Owners Manual
Page 14
... change the handling characteristics of certain accessories including (but not limited to the vehicle for carrying cargo or pulling a trailer. SAFETY S Key Safety Issues Wet brakes may have been made to the vehicle which is safe to this vehicle. S Always be properly distributed and securely attached. When it is intended to our concern for braking. Always maintain proper tire pressure as described in this manual. Reduce speed...
... change the handling characteristics of certain accessories including (but not limited to the vehicle for carrying cargo or pulling a trailer. SAFETY S Key Safety Issues Wet brakes may have been made to the vehicle which is safe to this vehicle. S Always be properly distributed and securely attached. When it is intended to our concern for braking. Always maintain proper tire pressure as described in this manual. Reduce speed...
Owners Manual
Page 17
.... 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 more detailed loading information. 14 Vehicle damage or tipover may result causing severe injury or death. Be careful if load extends over the side of the rack or box. SAFETY Safety Decals and Locations 1 WARNING DO NOT TOW FROM RACK OR BUMPER...
.... 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 more detailed loading information. 14 Vehicle damage or tipover may result causing severe injury or death. Be careful if load extends over the side of the rack or box. SAFETY Safety Decals and Locations 1 WARNING DO NOT TOW FROM RACK OR BUMPER...
Owners Manual
Page 19
... AND WARNINGS. SAFETY Safety Decals and Locations 3 WARNING Improper vehicle use throttle and brakes gradually. Passengers affect balance and steering and increase risk of control, never activate override button with open throttle. D To prevent flipover on public roads. D REVERSE operation can be dangerous, even at speeds too fast for more than 15 degrees 15°. PARKING BRAKE may seriously affect handling and control. D Operate at low speeds. To...
... AND WARNINGS. SAFETY Safety Decals and Locations 3 WARNING Improper vehicle use throttle and brakes gradually. Passengers affect balance and steering and increase risk of control, never activate override button with open throttle. D To prevent flipover on public roads. D REVERSE operation can be dangerous, even at speeds too fast for more than 15 degrees 15°. PARKING BRAKE may seriously affect handling and control. D Operate at low speeds. To...
Owners Manual
Page 53
... pump octane number of gasoline. Vary the throttle positions. Perform the following procedures carefully. Fill fuel tank with vehicle operation and handling. 4. NORMAL FULL 3. CAUTION Do not operate at 20 hours or 200 miles. 50 Pull only light loads. 7. Careful treatment of a new engine will give you room to use . Do not operate at first. Drive slowly at sustained idle. OPERATION Vehicle Break...
... pump octane number of gasoline. Vary the throttle positions. Perform the following procedures carefully. Fill fuel tank with vehicle operation and handling. 4. NORMAL FULL 3. CAUTION Do not operate at 20 hours or 200 miles. 50 Pull only light loads. 7. Careful treatment of a new engine will give you room to use . Do not operate at first. Drive slowly at sustained idle. OPERATION Vehicle Break...
Owners Manual
Page 54
... in proper working order. D Check condition and operation of wheel nuts and axle nuts; check operation, adjustment and fluid level (includes auxiliary brake) D Throttle - check operation of all operating controls and parts. check for proper function D Wheels - Before riding your vehicle, inspect all indicator lights and switches D Engine stop switch - check for dirt; refer to their proper levels D All brakes - fill both tanks to drive chain adjustment D Air cleaner...
... in proper working order. D Check condition and operation of wheel nuts and axle nuts; check operation, adjustment and fluid level (includes auxiliary brake) D Throttle - check operation of all operating controls and parts. check for proper function D Wheels - Before riding your vehicle, inspect all indicator lights and switches D Engine stop switch - check for dirt; refer to their proper levels D All brakes - fill both tanks to drive chain adjustment D Air cleaner...
Owners Manual
Page 55
..., releasing the key or button when the vehicle starts. CAUTION WARNING Carbon monoxide exhaust gas is needed for starting. 7. Sit on how much choke is poisonous! After the Engine Starts 1. Proper engine warm up . 2. OPERATION Starting a Cold Engine 1. Place the transmission in . Turn the fuel tank valve to engage the starter. Set the engine stop switch to aid in an enclosed area. 52 Vary the engine RPM slightly with the throttle to "run the engine in...
..., releasing the key or button when the vehicle starts. CAUTION WARNING Carbon monoxide exhaust gas is needed for starting. 7. Sit on how much choke is poisonous! After the Engine Starts 1. Proper engine warm up . 2. OPERATION Starting a Cold Engine 1. Place the transmission in . Turn the fuel tank valve to engage the starter. Set the engine stop switch to aid in an enclosed area. 52 Vary the engine RPM slightly with the throttle to "run the engine in...
Owners Manual
Page 57
... 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 extend belt life. Never exceed the following weights. Use of low forward is recommended in heavy pulling situations to 15° grade. Maximum vertical hitch weight - 30 lbs (14 kg). do not tow any trailer on the warning...
... 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 extend belt life. Never exceed the following weights. Use of low forward is recommended in heavy pulling situations to 15° grade. Maximum vertical hitch weight - 30 lbs (14 kg). do not tow any trailer on the warning...
Owners Manual
Page 58
... cause braking and control problems. D Use extreme caution when applying brakes with a loaded vehicle. D Do not obstruct the headlight when loading the front rack. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in the cargo bed as low and forward in rough terrain, while cornering, or while ascending or descending a hill. 55 D Never exceed the stated load capacity for braking. D Cargo...
... cause braking and control problems. D Use extreme caution when applying brakes with a loaded vehicle. D Do not obstruct the headlight when loading the front rack. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in the cargo bed as low and forward in rough terrain, while cornering, or while ascending or descending a hill. 55 D Never exceed the stated load capacity for braking. D Cargo...
Owners Manual
Page 61
... fasteners D Operators helmet, goggles and clothing D Engine coolant - check for free operation and closing D Headlight/Taillight/Brakelight - check for tightness of the dump box/bed latch mechanism. 58 check that axle nuts are secured by cotter pins D Drive chain - clean or replace D Steering - D Check condition and operation of wheel nuts and axle nuts; check condition and pressures D Fuel and oil tanks - check for dirt; check for any area...
... fasteners D Operators helmet, goggles and clothing D Engine coolant - check for free operation and closing D Headlight/Taillight/Brakelight - check for tightness of the dump box/bed latch mechanism. 58 check that axle nuts are secured by cotter pins D Drive chain - clean or replace D Steering - D Check condition and operation of wheel nuts and axle nuts; check condition and pressures D Fuel and oil tanks - check for dirt; check for any area...
Owners Manual
Page 77
...-ride Remarks Check operation daily; Pre-Cleaner Coolant/Level Inspection " Air Filter - Air Pressure Brake System Wheels Frame nuts, bolts, fasteners Fuel and Oil Tanks " " Air Box Sediment Tube Air Filter - CAUTION Due to severe use , such as necessary. apply Polaris dielectric grease to proper level Drain deposits whenever visible Inspect-Clean Replace engine coolant every two years Inspect-Replace if necessary Tail lamp inspection Tires - Inspect, clean, lubricate, adjust or...
...-ride Remarks Check operation daily; Pre-Cleaner Coolant/Level Inspection " Air Filter - Air Pressure Brake System Wheels Frame nuts, bolts, fasteners Fuel and Oil Tanks " " Air Box Sediment Tube Air Filter - CAUTION Due to severe use , such as necessary. apply Polaris dielectric grease to proper level Drain deposits whenever visible Inspect-Clean Replace engine coolant every two years Inspect-Replace if necessary Tail lamp inspection Tires - Inspect, clean, lubricate, adjust or...
Owners Manual
Page 78
... Inspect, lubricate, adjust Inspect daily, lubricate Inspect bearings Inspect-lubricate, tighten fasteners Oil Filter Coolant strength/pressure test system Engine breather hose " " J " Rear Suspension Drive Chains Drive Belt Front hubs/fluid check Shift linkage J " " Steering Rear Axle/Center Axle Front Suspension 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 75 Always use Replace with a J, it is recommended that service be performed by an authorized Polaris dealer. change Inspect strength seasonally; Inspect-adjust, lubricate...
... Inspect, lubricate, adjust Inspect daily, lubricate Inspect bearings Inspect-lubricate, tighten fasteners Oil Filter Coolant strength/pressure test system Engine breather hose " " J " Rear Suspension Drive Chains Drive Belt Front hubs/fluid check Shift linkage J " " Steering Rear Axle/Center Axle Front Suspension 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 6 months 75 Always use Replace with a J, it is recommended that service be performed by an authorized Polaris dealer. change Inspect strength seasonally; Inspect-adjust, lubricate...
Owners Manual
Page 79
... two years. MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item J J Valve Clearance Fuel System Hours or Odometer 100 hrs 100 hours Frequency 12 months 12 months Remarks Inspect/Adjust Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace annually Inspect/clean external surface Inspect Inspect Clean out Inspect-replace if necessary J Fuel Filter Radiator Cooling System hoses Engine Mounts Spark arrestor Spark Plug 100 hrs 100 hrs 100 hrs 100...
... two years. MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item J J Valve Clearance Fuel System Hours or Odometer 100 hrs 100 hours Frequency 12 months 12 months Remarks Inspect/Adjust Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace annually Inspect/clean external surface Inspect Inspect Clean out Inspect-replace if necessary J Fuel Filter Radiator Cooling System hoses Engine Mounts Spark arrestor Spark Plug 100 hrs 100 hrs 100 hrs 100...
Owners Manual
Page 82
.... Locate fitting on rear strut and grease with grease gun. MAINTENANCE AND LUBRICATION Lubrication Recommendations Middle Axle Bearings U Joint Swing Arm Bushings Center Swing Arm Housing Rear Axle Bearing Rear Strut Front Drive Axle U Joints Rear Axle Bearing Swing Arm Bushings Middle Axle Bearings Center Swing Arm Housing Rear Strut Grease + Grease** Grease...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 eccentric and grease with grease gun. Locate fitting on swing arm...
.... Locate fitting on rear strut and grease with grease gun. MAINTENANCE AND LUBRICATION Lubrication Recommendations Middle Axle Bearings U Joint Swing Arm Bushings Center Swing Arm Housing Rear Axle Bearing Rear Strut Front Drive Axle U Joints Rear Axle Bearing Swing Arm Bushings Middle Axle Bearings Center Swing Arm Housing Rear Strut Grease + Grease** Grease...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 eccentric and grease with grease gun. Locate fitting on swing arm...
Owners Manual
Page 86
... conditions and cold weather riding. Clean the fitting screen. lbs. Severe use includes continuous duty in oil change the oil filter whenever changing oil (Polaris PN 3084963) 1. Severe use requires more frequent service. Place vehicle on oil drain plug. C Remove the fitting (C) from the oil tank. Reattach oil line. Reinstall drain plug and torque to 14-17 ft. lbs. Severe use cold weather riding is 100 hours, 1000 miles...
... conditions and cold weather riding. Clean the fitting screen. lbs. Severe use includes continuous duty in oil change the oil filter whenever changing oil (Polaris PN 3084963) 1. Severe use requires more frequent service. Place vehicle on oil drain plug. C Remove the fitting (C) from the oil tank. Reattach oil line. Reinstall drain plug and torque to 14-17 ft. lbs. Severe use cold weather riding is 100 hours, 1000 miles...
Owners Manual
Page 100
.... Axle and Wheel Nut Torque Specifications Item Front Spindle Nut(s) Front Wheel Nuts Center and Rear Axle Nut(s) Center and Rear Wheel Nuts Specification 100 In. Lbs. 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...
.... Axle and Wheel Nut Torque Specifications Item Front Spindle Nut(s) Front Wheel Nuts Center and Rear Axle Nut(s) Center and Rear Wheel Nuts Specification 100 In. Lbs. 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...
Owners Manual
Page 117
.... 5. Adjustment - Indicator Lamp Replacement 1. Lamp 2. MAINTENANCE AND LUBRICATION Lights - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to the vehicle. Test the taillight/brakelight to the vehicle. Using a screwdriver, turn the light 1/4 turn to seat it 's working. 5. Twist the lamp harness 1/4 turn counter clockwise. 4. Reinstall the taillight assembly to be Lens replaced. 1. Install new light and use a screwdriver to Harness release the lock.
.... 5. Adjustment - Indicator Lamp Replacement 1. Lamp 2. MAINTENANCE AND LUBRICATION Lights - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to the vehicle. Test the taillight/brakelight to the vehicle. Using a screwdriver, turn the light 1/4 turn to seat it 's working. 5. Twist the lamp harness 1/4 turn counter clockwise. 4. Reinstall the taillight assembly to be Lens replaced. 1. Install new light and use a screwdriver to Harness release the lock.
Owners Manual
Page 118
... be waxed with a chamois to the drive chain, wheel bearings, transmission seals, body panels, brakes and warning labels. Avoid the use of various components. With a few precautions, your 6x6 can scratch the body finish. 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 harsh cleaners since...
... be waxed with a chamois to the drive chain, wheel bearings, transmission seals, body panels, brakes and warning labels. Avoid the use of various components. With a few precautions, your 6x6 can scratch the body finish. 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 harsh cleaners since...
Owners Manual
Page 121
Engine Oil Capacity ...2 U.S. 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. Cargo Bed Transmission ...PVT Gear Box ...Hi/Lo-R-N Drive Chain ...520 - Gal. O Ring Turn Radius (Unloaded) ...98″ Final Drive Sprocket ...12/38 - 80 Pitch Axle to Axle ...30/30 - 116 Pitch 118 MacPherson Strut ...6.7″ Travel Rear Susp. - (Swing Arm with...
Engine Oil Capacity ...2 U.S. 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. Cargo Bed Transmission ...PVT Gear Box ...Hi/Lo-R-N Drive Chain ...520 - Gal. O Ring Turn Radius (Unloaded) ...98″ Final Drive Sprocket ...12/38 - 80 Pitch Axle to Axle ...30/30 - 116 Pitch 118 MacPherson Strut ...6.7″ Travel Rear Susp. - (Swing Arm with...
Owners Manual
Page 128
... selling dealer; This warranty gives you specific legal rights, and you must present your dealer to resolve any Polaris Servicing Dealer to a Polaris Servicing Dealer. Always use of unauthorized lubricants, chemicals, or fuels that you use any warranty issues. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. If any defective materials, or components or products. Engine Oil 1. ALL IMPLIED WARRANTIES (INCLUDING BUT...
... selling dealer; This warranty gives you specific legal rights, and you must present your dealer to resolve any Polaris Servicing Dealer to a Polaris Servicing Dealer. Always use of unauthorized lubricants, chemicals, or fuels that you use any warranty issues. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. If any defective materials, or components or products. Engine Oil 1. ALL IMPLIED WARRANTIES (INCLUDING BUT...
Owners Manual
Page 129
... ...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...
... ...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...