Stop and lock the parking brakewhilemaintaining bodyweight uphill. 2. Leave transmission in forward and shut off engine. 3. Dismount on left or uphill side of vehicle. 4. Staying uphill of vehicle, turn handlebars full right (facing front of ve-

hicle). 5. While holding service brake, release parking brake lock and slowly al-

low vehicle to roll around to your right until it is pointing across the hill or slightly downward.

6. Lock the parking brake and remount vehicle from the uphill side, maintaining body weight uphill.

7. Restart engine with transmission still in forward, and proceed slowly, controlling speedwith the service brake, until vehicle is on reasonably level ground.

8

Uphill

WARNING Avoid climbing steep hills. Loss of vehicle control or overturning of vehicle could occur.

D Use extreme care when operating your 6x6 in hilly terrain.

68

RIDING

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. 4. After crossing, dry the brakes by applying light pressure to the lever

until braking action is normal. S Avoid operating the 6X6 through deep or fast flowing water. If you

cannot avoid water which exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, maintain a slow and steady forward motion. Do not make sudden turns or stops and do not make sudden throttle changes.

CAUTION If your 6X6 becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the machine is not thoroughly inspected.

69

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. Never activate override button while throttle is open. Loss of control

may result. NOTE: This vehicle is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed. Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.

WARNING Indicates a potential hazard which could result in serious injury or death.

70

RIDING

Riding Safely Backing Up

WARNING 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. Avoid backing on steep inclines.

Avoid turning at sharp angles in reverse.

71

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.

WARNING Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen obstacles.

D Keep alert and constantly look for obstacles on the trail.

72

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. Shut off fuel supply.

WARNING Always check to be sure that the parking brake has been disengaged before operating the vehicle. An accident could result if the parking brake is left on while the vehicle is operated. The parking brake may relax when left on for a long period of time. This could cause an accident. Do not leave the vehicle on a hill depending on the park brake for more than five minutes. Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a side hill position.

73

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 S torx wrench (rack removal)

74

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

" 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.

Item Hours or Odometer

Frequency Remarks

Headlamp Inspection Pre-ride Pre-ride Check operation daily; apply Polaris di- electric grease to connector when re- placed

Tail lamp inspection Pre-ride Pre-ride Check operation daily; apply Polaris di- electric grease to socket when replaced

Tires - Air Pressure Pre-ride Pre-ride Inspect daily, pre-ride inspection item

Brake System Pre-ride Pre-ride Pre-ride inspection item

Wheels Pre-ride Pre-ride Pre-ride inspection item

Frame nuts, bolts, fasteners Pre-ride Pre-ride Pre-ride inspection item

Fuel and Oil Tanks Pre-ride Pre-ride Fill to proper level

" Air Box Sediment Tube Daily Daily Drain deposits whenever visible

" Air Filter - Pre-Cleaner Daily Daily Inspect-Clean

Coolant/Level Inspection Daily Daily Replace engine coolant every two years

" Air Filter - Main Element Weekly Weekly Inspect-Replace if necessary

CAUTION Due to the nature of the adjustments marked with aJ, it is recommended that service be performed by an authorized Polaris dealer.

75

MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule (Cont.)

" 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.

Item Hours or Odometer

Frequency Remarks

J Brake pad wear 10 hrs/100 miles

Monthly Inspect periodically

" Engine breather filter 20 hrs Monthly Inspect--replace annually and as need- ed

Battery 20 hrs Monthly Check Terminals/clean/check fluid level

" Transmission Oil Level 25 hrs Monthly Inspect monthly; change annually

" General Lubrication 50 hrs 3 months Lubricate all fittings, pivots, cables, etc.

J Throttle Cable/ETC Switch 50 hrs 6 months Inspect--adjust, lubricate, replace if nec- essary; pre-ride inspection item

Choke (Enricher) Cable 50 hrs 6 months Inspect--adjust, lubricate, replace if nec- essary

Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage

" Engine Oil - Level/Change 100 hrs/1000 miles

6 months Check Level Daily; Break in Service at 1 month. Change oil more often in cold weather use

Oil Filter 100 hrs/1000 miles

6 months Replace with oil change

Coolant strength/pressure test system

100 hrs 6 months Inspect strength seasonally; pressure test system annually

Engine breather hose 100 hrs 6 months Inspect

" Rear Suspension 50 hrs 6 months Inspect, tighten fasteners

" Drive Chains 50 hrs 6 months Inspect daily, adjust and lubricate if needed

J Drive Belt 50 hrs 6 months Inspect--adjust, replace if necessary

" Front hubs/fluid check 50 hrs 6 months Check monthly

Shift linkage 50 hrs 6 months Inspect, lubricate, adjust

J Steering 50 hrs 6 months Inspect daily, lubricate

" Rear Axle/Center Axle 50 hrs 6 months Inspect bearings

" Front Suspension 50 hrs 6 months Inspect--lubricate, tighten fasteners

CAUTION Due to the nature of the adjustments marked with aJ, it is recommended that service be performed by an authorized Polaris dealer.

76

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule Item Hours or

Odometer Frequency Remarks

J Valve Clearance 100 hrs 12 months Inspect/Adjust

J Fuel System 100 hours 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Re- place lines every two years.

J Fuel Filter 100 hrs 12 months Replace annually

Radiator 100 hrs 12 months Inspect/clean external surface

Cooling System hoses 100 hrs 12 months Inspect

Engine Mounts 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

Spark Plug 100 hrs 12 months Inspect--replace if necessary

" Front hubs/fluid change 100 hrs 12 months

J Clutches (drive and driven) 100 hrs 12 months Inspect, clean

J Shift selector box 200 hrs 24 months Change lubricant every two years

J Brake fluid 200 hrs 24 months Change every two years

Headlight Aim As required As required Adjust if necessary

J Toe adjustment As required As required Periodic inspection, adjust when parts are replaced

Recoil housing As required As required Drain moisture out after riding in water

Idle Speed As Required As Required Adjust

77

MAINTENANCE AND LUBRICATION Lubrication Recommendations

Item Lube Rec. Method Frequency*

Brake Fluid DOT 3 Only Maintain proper level. See page 40.

As required; change every two years or 200 hours

Drive Chains O-Ring chain lube or SAE 80/90

Lubricate as often as re- quired (before each ride in wet conditions).

As required

Gear Selector 10 W Non-detergent Oil

Maintain oil level at the center of the shift rail. Do not overfill.

Change every 2 years or 200 hours.

Transmission Oil Polaris Premium Synthetic gearcase lube

Fill to bottom of the filler hole.

Change annually or at 100 hours

Front Prop Shaft U-joints

Grease+ Locate Fittings and Grease

Every 3 months or 50 hours

Front Drive Axle (U Joint) (AWD Models)

Grease+ Locate grease fitting and grease with grease gun.

Every 3 months or 50 hours

Transmission plug

Front Prop Shaft (U-Joint)

Fill plug

78

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Demand 6 Hubs - All Wheel Drive

Premium Hub Lube

Remove set screw in hubs. Ro- tate wheels to 4:00 position. If lu- bricant is not visible add more. Reinstall set screw.

Annually or at 100 hrs

Ball Joint Grease** Locate zerk on back side of struts and grease with grease gun.

Every 3 months or at 50 hrs

Front A Arm Pivot Shaft

Grease** Locate zerk on pivot shaft and grease with grease gun.

Every 3 months or at 50 hrs

Steering Post Bushings

Grease** Locate fitting on steering post and grease with grease gun.

Every 3 months or at 50 hrs

Steering Post Bushings

Inner Tie Rod End

Ball Joint

Front A-Arm Pivot Shaft

Upper

4:00 position

Demand 6 Hubs

79

MAINTENANCE AND LUBRICATION Lubrication Recommendations

Front Drive Axle U Joints

Grease + Locate grease fitting and grease with grease gun.

Every 3 months or 50 hrs

Rear Axle Bearing

Grease** Locate fitting on eccentric and grease with grease gun.

Every 3 months or 50 hrs

Swing Arm Bushings

Grease** Locate fitting on swing arm and grease with grease gun.

Monthly or at 20 hrs

Middle Axle Bearings

Grease* Locate fitting on eccentric and grease with grease gun.

Every 3 months or 50 hrs

Center Swing Arm Housing

Grease* Locate fitting on swing arm housing and grease with grease gun.

Every 3 months or 50 hrs

Rear Strut Grease* Locate fitting on rear strut and grease with grease gun.

Every 3 months or 50 hrs

* 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.

Rear Axle Bearing

Middle Axle Bearings

Swing Arm Bushings

Rear Strut

Center Swing Arm Housing

U Joint

80

MAINTENANCE AND LUBRICATION

Lubrication Recommendations Transmission Lubrication The transmission fill plug (1) is located on the right side of the machine behind the propshaft shield or footwell. The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the 6X6 on a level surface, remove fill plug (2) and check the lubricant level. Lubricant level is correct when it reaches the bottom of the filler hole. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478).

Transmission Oil Changing Procedure 1. Remove propshaft shield from the right side of the vehicle.

2. Remove fill plug.

3. Remove transmission drain plug located on the bottom left hand side and drain the oil. Catch and discard used oil properly.

4. Clean and reinstall the drain plug.

5. Add Polaris Premium SyntheticGearcase Lubricant (PN2871478 - 12 oz. bottle) until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall propshaft shield or footwell and screws removed in step 1.

1

2

81

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. With the 6X6 on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept at the bottom of fill plug thread. The correct gearcase lubricant to use is GL5 80-90 Weight Gear Lube.

Gearcase Oil Changing Procedure 1. Remove fill plug.

2. Remove gearcase drain plug located on the bottom right hand side and drain the oil.

3. Clean and reinstall the drain plug and tighten securely (14 ft. lbs/1.93 kgm).

4. Add GL 80-90Weight Gear Lube to the bottom thread on the fill hole.

5. Reinstall filler plug.

6. Check for leaks.

3

82

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

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. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40 F to 120 F. Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation. Oil System The oil tank is located on the left side of the vehicle. To check the oil: 1. Set machine on a level

surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine, remove dipstick and wipe dry with a clean cloth. 4. Screw in the dipstick completely, remove it and read the oil level.

NOTE: The dipstick must be screwed in to keep the angle and depth of stick consistent.

5. Remove dipstick and check to see that the oil level is between the full and add marks. Add oil as indicated by the level on the dipstick. Do not overfill. If oil level rises above the full mark, water and/or fuel may be collecting in the tank and oil should be changed.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CAUTION Use only Polaris Premium 4 All Season synthetic oil, or API certified SH oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

83

MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change

The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. Severe use cold weather riding is all riding below 10F, and riding between 10F 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. 2. Clean area around drain plug at the bottom of the oil tank. 3. Place a drain pan beneath the oil tank and remove the drain plug. 4. Allow oil to drain completely. 5. Install a new sealing washer (PN 5850135) on oil drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

6. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)

7. Disconnect the lower oil delivery hose. Remove the fitting (C) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. Reattach oil line. If banjo fitting (D) is used, torque to 14-17 ft. lbs. If hose clamp (E) is used, tighten securely.

CAUTION Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

OR

A

B

C

C D

E

84

MAINTENANCE AND LUBRICATION

Lubrication Recommendations 8. Place shop towels beneath oil filter. Using an oil filter wrench, turn

filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface on crankcase. 10. Lubricate the O-Ring on the new filter with a film of new engine oil.

Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine.

11. Install new filter and tighten by hand 1/2 to 3/4 turn after gasket contact.

12. Approximately 1 cup of engine oil will remain in the crankcase. To drain, remove drain plug found on lower right side of crankcase. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

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.

15. Place gear selector in neutral and set parking brake. 16. Start engine and let it idle for one to two minutes. Stop engine and

inspect for leaks. 17. Re-check oil level on the dipstick and add oil as necessary to bring the

level to the upper mark on the dipstick. 18. Dispose of used filter and oil properly.

85

MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work:

Maintenance Interval Performed

Servicing Date

Servicing Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs.

50 Hrs.

75 Hrs.

100 Hrs.

86

MAINTENANCE AND LUBRICATION

Engine Cooling System Radiator Coolant Level In- spection

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

To access the radiator pressure cap: Remove the four screw securing front rack. Remove front cover by placing your fingers under the front of the cover and pulling upward. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part. To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added. 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 manufacturers mixing recommendations for the freeze protection required in your area. Using a funnel, slowly add coolant as necessary through the radiator filler neck.

Rack

Front Cover

WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

87

MAINTENANCE AND LUBRICATION Engine Cooling System

Coolant Level The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle. The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle past the pressure cap and into the radiator. NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturers mixing recommendations for the freeze protection required in your area. To access the recovery bottle on Gen IV machines it is necessary to remove the left side panel as described on page 102.

Recovery Bottle

88

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. Loosen clamp and remove filter.

4. Remove fabric type pre-filter frommain filter. Wash pre-filter in soapy water and dry it.

5. Reinstall pre-filter over main filter. Replace main filter as required.

6. Reinstall filter into air box and tighten clamp. Do not over tighten clamp or filter damage may occur.

CAUTION Operation of your 6X6 without a breather filter can cause engine damage.

Main Filter

Pre--filter

89

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. Remove the clamps and pull the filter out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine.

2. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging. Replace as needed.

3. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

4. Reinstall filter and clamps with arrow pointing toward engine. NOTE: The breather filter is intended to be used with airbox pre-filter in place. Without the pre-filter, the breather filter can clog quickly. Never operate your vehicle without the pre-filter. NOTE: Inspect the filter monthly or every 20 hours of operation, whichever comes first. Replace filter as needed.

Breather filter

90

MAINTENANCE AND LUBRICATION

Adjustments

Toe Alignment You can check the toe alignment of the vehicle using the following method. The recommended toe alignment is 1/8 to 1/4 toe out. If you discover improper adjustment have your dealer correct it. 1. Set handlebars in a straight ahead

position and hold them in this posi- tion. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2. Place stands in front of the ma- chine, perpendicular to the rear tires.

3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine.

4. Measure from string to rim at front and rear of front rim. Rear rimmea- surement should be 1/16 - 1/8 (.2 to .3 cm)more than front rimmea- surement.

WARNING 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.

91

MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle.

Camber and Caster The camber and caster are non-adjustable.

Handlebar Adjustment Your 6x6 has handlebars which can be adjusted for your personal fit. 1. Remove handlebar cover

and loosen the four bolts.

2. Adjust handlebar to desired height. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right.

3. Torque handlebar adjuster block bolts to 10 to 12 ft. lbs.

Optional Suspension Springs Although your Polaris 6x6 suspension has the capability of providing you with the best ride possible, the following accessory springs are available to better suit your individual riding preference. 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.

Sportsman 6x6 - Front Strut Spring

7041375-067 OPTION 64/113 lb/in

7041450-195 STANDARD 101 lb/in

N/A

1 2

3

4

WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death.

SOFT FIRM

92

MAINTENANCE AND LUBRICATION

Adjustments Front Brake Front Wheel and Middle Axle Brake The front and middle axle brakes are hydraulic disc type brakes which are activated by the brake lever being moved toward the handlebar. These brakes are self-adjusting and require no adjustment. The following checks are recommended to keep the brake system in good operating condition. How often they need checking depends upon the type of driving that has been done. S Always keep brake fluid at

an adequate level (see page 40). Normal func- tioning of the diaphragm is to extend into the reser- voir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is indi- cated and the diaphragm should be replaced. Al- ways fill the reservoir as indicated whenever the cover is loosened or re- moved to insure proper diaphragm operation. 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. S Check security and surface condition of the disc. S Pads should be changed when worn to 3/64 (.1 cm), or about the

thickness of a dime.

3/64 (.1cm)

Middle Axle Brake

93

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. Wear Line S Pads should be changed

when worn to 3/64 (.1 cm) which is about the thickness of a dime.

S Inspect the brake disc spline and pad wear sur- face for excessive wear.

3/64 (.1 cm)

94

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.

3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of adjuster.

Boot Adjuster Sleeve Locknut Boot

95

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. 4. Remove the wheel nuts and remove the wheel.

Wheel Installation 1. With the transmission in gear

and the parking brake locked, place the wheel in the correct position on thewheel hub. Be sure the valve stem is toward the outside and rotation ar- rows on the tire point toward forward rotation.

2. Attach thewheel nuts and fin- ger tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the following torque:

S Torque center and rear wheel nuts to 50 ft. lbs. (6.9 kg/m). S Torque front wheel nuts to 20 ft. lbs. (2.1 kg/m).

Tapered side of nut goes in

Rear Wheel Assembly

CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. Make sure the tapered end of the rear wheel nut goes into the taper on the wheel.

96

MAINTENANCE AND LUBRICATION

Adjustments Tire Inspection

Tire Tread Depth Always replace tires when tread depth is worn to 1/8 (.3 cm) or less.

CAUTION 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.

Tread Depth 1/8I (.3 cm)

WARNING Operating your 6x6 with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth measures 1/8 (.3 cm) or less.

97

MAINTENANCE AND LUBRICATION Adjustments Tire Specifications

Tire Specifications 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 Inflation Pressure - 5 PSI

Cargo Bed Load Capacity 800 lbs. (363 kg)

Front Rack Load Capacity 75 lbs. (34 kg)

Gross Vehicle Weight 1970 lbs. (894 kg) including vehicle, driver and cargo. Vehicle weighs

895 lbs. (406 kg).

The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service.

Axle and Wheel Nut Torque Specifications

Item Specification

Front Spindle Nut(s) 100 In. Lbs.

Front Wheel Nuts 20 Ft. Lbs.

Center and Rear Axle Nut(s) 80 Ft. Lbs.

Center and Rear Wheel Nuts 50 Ft. Lbs.

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.

98

MAINTENANCE AND LUBRICATION

Adjustments Front Drive Chain Adjustment

Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the front chain. Then pull up and down on the chain. At this point the chain should have 3/16-3/8 (.48 cm - .95 cm) deflection. If the chain needs adjustment, use the following procedure.

Adjustment Procedure 1. Loosen chain guide. 2. Loosen two eccentric locking

bolts. 3. Loosen caliper mount bolts. 4. Insert a pin punch through the

sprocket hub and into the ec- centric axle housing.

5. Roll the vehicle ahead or back to adjust chain slack to the proper dimension.

6. Tighten caliper mount bolts 10-12 ft. lbs. (1.4 - 1.7 kg/m). 7. Tighten the eccentric locking bolts to 45 ft. lbs. (6.2 kg/m). 8. Confirm correct tension by rolling the 6x6 forward, checking chain

tension in several places around the chain. 9. Reinstall chain guard. NOTE: Reposition chain guide to allow 1/8 (.3 cm) clearance between sprocket and guide.

CAUTION 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.

Proper Splicelink Clip Opening Position

2

3

Front Drive Chain Adjustment

99

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).

1/4-1/2 (.6-1.3 cm)

3/16-3/8 (.48 cm - .95 cm)

100

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. Warm up the engine by running the ve-

hicle approximately five minutes.

2. Place the transmission in gear with the parking brake applied.

3. Adjust the carburetor idle screw in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.

Idle Screw

101

MAINTENANCE AND LUBRICATION Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000 foot (304.8 m) increase in elevation. Although this power cannot be regained, changes to the carburetor and drive system can be made to allow efficient operation. These changes include: 1. Carburetor re-jetting to compensate for atmospheric pressure and oxy-

gen loss. 2. Transmission convertor modification to adjust for engine horsepower

loss. Contact your dealer. 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 AMBIENT TEMPERATURE

Below 40_F Below 5_C

Above 40_F Above 5_C

Altitude Meters

0-1800 (0-6000)

147.5 142.5

(Feet) Over 1800 (Over 6000)

140 135

102

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 the two rear tabs.

3. Place hand on top of side panel behind the fuel tank. With a quick and firm motion, push down on the side panel to disengage the top rear two tabs. Then pull up on side panel to disengage front upper and lower tab.

4. To reinstall side panel, align panel tabs with slots on front cab. Push panel upward and forward until tabs lock. Bend rear of side panel and insert the two tabs into the rear cab.

Pull forward and out to disengage two rear tabs.

Step 1.

Push down to disengage top rear two tabs.

Step 2.

To reinstall, align panel tabs with slots. Push upward and forward un- til tabs lock.

Step 3.

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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. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. 1. Normal The insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. 2. Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments. Spark Plug Removal and Replacement

The spark plug is removed by using the special wrench provided in the tool pouch under the seat. Reach under the right hand fender and then back for access. Remove the spark plug cap and then the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. (2.3 kg/m). Never deviate from the recommended spark plug as engine damage can occur.

WARNING Never attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you causing severe injury.

104

MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING S Because exhaust system temperatures can reach 1000F, 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.

S Wear eye protection. S Do not stand behind or in front of the vehicle while purging

the carbon from the spark arrestor. S Never run the engine in an enclosed area. The exhaust con-

tains poisonous carbon monoxide gas. S Do not go under the machine while it is inclined. Failure to heed these warnings could result in serious personal injury or death.

105

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. Purge accumulated carbon from the system by momentarily revving the engine several times.

3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the cleanout plugwhile revving the engine several more times.

4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake and block the wheels. Make sure the ma- chine is in neutral and repeat steps 2 and 3.

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake and block the wheels. Make sure the ma- chine is in neutral and repeat steps 2 and 3.

6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool. 8. Reinstall the arrestor plug.

A

106

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. Reinstall screw once housing has been drained. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil. Do not open the crankcase drain unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if crankcase drain is opened.

Recoil Drain (above front propshaft on shaft drive models)

Crankcase Drain

107

MAINTENANCE AND LUBRICATION PVT System

WARNING The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this system remains safe:

D Donotmodify any component of thePVT system. Doing somay reduce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modificationwill cause the system to be out of balance, creating vibration and additional loads on components.

D Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your deal- er!

D This PVT system is intended for use on Polaris products only.

D The PVT housing must be securely in place during operation.

Failure to comply with this warning can result in severe injury or death.

108

MAINTENANCE AND LUBRICATION

Battery

Replenishing the 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. To refill use only distilled water. Tap water contains minerals which are harmful to a 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.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

WARNING

Maintain between upper and lower level marks

109

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. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV, being careful not to tip it sideways and

spill electrolyte.

Battery Installation and Connections

Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean rags. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery.

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV.

CAUTION

To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death.

WARNING

110

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. Avoid skin contact with electrolyte, severe burns could result.

3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5. Reinstall battery cover and attach the hold down strap. 6. Verify that cables are properly routed.

NOTE: S When your ATV is placed in storage for three months or more, the

battery should be removed, charged to proper level, and stored in a cool dry place.

S Before reusing, take the battery to your dealer for testing and re- charging.

S Power plug leads may need to be bent down so that the battery cov- er may be installed.

S When installing a new battery, make certain it is fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery. It can also hinder vehicle performance.

Indicates a potential hazard that could result in serious injury or death.

WARNING

111

MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement

.

1. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod.

2. Lift the pod lightly while depressing the tabs. 3. Remove the screw in the back of the headlight pod 4. Lift pod cover up. Disconnect speedometer harnesses from

speedometer. Unplug indicator light harness and remove pod cover.

5. Unplug headlamp from wiring harness. 6. Remove boot and locking collar from back of lamp housing. 7. Grasp base of lamp and lift it out. 8. Reverse previous steps to replace lamp and reassemble pod. Make

sure tab on lamp locates properly in housing.

WARNING 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

Snap pins into tabs

Position knob in slot and secure in locking tabs

Slip O-Ring over pin

Adjustment Knob Stop

Route plug over handlebar

112

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 (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight beam should be aimed 2 (5.1 cm) below the mark placed on thewall in step 2. NOTE: Rider weight must be included on the seat.

5. Adjust beam to desired position by turning the adjustment knob.

113

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.

2. Remove three Phillips screws at back of headlight pod.

3. Lift pod cover up. Disconnect speedometer harnesses from speedometer. Unplug indicator light harness and remove pod cov- er.

4. Unplug headlamp from wiring har- ness.

5. Remove O-Ring from headlight pivot pins.

6. Pull headlight housing up to re- lease from locking tabs.

7. Lift adjusting knob up to remove from locking tabs.

8. Carefully pull assembly up and out of pod.

9. Reverse steps to install new hous- ing and reassemble pod.

10.Adjust headlight aim by turning adjusting knob.

O-Ring

5 1/8 (13 cm)

Distance from headlamp parting line to end of adjustment knob stop is 5 1/8 (13 cm).

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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. Pull the lamphar- ness out of the back of the assem- bly.

3. Remove the lamp from the harness and replace it with the recom- mended lamp.

4. Test the taillight/brakelight to see that its working.

5. Replace the lamp harness into the back of the taillight assembly, twist- ing 1/4 turn to lock in place.

6. Reinstall the taillight assembly to the vehicle.

Indicator Lamp Replacement 1. Follow steps 1 - 3 of Headlight

Housing Replacement on pre- vious page.

2. Unplug light from harness.

3. Using a screwdriver, turn the light 1/4 turn counter clockwise.

4. Install new light and use a screw- driver to seat it into place, 1/4 turn clockwise.

5. Reassemble pod.

Taillight Assembly

Lamp Lamp Harness

Lens

115

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, transmission seals, body panels, brakes and warning labels. Many expensive repair bills can result from using high pressure detergent systems. The best and safest way to clean your 6x6 is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots.

Waxing the 6x6 Your 6x6 can be waxed with any quality brand automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish.

116

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.

2. Turn the fuel valve to off and drain the carburetor.

3. Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylin- der. Operate the starter for a few seconds and reinstall the spark plug.

4. Remove the battery. Store it in a cool, dry place out of the sun. 5. Lubricate suspension pivot points, lower steering post and rear axle fit-

tings. 6. Drain the recoil housing. 7. Block the vehicle so all tires are suspended off the ground. 8. Cover the vehicle with a canvas cover. Do not use plastic or coated

materials since they do not allow ventilation of the vehicle.

Drain tube attached here

Drain Screw

117

MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting the 6x6 Whenever the 6x6 is to be transported the following measures should be taken. 1. Turn the fuel valve to off. 2. Be certain the fuel cap and oil cap are installed correctly. 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.

118

SPECIFICATIONS

Height 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Base 76.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Height 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Clearance 5.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight 895 lbs.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Susp. - MacPherson Strut 6.7 Travel. . . . . . . . . . . . . . . . . . . . . . Rear Susp. - (Swing Arm with Scissor Stabilizer) 7.5 Travel. . . . . . . Front Tire 25 x 8 - 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Tire 25 x 11 - 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Tire 25 x 11 - 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brake Fixed Disc Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floating Caliper Rear Brake Fixed Disc Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floating Caliper Auxiliary Brake Fixed Disc Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . .

Floating Caliper Fuel Capacity 4.25 U.S. Gal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Capacity 2 U.S. Qts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight 12V 60W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taillight 12V 5W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust USFS Approved. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Rack Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hitch Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Kit Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight 1970 lbs., including. . . . . . . . . . . . . . . . . . . . . . .

machine, driver & cargo Load Capacity 75 Lbs. Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 Lbs. Cargo Bed Transmission PVT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Box Hi/Lo-R-N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Chain 520 - O Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Radius (Unloaded) 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Drive Sprocket 12/38 - 80 Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . Axle to Axle 30/30 - 116 Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119

SPECIFICATIONS Engine Specifications

2002 Sportsman 6x6 Engine EH50PLE-06. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement 499 cc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 4 Cycle, Single Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Liquid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore x Stroke 92 x 75 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lube Dry Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Electric/Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition CDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug BKR5E (NGK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 250W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comp. Ratio 10.2:1 Full Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing 30@ 3500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetion 1/BST34 (CV Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Jet 142.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Jet 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jet Needle 4HB41-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Needle Jet Q-4(829). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Screw 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

120

WIRING DIAGRAM

121

TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis

Possible Causes Solutions/What to do

Loading the 6x6 into a pick- up or tall trailer when in high range.

Shift transmission to low range during loading of the 6x6 to prevent belt burn- ing.

Starting out going up a steep incline.

When starting out on an incline, use low range, or dismount the 6x6 after first applying the park brake and per- form the K turn as described on page 67 of this manual.

Driving at low RPM or low ground speed (at approxi- mately 3--7 MPH).

Drive at higher speed or use Low Range. The use of Low Range is high- ly recommended for cooler PVT oper- ating temperatures and longer compo- nent life.

Insufficient warm--up of 6x6s exposed to low ambi- ent temperatures.

Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will be- come more flexible and prevent belt burning.

Slow and easy clutch en- gagement.

Fast, effective use of the throttle for efficient engagement.

Towing/Pushing at low RPM/low ground speed.

Use Low Range only.

Plowing snow, dirt, etc./util- ity use.

Use Low Range only.

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TROUBLESHOOTING Possible Causes Solutions/What to do

Stuck in mud or snow. Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage clutch. WARN- ING: Excessive throttle may cause loss of control and vehicle overturn.

Climbing over large objects from a stopped position.

Shift the transmission to Low Range, carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle over- turn.

Belt slippage from water or snow ingestion into the PVT system.

Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to full throttle. Repeat several times as required. During this proce- dure, the throttle should not be held at the full position for more than 10 sec- onds. Clutch seals should be inspected for damage if repeated leaking occurs.

Clutch malfunction. For inspection of clutch components, please contact your Polaris dealer.

Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact you dealer for further service informa- tion.

GENERAL RANGE OPERATION GUIDELINES:

Low Range Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain (swamps, moun- tains, etc.), low ground speeds.

High Range High ground speeds, speeds above 7 MPH.

123

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 you may have.

ENGINE CRANKS BUT FAILS TO START

Stop Switch Off No Fuel Water in Fuel Spark Plug

Fuel Valve Off Drain System No Spark to Spark Plug

Contact Your Dealer

Clogged Fuel Valve

ENGINE STOPS OR LOSES POWER

No Fuel

Contact Your Dealer

Contact Your Dealer

Overuse of Choke

Spark Plug Fouled

Engine Overheated

Clean Engine Exterior

Turn Fuel Valve to Res

Water in Fuel

Air Filter Clogged

Reverse Speed Limiter

Malfunction

Electronic Throttle Control Malfunction

Fuel Vent Line Kinked or Plugged

Clean Radiator screen

124

WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a SIX MONTH 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. 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.

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. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that has been altered structurally, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause beyond Polaris control.

125

WARRANTY This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law. 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). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at Polaris. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect. Engine Oil 1. Always use Polaris engine oil. 2. Never substitute or mix oil brands as serious engine damage and voiding of warranty can result.

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INDEX Accessories 117. . . . . . . . . . . . . . . . . . . . . . . Adjustments 90-102. . . . . . . . . . . . . . . . . . . Air Box Drain 89. . . . . . . . . . . . . . . . . . . . . Air Cleaner 88. . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 48. . . . . . . . . . . . . . . . . . . Backing Up 69-70. . . . . . . . . . . . . . . . . . . . . Battery Fluid 108. . . . . . . . . . . . . . . . . . . . . Battery Installation 109. . . . . . . . . . . . . . . . Battery Maintenance 108-110. . . . . . . . . . . . Battery Removal 109. . . . . . . . . . . . . . . . . . Brake, Auxiliary 41. . . . . . . . . . . . . . . . . . . Brake, Front 92. . . . . . . . . . . . . . . . . . . . . . Brake, Parking 42. . . . . . . . . . . . . . . . . . . . Brake, Rear 93. . . . . . . . . . . . . . . . . . . . . . . Brakelight Lamp Replacement 114. . . . . . . . Brakes, Front 40. . . . . . . . . . . . . . . . . . . . . Brakes, Rear 40. . . . . . . . . . . . . . . . . . . . . . Breather Filter 89. . . . . . . . . . . . . . . . . . . . . Camber And Caster 91. . . . . . . . . . . . . . . . Carburetor Adjustment 100. . . . . . . . . . . . . Carburetor Adjustments 101. . . . . . . . . . . . Carrying Loads 54-56. . . . . . . . . . . . . . . . . . Choke Adjustment 94. . . . . . . . . . . . . . . . . Choke Lever 39. . . . . . . . . . . . . . . . . . . . . . Cleaning 115. . . . . . . . . . . . . . . . . . . . . . . . Controls 37-46. . . . . . . . . . . . . . . . . . . . . . . Controls And Features 37-49. . . . . . . . . . . . Coolant Level 87. . . . . . . . . . . . . . . . . . . . . Coolant Level Inspection 86. . . . . . . . . . . . Crossing Streams 68. . . . . . . . . . . . . . . . . . Daily Pre- ride Inspection 51, 58. . . . . . . . . . Disengaging Wheel Hubs 49. . . . . . . . . . . . Drive Chain Adjustment 98-99. . . . . . . . . . . Dumping Cargo Bed 56. . . . . . . . . . . . . . . . Engine Cooling System 86-87. . . . . . . . . . . Engine Electrical Switches 38. . . . . . . . . . . Engine Idle Rpm Adjustment 100. . . . . . . . Engine Specifications 119. . . . . . . . . . . . . . . Features 47-49. . . . . . . . . . . . . . . . . . . . . . . Filter Systems 88-89. . . . . . . . . . . . . . . . . . . Frame VIN 6. . . . . . . . . . . . . . . . . . . . . . . . Front Gearcase Lubrication 81. . . . . . . . . . Front Wheel Hub Tightening 97. . . . . . . . . Fuel System 43-44. . . . . . . . . . . . . . . . . . . . Gearcase Oil Changing 81. . . . . . . . . . . . . Handlebar Adjustment 91. . . . . . . . . . . . . . Headlight Adjustment 112. . . . . . . . . . . . . . . Headlight Housing Replacement 113. . . . . . Headlight Lamp Replacement 111. . . . . . . . Identification Numbers 6. . . . . . . . . . . . . . . Indicator Lamp Replacement 114. . . . . . . . . Indicator Lights 47. . . . . . . . . . . . . . . . . . . Jetting Chart 101. . . . . . . . . . . . . . . . . . . . . Light Switches 47. . . . . . . . . . . . . . . . . . . . Lights-Adjustment-Replacement 111-114. . Load Distribution 59. . . . . . . . . . . . . . . . . .

Lubrication Recommendations 77-84. . . . . . Main Switch 38. . . . . . . . . . . . . . . . . . . . . . Maintenance And Lubrication 73-117. . . . . Maintenance Record 85. . . . . . . . . . . . . . . . Making Turns 61. . . . . . . . . . . . . . . . . . . . . Noise Control System 57. . . . . . . . . . . . . . . Oil Change 83. . . . . . . . . . . . . . . . . . . . . . . Oil Filter Change 83. . . . . . . . . . . . . . . . . . Oil System 43-44, 82. . . . . . . . . . . . . . . . . . Operating Safety 56. . . . . . . . . . . . . . . . . . . Operation 50-55. . . . . . . . . . . . . . . . . . . . . . Operator Safety 21-36. . . . . . . . . . . . . . . . . . Parking On An Incline 72. . . . . . . . . . . . . . Periodic Maintenance Schedule 74-76. . . . . Premium 4 Synthetic Lubricant 82. . . . . . . Pvt System 107. . . . . . . . . . . . . . . . . . . . . . Recoil Starter 46. . . . . . . . . . . . . . . . . . . . . Riding 58-72. . . . . . . . . . . . . . . . . . . . . . . . . Riding Gear 12. . . . . . . . . . . . . . . . . . . . . . Riding On Slippery Surfaces 63-64. . . . . . . Riding Safely 59-72. . . . . . . . . . . . . . . . . . . Safety 8-36. . . . . . . . . . . . . . . . . . . . . . . . . . Safety 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals And Locations 13-20. . . . . . . Safety Training 3. . . . . . . . . . . . . . . . . . . . . Serial Number 6. . . . . . . . . . . . . . . . . . . . . . Side Panel Removal 102. . . . . . . . . . . . . . . Sidehilling 62. . . . . . . . . . . . . . . . . . . . . . . Spark Arrestor 57, 104-106. . . . . . . . . . . . . Spark Plug Removal103 Spark Plugs 103. . . . . . . . . . . . . . . . . . . . . . Specifications 118-119. . . . . . . . . . . . . . . . . Starting A Cold Engine 52. . . . . . . . . . . . . . Starting A Warm Engine 53. . . . . . . . . . . . . Steering Inspection 91. . . . . . . . . . . . . . . . . Stop Switch 38. . . . . . . . . . . . . . . . . . . . . . . Storage Of The 6x6 116. . . . . . . . . . . . . . . . . Suspension Springs 91. . . . . . . . . . . . . . . . . Table Of Contents 4-5. . . . . . . . . . . . . . . . . . Taillight Lamp Replacement 114. . . . . . . . . . Throttle Lever 39. . . . . . . . . . . . . . . . . . . . . Tire Inspection 96. . . . . . . . . . . . . . . . . . . . Tire Specifications 97. . . . . . . . . . . . . . . . . Toe Alignment 90. . . . . . . . . . . . . . . . . . . . Tool Kit 73. . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 97. . . . . . . . . . . . . . . Towing Capacities 54. . . . . . . . . . . . . . . . . Trail Obstacles 71. . . . . . . . . . . . . . . . . . . . Transmission Gear Selector Operation 45. . Transmission Lubrication 80. . . . . . . . . . . . Transmission Oil Changing 80. . . . . . . . . . Transporting The 6x6 117. . . . . . . . . . . . . . . Traveling Downhill 65. . . . . . . . . . . . . . . . . Traveling Uphill 66. . . . . . . . . . . . . . . . . . . Troubleshooting 121-123. . . . . . . . . . . . . . . Turning Around On A Hill 67. . . . . . . . . . .

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INDEX Welcome 2. . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Installation 95. . . . . . . . . . . . . . . . . . Wheel Removal 95. . . . . . . . . . . . . . . . . . . Wiring Diagram 120. . . . . . . . . . . . . . . . . . Understanding Warnings 7. . . . . . . . . . . . .

Vehicle Break- in Period 50. . . . . . . . . . . . . Vehicle Identification Numbers 6. . . . . . . . Vehicle Nomenclature 37. . . . . . . . . . . . . . . Warranty 124-125. . . . . . . . . . . . . . . . . . . . .

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