2002 Polaris Sportsman 6x6 Problems and Repair Information
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Popular 2002 Polaris Sportsman 6x6 Manual Pages
Owners Manual - Page 5
... our world-wide family of experience in engineering, design, and development have gone into making your Polaris vehicle the finest machine we've ever produced. Your Polaris dealer knows your vehicle best and is interested in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician. Polaris and Polaris The Way...
Owners Manual - Page 11
... is based upon the latest product data and specifications available at various intervals. THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. Respect the environment; and You will gain the respect of Polaris Industries Inc. Polaris Industries Inc. No part of this manual shall be reproduced or used without the written...
Owners Manual - Page 14
... at various mileage intervals. Due to our concern for the safety of certain accessories including (but not limited to the vehicle for this manual. We also advise you that these purposes. S Always be aware that the warranty on the vehicle.
11 S Always use of bodily injury. Always maintain proper tire pressure as described in this vehicle have reduced...
Owners Manual - Page 23
...the filter element will severely damage the engine. D Factory setting: 40_ to 27_ C. See your Owner's Manual. at 0-3000 feet (5_ to 80_ F. Consult owner's manual for details. VERTICAL WEIGHT: 35 LBS. (16 KG) 7078261
(On Hitch)
D
Operation of this vehicle without engine breather filter(s) can cause engine damage. ATTENTION
Specific carburetor jetting and adjustments are required...
Owners Manual - Page 27
Apply the service brake, gradually. WHAT CAN HAPPEN Could result in the Owner's Manual. If you begin rolling backwards: Keep weight uphill; Dismount on uphill side, or to brakes, throttle and steering for possible damage.
24 never apply engine power. Turn the vehicle around and remount, following the procedure described in vehicle overturning. Never apply the...
Owners Manual - Page 38
... situations could lead to an accident. All parts and accessories added to instructions. or equivalent components designed for use on this vehicle, or operation of this vehicle through improper installation or use the size and type tires specified in the Owner's Manual for this vehicle with improper tires, or with improper modifications. WHAT CAN HAPPEN Use of...
Owners Manual - Page 42
... the lever is provided for correct choke and throttle settings during starting the engine and occasionally during riding and cause an accident. Always check the lever for service repairs whenever throttle problems arise. CONTROLS AND FEATURES
Controls
Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. In the event the throttle...
Owners Manual - Page 48
... Should you experience any shifting problem see your dealer. Do not attempt to shift gears with the parking brake locked whenever the vehicle is recommended in gear with the engine idling, move the lever to the desired gear. Always place the transmission in heavy pulling situations to assure proper transmission function. reverse; WARNING
1. neutral; Do...
Owners Manual - Page 49
... especially when travelling in wet areas. See page 42. 2. If it stops This will allow vehicle operation until the starter mechanism engages. 3. Recoil Starter
CAUTION
Do not extend the starter rope so ...
46
CONTROLS AND FEATURES
Controls
Recoil Starter If the battery is weak and cannot start the engine, use of the machine will cause damage to start handle is set. Pull the rope ...
Owners Manual - Page 50
... (Red) NOTE: Will light only if engine overheats. With engine running, verify function of reduced visibility such as fog, rain and darkness.
47 Handlebar light switch and headlight Hi-Lo beam control NOTE: Will not light unless main switch is used. Transmission neutral indicator (Green) 6. This vehicle is not equipped with highway approved lighting...
Owners Manual - Page 53
... more efficient performance and longer life for the engine. Serious engine damage and voiding of warranty can build up and cause damage to close fitted engine parts.
5. NORMAL FULL
3. Maintain Oil Level In Normal Range Select an area which has a minimum pump octane number of 87= (R+ M)/2. 2. Do not operate at 20 hours or 200 miles.
50 Change...
Owners Manual - Page 55
... the engine stop switch to avoid engine damage. Vary the engine RPM slightly with the throttle to aid in an enclosed area. 52 Proper engine warm up is poisonous! Activate the starter for another five seconds. OPERATION
Starting a Cold Engine
1. If engine does not start the vehicle outdoors.
Place the transmission in . CAUTION
WARNING
Carbon monoxide exhaust gas is...
Owners Manual - Page 56
Place the transmission in starting. 7. If the engine is permitted. 6. Turn the fuel tank valve to a point where it does not readily start and all conditions are favorable, change the spark plug.
53 Sit on the vehicle. 5. If the engine does not start , intermittent use of the choke button pulled half way out is over-choked...
Owners Manual - Page 63
... brakes on the handlebars. 2. RIDING
Riding Safely
1. After starting the engine and allowing it to warm up, shift the transmission into gear. 3.
Release the parking brake. 5. Slowly depress the throttle with both feet on the footrests and both hands on level surfaces. Vehicle speed is controlled by the amount of travel. 4. Sit upright...
Owners Manual - Page 70
..., maintaining body weight uphill. 7. Dismount on reasonably level ground. Restart engine with transmission still in forward, and proceed slowly, controlling speed with the service brake, until it is on left or uphill side of vehicle could occur.
Loss of vehicle control or overturning of vehicle. 4. One maneuver which can be used when it down the hill...
Owners Manual - Page 78
... or Odometer 10 hrs/100 miles 20 hrs 20 hrs 25 hrs 50 hrs 50 hrs 50 hrs 50 hrs 100 hrs/1000 miles 100 hrs/1000 miles 100 hrs 100 hrs 50 ... cold weather use Replace with a J, it is recommended that service be performed by an authorized Polaris dealer. Item J " Brake pad wear Engine breather filter Battery " " J Transmission Oil Level General Lubrication Throttle Cable/ETC Switch Choke (Enricher)...
Owners Manual - Page 98
... wheel nuts to the following torque: S Torque center and rear wheel nuts to 20 ft. Stop the engine, place the transmission in 3. Wheel Installation 1. CAUTION
If wheels are improperly installed it could affect vehicle handling and tire wear. Make sure the tapered end of the rear wheel nut goes into the taper on the...
Owners Manual - Page 103
... engine by running the vehicle approximately five minutes. 2. Turning the screw in or out until the desired idle RPM is reached. MAINTENANCE AND LUBRICATION
Adjustments
Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: Idle Screw 1. Place the transmission...
Owners Manual - Page 124
...longer component life. Warm engine at approximately 3--7 MPH). Fast, effective use of this manual. Driving at low RPM or low ground speed (at least 5 min., then with transmission in neutral, advance throttle ..., etc./utility use low range, or dismount the 6x6 after first applying the park brake and perform the "K" turn as described on an incline, use .
121 Use Low Range only. TROUBLESHOOTING
...
Owners Manual - Page 129
... Tire Specifications ...97 Toe Alignment ...90 Tool Kit ...73 Torque Specifications ...97 Towing Capacities ...54 Trail Obstacles ...71 Transmission Gear Selector Operation . . 45 Transmission Lubrication ...80 Transmission Oil Changing ...80 Transporting The 6x6 ...117 Traveling Downhill ...65 Traveling Uphill ...66 Troubleshooting ...121-123 Turning Around On A Hill ...67
126 INDEX
Accessories...
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