Owners Manual
Page 6
... your owner's manual, which includes valuable information about all warnings before operating a Polaris Sportsman 6x6. You were also provided with printed materials that covers all aspects of age. Age Restrictions This vehicle is not a toy and can request this free safety training from a party other vehicles, such as motorcycles and cars. If you purchased a used Polaris Sportsman 6x6 from any authorized Polaris dealer. 4 READ YOUR OWNER'S MANUAL WARNING...
... your owner's manual, which includes valuable information about all warnings before operating a Polaris Sportsman 6x6. You were also provided with printed materials that covers all aspects of age. Age Restrictions This vehicle is not a toy and can request this free safety training from a party other vehicles, such as motorcycles and cars. If you purchased a used Polaris Sportsman 6x6 from any authorized Polaris dealer. 4 READ YOUR OWNER'S MANUAL WARNING...
Owners Manual
Page 11
... recommended turning procedures as described in your experience. SAFETY Operator Safety WARNING Serious injury or death can result if you . S Always avoid operating this vehicle. S Never operate this manual and all labels carefully, and follow these instructions and procedures, which are outlined in safe operating condition. S Never operate this manual. S Always follow the inspection and maintenance procedures and schedules outlined...
... recommended turning procedures as described in your experience. SAFETY Operator Safety WARNING Serious injury or death can result if you . S Always avoid operating this vehicle. S Never operate this manual and all labels carefully, and follow these instructions and procedures, which are outlined in safe operating condition. S Never operate this manual. S Always follow the inspection and maintenance procedures and schedules outlined...
Owners Manual
Page 13
..., tires, sprayers, or large racks, may change the handling characteristics of the vehicle, or make any modifications have reduced stopping ability. S Never exceed the stated load capacity for braking. Allow a greater distance for your vehicle. Therefore, we strongly recommend that consumers do not install on a Polaris Sportsman 6x6 any equipment that may increase the speed or power of the vehicle. Use only Polaris-approved accessories, and...
..., tires, sprayers, or large racks, may change the handling characteristics of the vehicle, or make any modifications have reduced stopping ability. S Never exceed the stated load capacity for braking. Allow a greater distance for your vehicle. Therefore, we strongly recommend that consumers do not install on a Polaris Sportsman 6x6 any equipment that may increase the speed or power of the vehicle. Use only Polaris-approved accessories, and...
Owners Manual
Page 37
... to the center RUN position and turn on unless the main switch is not in use of control, resulting in severe injury or death. To obtain additional power while backing, depress the override button. To start the engine, slide the stop switch to unauthorized use . Release the key when the engine starts. Turn the key off all electrical power to provide the operator with a reverse speed limiter system...
... to the center RUN position and turn on unless the main switch is not in use of control, resulting in severe injury or death. To obtain additional power while backing, depress the override button. To start the engine, slide the stop switch to unauthorized use . Release the key when the engine starts. Turn the key off all electrical power to provide the operator with a reverse speed limiter system...
Owners Manual
Page 43
... miles per hour for extended periods of the engine recoil starter. Depress the auxiliary brake if shifting into high or park. Belt Life To extend belt life, use low forward gear in gear with engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to assure proper transmission function. Do not attempt to the desired gear. CONTROLS Gear...
... miles per hour for extended periods of the engine recoil starter. Depress the auxiliary brake if shifting into high or park. Belt Life To extend belt life, use low forward gear in gear with engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to assure proper transmission function. Do not attempt to the desired gear. CONTROLS Gear...
Owners Manual
Page 45
FEATURES All Wheel Drive (AWD) System 1 2 The Polaris Sportsman 6x6 is moving. The AWD switch may be turned on or off when the front hubs are spinning may remain in AWD and the front wheels will automatically engage any time the rear wheels lose traction. If the switch is in rear wheel drive at all times. When the rear wheels regain traction, the front wheels will not release until the rear wheels regain traction. There is no limit...
FEATURES All Wheel Drive (AWD) System 1 2 The Polaris Sportsman 6x6 is moving. The AWD switch may be turned on or off when the front hubs are spinning may remain in AWD and the front wheels will automatically engage any time the rear wheels lose traction. If the switch is in rear wheel drive at all times. When the rear wheels regain traction, the front wheels will not release until the rear wheels regain traction. There is no limit...
Owners Manual
Page 48
... instrument cluster. 1. It can, however, also indicate that the ATV is in : H = High Range L = Low Range N = Neutral R = Reverse P = Park E or blank = Error - Low Battery and Over Voltage - This warning usually indicates that the transmission switch needs repair. 2. As the 3 2 4 shift lever is in between gears. The 5 1 error message usually means the gear selector is being operated at start-up for proper diagnosis. High Engine Coolant...
... instrument cluster. 1. It can, however, also indicate that the ATV is in : H = High Range L = Low Range N = Neutral R = Reverse P = Park E or blank = Error - Low Battery and Over Voltage - This warning usually indicates that the transmission switch needs repair. 2. As the 3 2 4 shift lever is in between gears. The 5 1 error message usually means the gear selector is being operated at start-up for proper diagnosis. High Engine Coolant...
Owners Manual
Page 53
.... 7. Change both at full throttle or high speeds for extended periods during the break-in the oil and the filter. OPERATION Vehicle Break-in Period The break-in period for your new Polaris Sportsman 6x6 is as important as the first ten hours of operation or the time it takes to use the first two tanks of gasoline. Perform regular checks on fluid levels, controls...
.... 7. Change both at full throttle or high speeds for extended periods during the break-in the oil and the filter. OPERATION Vehicle Break-in Period The break-in period for your new Polaris Sportsman 6x6 is as important as the first ten hours of operation or the time it takes to use the first two tanks of gasoline. Perform regular checks on fluid levels, controls...
Owners Manual
Page 57
... the headlight when loading the front rack. Avoid terrain or situations that may cause loss of control or brake instability. Do not obstruct the headlight beam with a loaded vehicle. Maximum Towing Capacities (Level Ground) Maximum towing load weight is 1500 lbs. (681 kg) on level ground only and 850 lbs. (386 kg) on a grade steeper than 15°. Do not tow any trailer on...
... the headlight when loading the front rack. Avoid terrain or situations that may cause loss of control or brake instability. Do not obstruct the headlight beam with a loaded vehicle. Maximum Towing Capacities (Level Ground) Maximum towing load weight is 1500 lbs. (681 kg) on level ground only and 850 lbs. (386 kg) on a grade steeper than 15°. Do not tow any trailer on...
Owners Manual
Page 75
... As required As required As required " J J J Front hubs Clutches (drive and driven) Shift selector box Brake fluid Headlight aim J Toe adjustment Recoil housing Idle speed " J More often under severe use Replace with oil change oil more often in service at tank cap, lines, fuel valve, filter, pump and carburetor; change Oil filter 6 months Coolant Breather hose " " J " Rear suspension Drive chains Drive belt Front hubs Shift linkage J " " J J Steering Rear axle / Center axle Front suspension Valve clearance Fuel system 6 months 6 months 6 months 6 months 6 months 6 months...
... As required As required As required " J J J Front hubs Clutches (drive and driven) Shift selector box Brake fluid Headlight aim J Toe adjustment Recoil housing Idle speed " J More often under severe use Replace with oil change oil more often in service at tank cap, lines, fuel valve, filter, pump and carburetor; change Oil filter 6 months Coolant Breather hose " " J " Rear suspension Drive chains Drive belt Front hubs Shift linkage J " " J J Steering Rear axle / Center axle Front suspension Valve clearance Fuel system 6 months 6 months 6 months 6 months 6 months 6 months...
Owners Manual
Page 78
...arm housing and grease with grease gun. Locate fitting on rear strut and grease with grease gun. Locate fitting on swing arm and grease with grease gun. MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Drive Axle U Joints (1) Rear Axle Bearing (2) Swing Arm Bushings (3) Middle Axle Bearings (4) Center Swing Arm Housing (5) Rear Strut... use, such as wet or dusty conditions Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2 Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging. 4 1 3 ...
...arm housing and grease with grease gun. Locate fitting on rear strut and grease with grease gun. Locate fitting on swing arm and grease with grease gun. MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Drive Axle U Joints (1) Rear Axle Bearing (2) Swing Arm Bushings (3) Middle Axle Bearings (4) Center Swing Arm Housing (5) Rear Strut... use, such as wet or dusty conditions Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2 Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging. 4 1 3 ...
Owners Manual
Page 82
... miles, or every six months, whichever comes first. Position the vehicle on the oil drain plug. Run the engine for two to drain completely. 4. Severe use requires more frequent service. when most trips are at the bottom of the oil tank and the bottom of the engine. 2. CAUTION The recommended oil change the oil filter whenever changing oil. 1. and operation between 10° F. Disconnect the lower oil delivery hose...
... miles, or every six months, whichever comes first. Position the vehicle on the oil drain plug. Run the engine for two to drain completely. 4. Severe use requires more frequent service. when most trips are at the bottom of the oil tank and the bottom of the engine. 2. CAUTION The recommended oil change the oil filter whenever changing oil. 1. and operation between 10° F. Disconnect the lower oil delivery hose...
Owners Manual
Page 83
... SH oil, 0-40W. CAUTION 12. Also make sure the gasket is not drained, add about 1 3/4 quarts initially. 13. Place shop towels beneath the oil filter. Start the engine and let it idle for leaks. 15. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 7. Lubricate the gasket on the dipstick. 16. Place the gear selector in good condition. Using an oil filter wrench, turn after gasket contacts the engine. 10...
... SH oil, 0-40W. CAUTION 12. Also make sure the gasket is not drained, add about 1 3/4 quarts initially. 13. Place shop towels beneath the oil filter. Start the engine and let it idle for leaks. 15. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 7. Lubricate the gasket on the dipstick. 16. Place the gear selector in good condition. Using an oil filter wrench, turn after gasket contacts the engine. 10...
Owners Manual
Page 90
... the handlebar cover and 4 loosen the block bolts (1). 2. in the sequence shown in FIRM N/A 88 Handlebar Adjustment Your vehicle has handlebars that can cause limited steering or loosening of the handlebars, resulting in the block. 4. Torque the handlebar adjuster block bolts to left or right. 3. Perform the handlebar adjustment exactly as outlined. Optional Suspension Springs Although the Polaris Sportsman 6x6 suspension has...
... the handlebar cover and 4 loosen the block bolts (1). 2. in the sequence shown in FIRM N/A 88 Handlebar Adjustment Your vehicle has handlebars that can cause limited steering or loosening of the handlebars, resulting in the block. 4. Torque the handlebar adjuster block bolts to left or right. 3. Perform the handlebar adjustment exactly as outlined. Optional Suspension Springs Although the Polaris Sportsman 6x6 suspension has...
Owners Manual
Page 111
.... 109 Waxing the Vehicle Your vehicle can be cleaned much like an automobile. MAINTENANCE AND LUBRICATION Cleaning and Storage Keeping your vehicle can be waxed with any water that may have entered the engine or exhaust system. Grease all zerk fittings immediately after washing with a chamois to the drive chain, wheel bearings, transmission seals, body panels, brakes and warning labels. Washing the Vehicle The best and safest...
.... 109 Waxing the Vehicle Your vehicle can be cleaned much like an automobile. MAINTENANCE AND LUBRICATION Cleaning and Storage Keeping your vehicle can be waxed with any water that may have entered the engine or exhaust system. Grease all zerk fittings immediately after washing with a chamois to the drive chain, wheel bearings, transmission seals, body panels, brakes and warning labels. Washing the Vehicle The best and safest...
Owners Manual
Page 112
... fuel valve off the engine and remove the key so it in gear and lock the parking brake. 110 Turn the fuel valve off the ground. 8. Be sure the fuel cap and oil cap are suspended off and drain the carburetor. Drain tube 3. Operate the starter for Drain Screw a few seconds and reinstall the spark plug. 4. Cover the vehicle with another unit. 1. Lubricate the suspension pivot points, the lower steering post and the rear axle fittings. 6. MAINTENANCE...
... fuel valve off the engine and remove the key so it in gear and lock the parking brake. 110 Turn the fuel valve off the ground. 8. Be sure the fuel cap and oil cap are suspended off and drain the carburetor. Drain tube 3. Operate the starter for Drain Screw a few seconds and reinstall the spark plug. 4. Cover the vehicle with another unit. 1. Lubricate the suspension pivot points, the lower steering post and the rear axle fittings. 6. MAINTENANCE...
Owners Manual
Page 113
SPECIFICATIONS SPORTSMAN 6x6 Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Cargo Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1970 lbs. (including machine, driver, cargo) 4.25 gallons/16.09 liters 1500 lbs...
SPECIFICATIONS SPORTSMAN 6x6 Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Cargo Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1970 lbs. (including machine, driver, cargo) 4.25 gallons/16.09 liters 1500 lbs...
Owners Manual
Page 121
... with controlling state law. Polaris suggests that are void because of state or federal law, all other rights which vary from the use of non-recommended lubricants may not apply to perform warranty service. Please work with the vehicle. Engine Oil 1. Mixing oil brands or using non-recommended oil may use any warranty issues. however, you may cause engine damage. This warranty does not cover the...
... with controlling state law. Polaris suggests that are void because of state or federal law, all other rights which vary from the use of non-recommended lubricants may not apply to perform warranty service. Please work with the vehicle. Engine Oil 1. Mixing oil brands or using non-recommended oil may use any warranty issues. however, you may cause engine damage. This warranty does not cover the...
Owners Manual
Page 122
INDEX A Accessories ...70 Adjustments ...87-95 Age Restrictions ...4 Air Box Drain ...86 Air Filter ...85 All Wheel Drive (AWD) System ...43-44 Auxiliary Brakes ...37 F Fuel Tank ...40 Fuel Valve ...40 G Gear Selector Operation ...41 Gearcase Oil Changing ...78 B Battery ...102-104 Battery Fluid ...103 Battery Installation and Connections ...104 Battery Removal ...103 Battery Storage ...104 Belt Life ...41 Brake Front ...89 Brake Parking ...39 Brake Rear ...90 Brakes ...37-38 Breather Filter ...86 H Handlebar Adjustment ...88 Hauling Cargo ...55...
INDEX A Accessories ...70 Adjustments ...87-95 Age Restrictions ...4 Air Box Drain ...86 Air Filter ...85 All Wheel Drive (AWD) System ...43-44 Auxiliary Brakes ...37 F Fuel Tank ...40 Fuel Valve ...40 G Gear Selector Operation ...41 Gearcase Oil Changing ...78 B Battery ...102-104 Battery Fluid ...103 Battery Installation and Connections ...104 Battery Removal ...103 Battery Storage ...104 Belt Life ...41 Brake Front ...89 Brake Parking ...39 Brake Rear ...90 Brakes ...37-38 Breather Filter ...86 H Handlebar Adjustment ...88 Hauling Cargo ...55...
Owners Manual
Page 123
... Towing Capacities ...55 Transmission Lubrication ...77 Transmission Oil Change ...77 Transporting the Vehicle ...110 Trip Meter ...47 TROUBLESHOOTING ...114-117 Turning Around on a Hill ...63 S Safe Riding Gear ...16 SAFETY ...7-33 Safety Decals and Locations ...12-15 Safety Training ...4 Service Brakes ...37 Setting the Parking Brake ...39 Side Panel Removal ...94 Sidehilling ...60 Spark Arrestor ...69, 99 Spark Plug Removal ...98 Spark Plugs ...98 SPECIFICATIONS ...111-112 Starting a Cold Engine ...53 Starting a Warm Engine ...54 Steering Inspection ...88 Stop Switch ...35 Suspension...
... Towing Capacities ...55 Transmission Lubrication ...77 Transmission Oil Change ...77 Transporting the Vehicle ...110 Trip Meter ...47 TROUBLESHOOTING ...114-117 Turning Around on a Hill ...63 S Safe Riding Gear ...16 SAFETY ...7-33 Safety Decals and Locations ...12-15 Safety Training ...4 Service Brakes ...37 Setting the Parking Brake ...39 Side Panel Removal ...94 Sidehilling ...60 Spark Arrestor ...69, 99 Spark Plug Removal ...98 Spark Plugs ...98 SPECIFICATIONS ...111-112 Starting a Cold Engine ...53 Starting a Warm Engine ...54 Steering Inspection ...88 Stop Switch ...35 Suspension...