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Polaris Sportsman 6x6 User Manual

Polaris Sportsman 6x6
131 pages
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Table of Contents

Questions and Answers:

Polaris Sportsman 6x6 Specifications

General IconGeneral
BrandPolaris
ModelSportsman 6x6
CategoryOffroad Vehicle
LanguageEnglish

Summary

Welcome

Attention and Safety Guidelines

Know Your Vehicle Before Riding

Understand vehicle operation and responsibilities before riding.

Safety Training Importance

Importance of safety training and how to obtain it.

Vehicle Identification Numbers

Safety Warnings and Symbols Explained

Understanding Warnings

Explains signal words and symbols used in the manual for safety.

Key Safety Issues and Considerations

Safety Decals and Locations

Operator Safety

Controls Overview

Vehicle Control Nomenclature

Diagram identifying main controls and components of the vehicle.

Engine Electrical Switches

Override Switch (Reverse Speed Limiter)

System to obtain additional power while backing up.

Main Switch

Controls engine starting and power to the vehicle.

Engine Stop Switch

Provides a quick means of engine shutdown in emergencies.

Throttle Lever and Choke Knob

Throttle Lever Function

Controls engine speed and vehicle movement via spring-loaded lever.

Choke Knob Function

Used for correct choke and throttle settings during engine starting.

Front and Rear Brakes

Master Cylinder Fluid Level Check

Checking brake fluid level through indicator window on handlebars.

Service Brakes Operation

Hydraulically activated disc brakes controlled by the left handlebar lever.

Braking System: Auxiliary Brake

Service Brakes (Left Handlebar Lever)

Controls braking action to all six wheels.

Auxiliary Brakes (Right Handlebar Lever)

Controls auxiliary brake for rear axles for additional braking.

Parking Brake

Setting the Parking Brake

Procedure for setting and releasing the parking brake lock.

Fuel and Oil System

Fuel Tank Filler Cap and Capacity

Location, capacity, and fuel type recommendations for the fuel tank.

Fuel Tank Supply Valve Positions

Explains OFF, ON, and RES positions for the fuel supply valve.

Transmission Gear Selector Operation

Gear Selector Lever Positions

Details the four positions: high forward, reverse, neutral, and low forward.

Recoil Starter Operation

Using the Recoil Starter

Procedure for starting the engine using the recoil starter.

Light Switches and Indicator Lights

Main Switch and Handlebar Light Switch

Controls vehicle power and headlight beam selection.

Indicator Lights Function

Explains the purpose of various indicator lights (Hi beam, reverse, etc.).

All Wheel Drive System Operation

AWD System Engagement

How the AWD system engages front wheels based on traction.

Disengaging Wheel Hubs

Identifying Engaged Hubs

How to tell if front hubs are engaged and the effects on steering.

Vehicle Break-in Period

Daily Pre-Ride Inspection

Item/Inspection Procedure Checklist

Detailed list of items to inspect before each ride for safety.

Starting a Cold Engine

Engine Starting Procedure

Step-by-step guide for starting a cold engine with choke and ignition.

After the Engine Starts

Procedure for warming up the engine after it has started.

Starting a Warm Engine

Carrying Loads

Maximum Capacities (Level Ground)

Specifies maximum load for front rack and cargo bed.

Maximum Towing Capacities

Details maximum towed load weight and vertical hitch weight.

Dumping the Cargo Bed

Cargo Bed Dumping Procedure

Steps for safely dumping the cargo bed on a level site.

Noise Emission Control System Regulation

Daily Pre-Ride Inspection

Item/Inspection Procedure Checklist

Detailed list of items to inspect before each ride for safety.

Riding Safely: Load Distribution

Proper Load Distribution Guidelines

How to load cargo bed and front rack for optimal balance.

Riding Safely: Basic Operation

Starting Engine and Basic Driving

Steps for starting engine, shifting gears, and beginning to drive.

Riding Safely: Making Turns

Practicing Safe Turning Techniques

Technique for smooth turning, utilizing body weight and rear axle mechanics.

Riding Safely: Sidehilling

Sidehilling Safety Precautions

How to safely navigate sidehills, including actions if tipping occurs.

Riding Safely: Riding On Slippery Surfaces

Riding on Slippery Surfaces

Special attention for wet trails, loose gravel, or freezing weather.

Riding Safely: Traveling Downhill

Descending Hills Safely

Procedure for safe downhill travel, including body weight transfer.

Riding Safely: Traveling Uphill

Ascending Hills Safely

Guidelines for safe uphill travel, avoiding steep hills and maintaining speed.

Riding Safely: Turning Around On A Hill

K-Turn Maneuver on Hills

Procedure for turning around on a hill when the vehicle stalls.

Riding Safely: Crossing Streams

Fording Streams Safely

Steps for safely crossing water bodies, including brake drying.

Riding Safely: Backing Up

Backing Up Procedure

Guidelines for safe backing, avoiding downhill backing and sharp turns.

Riding Safely: Trail Obstacles

Keeping Alert for Trail Obstacles

Importance of looking ahead and identifying hazards on the trail.

Riding Safely: Parking On An Incline

Vehicle Parking Procedure on Inclines

Steps for parking on inclines, including wheel blocking.

Tool Kit Contents

Periodic Maintenance Schedule

Maintenance Schedule Overview

Chart detailing inspection, adjustment, and lubrication intervals.

Lubrication Recommendations

Brake Fluid and Drive Chain Lubrication

Recommendations for brake fluid type and drive chain lubrication.

Gear Selector and Transmission Oil

Lubrication requirements for gear selector and transmission.

Front Prop Shaft and Axle U-Joints

Lubrication for front prop shaft and front drive axle U-joints.

Periodic Maintenance Schedule (Continued)

Brake Pads, Breather Filter, Battery, Transmission Oil Maintenance

Maintenance for brake pads, breather filter, battery, and transmission oil.

General Lubrication, Cables, and Carburetor Float Bowl

Lubrication and maintenance for cables and carburetor float bowl.

Engine Oil, Cooling System, Suspension, and Drive Chains

Maintenance for engine oil, cooling system, suspension, and drive chains.

Periodic Maintenance Schedule (Continued)

Valve Clearance, Fuel System, Radiator, and Cooling Hoses

Maintenance for valve clearance, fuel system, radiator, and hoses.

Engine Mounts, Spark Arrestor, Spark Plugs, Clutches, Selector, Brake Fluid

Maintenance for mounts, spark arrestor, plugs, clutches, selector, and brake fluid.

Transmission Lubrication

Transmission Fill Plug and Lubricant Level

Location of fill plug and how to check transmission lubricant level.

Transmission Oil Changing Procedure

Step-by-step guide for changing the transmission oil.

Front Gearcase Lubrication

Front Gearcase Fill Plug and Lubricant

Location of fill plug and correct lubricant for the front gearcase.

Gearcase Oil Changing Procedure

Procedure for changing the front gearcase oil.

Synthetic Lubricant and Oil System

Premium 4 Synthetic Lubricant Properties

Details on Polaris Premium 4 synthetic engine oil and its benefits.

Oil System: Checking Oil Level

Procedure for checking engine oil level using the dipstick.

Oil and Filter Change

Recommended Oil Change Intervals

Specifies intervals for oil and filter changes, including severe use.

Oil Drain and Filter Removal

Procedure for draining oil and removing the oil filter.

Oil Filter Installation and New Oil Addition

Steps for installing a new filter and adding new engine oil.

Periodic Maintenance Record

Engine Cooling System: Radiator Coolant Level Inspection

Radiator Pressure Cap Access

How to access the radiator pressure cap by removing the front rack and cover.

Coolant Replacement Recommendation

Recommendation to drain and refill coolant every two years.

Engine Cooling System: Coolant Level

Coolant Level Maintenance via Recovery Bottle

How the recovery system maintains engine coolant levels.

Filter Systems: Air Filter Service

Air Filter Replacement Procedure

Steps for removing, cleaning, and reinstalling the air filter.

Filter Systems: Air Box Drain and Breather Filter

Air Box Drain Maintenance

Periodically check and empty the air box drain tube.

Breather Filter and Hoses Inspection

Inspection and maintenance of the breather filter and hoses.

Adjustments: Toe Alignment

Checking Vehicle Toe Alignment

Method for checking vehicle toe alignment and recommended adjustment.

Adjustments: Steering and Handlebar

Steering Inspection for Loose Parts

Periodic check of steering assembly for loose nuts and bolts.

Handlebar Adjustment Procedure

How to adjust handlebars for personal fit and correct torquing.

Adjustments: Front Brake

Front Wheel and Middle Axle Brake Checks

Recommended checks for front and middle axle brake systems.

Adjustments: Rear Brake

Rear Brake Pad Wear Inspection

How to check rear brake pad wear and disc spline for wear.

Adjustments: Throttle Cable Free Play

Throttle Cable Free Play Adjustment Procedure

Procedure for adjusting throttle cable free play at the handlebar.

Adjustments: Wheel Removal and Installation

Wheel Removal Procedure

Steps for safely removing a vehicle wheel.

Wheel Installation and Torque Specifications

Procedure for installing wheels and tightening lug nuts to correct torque.

Adjustments: Tire Inspection

Tire Tread Depth Replacement

Guideline for replacing tires when tread depth is worn to 1/8 inch.

Tire Specifications and Torque

Tire Specifications

Details on front, center, and rear tire sizes and inflation pressures.

Axle and Wheel Nut Torque Specifications

Torque values for various axle and wheel nuts.

Adjustments: Front Drive Chain

Front Drive Chain Slack Measurement

How to measure chain slack and the proper deflection specification.

Front Drive Chain Adjustment Procedure

Steps for adjusting the front drive chain tension.

Adjustments: Rear Axle Drive Chain

Rear Chain Adjustment Procedure

Procedure for adjusting the rear axle drive chain slack.

Adjustments: Carburetor/Engine Idle RPM

Engine Idle RPM Adjustment Procedure

How to adjust the carburetor idle screw to set engine idle RPM.

Adjustments: Carburetor Adjustments

Carburetor Adjustments for Altitude/Temperature

How altitude and temperature affect engine operation and adjustments.

Jetting Chart

Chart providing jetting specifications based on altitude and temperature.

Side Panel Removal

Spark Plugs: Usage and Condition

Spark Plug Specifications

Details on recommended spark plug type, gap, and torque.

Spark Plug Condition Indicators

Interpreting spark plug condition (normal, wet fouled) for engine health.

Spark Arrestor Maintenance

Spark Arrestor Maintenance (Continued)

Purging Accumulated Carbon from Exhaust

Procedure for purging carbon from the spark arrestor.

Recoil Housing Maintenance

PVT System Safety and Maintenance

Battery: Fluid Level and Safety

Replenishing Battery Fluid

How to refill battery fluid using distilled water and safety precautions.

Battery: Removal and Installation

Battery Removal Procedure

Steps for safely disconnecting and removing the vehicle battery.

Battery Installation and Connections

Procedure for correctly installing the battery and connecting cables.

Battery: Installation and Connections

Battery Installation Steps

Steps for setting battery in holder, installing vent tube, and connecting cables.

Lights: Headlight Lamp Replacement

Headlight Pod Removal

Steps for removing the headlight pod cover.

Headlamp Replacement Procedure

Steps for unplugging and replacing the headlamp bulb.

Lights: High Beam Headlight Adjustment

Lights: Headlight Housing Replacement

Lights: Lamp Replacements

Taillight/Brakelight Assembly Replacement

Procedure for replacing the taillight and brakelight lamps.

Indicator Lamp Replacement

Procedure for replacing indicator lamps.

Cleaning and Storage: Cleaning the 6x6

Washing the 6x6 Vehicle

Recommended method for washing the vehicle safely.

Waxing the 6x6

Guidance on waxing the vehicle's body finish.

Cleaning and Storage: Vehicle Storage

Vehicle Storage Preparation Steps

Steps for preparing the vehicle for extended or off-season storage.

Cleaning and Storage: Transporting the 6x6

Measures for Transporting the Vehicle

Steps to take when transporting the 6x6 vehicle.

Specifications: General

Vehicle Dimensions and Weights

Height, width, length, wheelbase, seat height, ground clearance, weight.

Suspension, Tires, and Brakes

Details on suspension travel, tire sizes, and brake types.

Capacities and Load Limits

Fuel, oil, cargo bed, and front rack load capacities.

Specifications: Engine

Engine Type and Displacement

Engine type, displacement, bore, stroke, and cooling system.

Ignition, Carburetion, and Spark Plug

Details on ignition system, carburetion, and spark plug type.

Wiring Diagram

Troubleshooting: Clutch Drive Belt Issues

Diagnosis and Solutions for Clutch Belt Problems

Troubleshooting common issues related to the clutch drive belt.

Troubleshooting: General Operation Issues

Solutions for Stuck in Mud/Snow and Climbing Obstacles

How to handle getting stuck or climbing large objects.

Belt Slippage and Clutch Malfunction

Troubleshooting belt slippage and clutch malfunctions.

General Range Operation Guidelines

Guidelines for using Low Range and High Range.

Troubleshooting: Engine Start Failures

Causes and Solutions for Engine Not Starting

Diagnostic flowchart for engine starting problems.

Warranty: Limited Warranty and Registration

Polaris Limited Warranty Terms

Details of the six-month limited warranty and registration requirements.

Warranty: Coverage, Exclusions, and Service

Warranty Coverage and Exclusions

What the warranty covers and common exclusions.

How to Obtain Warranty Service

Procedure for taking the vehicle for warranty service.

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