Polaris 2002 Sportsman 6x6 v2 Owner's Manual PDF

Pages 131
Year 2001
Language(s)
English en
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1 of 131

Summary of Content for Polaris 2002 Sportsman 6x6 v2 Owner's Manual PDF

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

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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...

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

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

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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...

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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...

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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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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...

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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...

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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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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...

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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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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...

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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...

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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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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...

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

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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...

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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...

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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:

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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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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...

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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...

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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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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...

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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...

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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...

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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...

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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...

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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...

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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...

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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...

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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...

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

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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...

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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...

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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...

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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...

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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...

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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...

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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...

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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...

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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...

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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

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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...

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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...

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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...

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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...

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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

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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-

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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...

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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...

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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...

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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

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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...

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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...

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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...

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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...

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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!

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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...

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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

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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...

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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-

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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-

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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

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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...

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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...

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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...

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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...

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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)

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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...

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" 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...

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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...

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

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

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** Grease conforming to NLGI No... 2, such as Conoco Superlube M or Mobilegrease Special

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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)...

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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...

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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

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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...

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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...

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

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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...

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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...

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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...

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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...

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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

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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...

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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

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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

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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

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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...

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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...

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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...

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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...

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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)...

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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-

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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-

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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...

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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

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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...

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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...

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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...

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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:

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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...

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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...

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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...

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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

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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

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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...

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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

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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...

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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

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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

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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... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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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 [email protected] 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...

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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...

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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...

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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...

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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...

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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... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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

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