Polaris Sportsman 9922233 manual

Owner's Manual Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. P antone 426 C for Maintenance and Safet y Spor tsman Big Boss 6X6[...]

W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth defects or other reproductive harm.[...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

P antone 426 C For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922233 Rev 03 Printed in USA Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER: S Operate on public roads. A collision can occur with another veh[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® W e believe Polaris sets a standard of excellence for[...]

2 POLARIS, THE W A Y OUT , SPOR TSMAN and BIG BOSS are registere d trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents, some m[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Emission Control Systems . . . . . . . . . . . . [...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potential persona l injury hazard. W ARNING A W ARNING indicates a hazardou[...]

5 INTRODUCTION Failure to hee d the warnin gs and safety precaution s contained in this manu al can result in severe injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. This vehicle handl es differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine [...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using yo ur key number) and matin g it with one of yo ur existing keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family members who will be riding the A T V to take a training course. If you purchased a new Polaris A TV in the United S tates, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available t[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. W ear pro- tective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Failure to ope rate the vehicle prop erly can result in a coll ision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See the OPERA TION section of the owner ’ s manual fo r proper operating procedures. Operating Without Inst[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme cautio n whenever hand ling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- el[...]

12 SAFETY Safety W arnings Protective App arel Riding on this vehicle without wea ring an approved helmet and protective eyewe ar increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield). Using Alcohol or Drugs Ope[...]

13 SAFETY Safety W arnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the vehicle and could resul t in loss of control and accident or overturn . Avoid operating the vehicle on pavement. The tires are designed for of f-road use. If i [...]

14 SAFETY Safety W arnings Physical Control of the V ehicle Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to contro l the vehicle or cause loss of balance and ejection from the vehicle. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels[...]

15 SAFETY Safety W arnings Descending Hill s Impr operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as describ ed in the owne r's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 57. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. If all forward speed [...]

17 SAFETY Safety W arnings Operating on Steep Hills Operating on e xcessively steep hills could cau se an overturn. Never operate on hills too steep for the vehicle or for your abilities. Ne ver operate the vehicle on hills steeper than 25 degrees. Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl [...]

18 SAFETY Safety W arnings Improper T ire Maintenance Operating this vehicle with improper tires or with improper or uneve n tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Opera[...]

19 SAFETY Safety W arnings Improper Cargo Loading Overloading the vehi cle or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capa city fo r this vehicle . • Cargo should b e properly di stributed and securely atta ched. • Reduce speed when carryi[...]

20 SAFETY Safety W arnings Operating Through Deep W ater Operating the vehi cle through d eep or fast-flowing water could cause th e tires to float, causing loss of control or overturn. Avoid operating the vehicle through deep or fast-flowing water . If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 59): ?[...]

21 SAFETY Safety W arnings Operating a Damaged V ehicle Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qual ified service dealer insp ect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active ve[...]

22 SAFETY Safety Labels and Locations W arning labels have b een placed on the vehicle for your protection. Read and follow t he instructions of the labels on the vehicle carefully . If any of the labels depicted in this ma nual differ fro m the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an info[...]

23 SAFETY Safety Labels and Locations T ire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 7.0 psi (48.3 kPa) Center: 10.0 psi (68.9 kPa) Rear: 10.0 psi (68.9 kPa) • Maximum weight capaci ty: 1 1 15 lbs. (507 kg[...]

24 SAFETY Safety Labels and Locations Cont ainer/No Passenger W arning W ARNING Remove flammable containers from box before refueling. W ARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers. Maximum Box Load 80 0 lbs. (363 kg) 7079316 + Clutch Cover Wa r n i n g + Age 16 W arning + Container/No[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you a re under the age of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you are under age 16. 7172588 Clutch Cover W arning W ARNING • Moving part s hazard und er belt-clutch gu ard. T o prevent seriou s injury , do not operate [...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Ov erride Switch This vehicle is equipped with a re verse speed limi ter system .T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button whil e the throttle is open can cause loss of control, wh ich may result in seri [...]

27 FEA TURES AND CONTROLS Switches Engine S top Switch Move the stop switch either left or right to the OFF position to stop the engine quickly . The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. Main Key Switch Use the main[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating this vehicle with sticking or imprope rly operating throttle control s could cause an accid ent. Never start or ope rate the vehicle if it has a sticking or improperly operating th rottle. Always c ontact your dealer for service before operating the vehicle. Failure to check or ma intain proper ope[...]

29 FEA TURES AND CONTROLS Brake Systems Aggressively applying the rear brake when backing down a hill may cause rear tipover , which coul d result in serious in jury or death. Never back down a hill. Use caution when applying the re ar brake. Do not aggressively apply the rear brake when going forward. The rear wheels may skid and slide sideways, c[...]

30 FEA TURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically ac ti- vated disc bra kes. Always test brake lever travel and master cylinder fluid level befo re riding. When squeezed, the lever should feel firm. Any spon[...]

31 FEA TURES AND CONTROLS Master Cylinde r/Br ake Fluid An over-full master cylinder may ca use brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygro scopic, meaning it rapidly absorbs moisture from the[...]

32 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in park. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the pa rking brake lock, squeeze and release the brake lever . I[...]

33 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the e ngine speed ab[...]

34 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Wheel Drive syst em is controlled by the 4X4 (A WD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descendin[...]

35 FEA TURES AND CONTROLS All Wheel Drive System Engaging A WD The 4X4 switch may be turned on or of f while the vehic le is moving. Initially , the vehicl e's electronic sy stem will not enable A WD until the engine RPM is below 3100. Once en abled, A WD remain s enabled until the 4X4 switch is turned of f. If the switch is turn ed of f while[...]

36 FEA TURES AND CONTROLS Active Descent Cont rol (ADC) System The ADC sy stem (if equippe d) allows engine brakin g to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascen ding or descending a hill. Engaging Active Descent Control The ADC system will auto matically engage when all four of [...]

37 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In additi on to showing vehicle sp eed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also inclu[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over - voltage may have occurred and the instrument cl uster may have sh ut of f to protect the e[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center S t andard Modes Use the MODE button to toggle thro ugh the mode op tions. The reve rse override button is also the MODE bu tton. See page 26. The transmission cannot be in reve rse wh en using this feature. Odometer Mode The odom eter records the miles trav eled by the v ehicle.[...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch of f and on. An y move- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the[...]

41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Scr een V iew this screen to check battery voltage level. T achometer Scr een V iew the tachometer to check engine speed. 4X4 Diagnost ic Screen The gauge indicates whether or not current is flowing through the all- wheel-drive coil. This screen i[...]

42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Pr ogrammable service inte rval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Cent[...]

43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purp oses only . Please see your Polaris de aler fo r all major repairs. See page 45 for Blink Codes and Failu re Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module[...]

44 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the cha rt (injector , fuel pu mp, etc.), or the item has failed. Short-to-Gr ound: The wire is shorted to ground between the electronic control unit and the item listed in[...]

45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Description 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System V oltage Low 31 System V oltage High 36 Ignition Coil A Prim/Sec Circ[...]

46 OPERA TION Failure to ope rate the vehicle prop erly can result in a coll ision, loss of control, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in p eriod for your new Polaris vehicle is the first ten [...]

47 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en ar[...]

48 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 29 84 Brake fluid Ens[...]

49 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Never carry a pa ssenger on th is vehicle. 4. Engine exha[...]

50 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you r ide. Find out where the d e signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or local officials. Help kee[...]

51 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in park. 3. Lock the parking br ake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. Sit on the vehicle and move the eng[...]

52 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e foo trests and both hands on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check you r surroundings and determine your path of travel. 6. Release the parking brake. 7. Slow[...]

53 OPERA TION T urning the V ehicle Y our vehicle is equipped with a solid rear axle, which drives both 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 turn- ing and the inside tire must slip traction sl ightly . T o turn, steer in the direction of the [...]

54 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezin g weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before whee ls begin to lose traction. NOTICE: Sever[...]

55 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure coul d cause loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 s witch to ADC 4X4 (if equipped) befo re ascending or descending a hill. See page 36. 2. Drive straig[...]

56 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. S[...]

57 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 s witch to ADC 4X4 (if equipped) befo re ascending or descending a hill. See page 36. 2. A void steep hills (25 ° maximum ). 3. Shift body weight uph ill. 4. Drive straight downhill. 5. Slow down. Excessive speed wh en traveling downhill can caus[...]

58 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping body weight up hill. 2. Always move the 4X4 sw itch to ADC 4X4 (if equipped) befo re ascending or descending a hill. See page 36. 3. Leave the tr[...]

59 OPERA TION Driving Through W ater Y our vehicle can operate through water with a maximum recommende d depth equal to the bottom of the footrests. Fol- low these procedures when operating through water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks hav e gradual inclines. 3. A void operating t[...]

60 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamiliar[...]

61 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turnin g at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unl[...]

62 OPERA TION Hauling Cargo Overloading the vehi cle or carrying o r to wing ca rgo improperly can alter vehicl e handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these p recautions when hauling cargo: • Never exceed the maximum weight capaci ty of the vehicle. When determi[...]

63 OPERA TION Hauling Cargo 1. Always read and u nderstand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owne r's manu al and on the safety labels. The total load (operator , access ories, car go and weight on hitch) must not exceed the maximum weight c[...]

64 OPERA TION Hauling Cargo Dumping Cargo 1. Select a level site to dump the car go. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking br ake. 3. Dismount the veh icle. 4. Check car go d istribution. If car go has shifted to the rear of the box, exercise caution. W ARNING! If the weig ht distribution in th[...]

65 OPERA TION Parking on an Incline A void parking on an in cline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in park. 3. Lock the parking br ake. 4. Always block the rear wh eels on the downhill side.[...]

66 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was teste d and qual[...]

67 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance ch art. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

68 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked wi th a  could result i n component failure an d cause an accid ent, which may result in serious inj ury or death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more often for ve hicles subje[...]

69 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - W eekly - Inspect; replace as needed X Q Brake pad wear 10 H Monthly 60 (100) Inspect periodically X Engine oil change (break-in) 20 H 1 M 125 (200) Perform a break-in oil change Battery 20 H [...]

70 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service  Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X Engine oil change 100 H 6 M 620 (1000) Per form a break-[...]

71 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will[...]

72 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's re commendatio ns for ambient tempera- ture operatio [...]

73 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 67. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level surface. 2. S tart the engine. Allow it to warm up at idle for two to three minutes. S top the eng[...]

74 MAINTENANCE Engine Oil Oil and Filter Change 10. Lubricate the o-ring on the new filte r with a film of fresh engine oil. Check to make sure the o -ring is in good condition. 1 1. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn. 12. Remove the dips t[...]

75 MAINTENANCE T ransmission Oil Always check and change the transmission oil at t he intervals outlined in the Periodic Mainte- nance Chart beginning o n page 67. Maintain the oil le vel at the bottom of the fill plug hole. The fill plug is located on the right side of the A T V behind the footwell. Th e drain plug is located on the bottom left si[...]

76 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Ch art beginn ing on page 67. W e rec- ommend the use of Po laris Demand Drive Plu s Fluid. Use of other fluids may result in improper operati on of components. See page 12 4 for the part numbers[...]

77 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug. 2. Place a drain pan under the demand drive unit. 3. Remove the drain plug. Allow the fluid to drain completely . 4. Clean and reinstall the drain plug . T orque to 1 1 ft. lbs. (15 Nm). 5. Add the recomme nded fluid. 6[...]

78 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the in tervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain the fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz. (150 ml). Do not overfill. The fill plug is located on the rear of the gearcase. The drain plug i[...]

79 MAINTENANCE Middle Gearcase Oil Always check and change the mid- dle gearcase oil at the intervals outlined in the Periodic Mainte- nance Chart beginning on page 6 7. W e recommend the use of Polaris A T V Angle Drive Fluid (or GL5 80-90 weight gear lub e). See page 124 for the part num bers of Polaris products. The middle gearcase fill plug is [...]

80 MAINTENANCE Active Descent Control (ADC) Fluid If your veh icle is equip ped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fluid and ADC fluid). See page 76 for d emand drive fluid main tenance. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart begin[...]

81 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level su rface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly cl ean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and di[...]

82 MAINTENANCE Cooling System The engin e coolant leve l is controlled, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases , the expa nding (heated) excess coolant is forced out of the[...]

83 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recove[...]

84 MAINTENANCE Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drop s. If the fluid leve l is low and the diaphragm is not extended, a leak is likely and the diaphragm shou ld be replaced. T [...]

85 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attemp t to adjust tie rod alignment. Al l tie rod adjustments should be perfo[...]

86 MAINTENANCE S teering Assembly The steerin g assembly of the vehicle should be checked periodically for loose nuts and bo lts. If loose nuts and bolts are found, see your Polaris dealer for service before ope rating the v ehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rea r cab. W ith a firm motion, p[...]

87 MAINTENANCE Ti r e s Operating your veh icle with worn tires, improperl y inflated ti res, non-standard tires or impro perly installed tires will affect vehicle handl ing and could cause an accident resulting in serious injury or death . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle. [...]

88 MAINTENANCE Ti r e s Wheel Inst allation 1. Place the transmission in park. 2. Lock the parking br ake. 3. Place the wheel on the hub with the valve stem toward the out side and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger -tighten them. 5. Lower the veh icle to the ground . 6. T orque the wh[...]

89 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W a sh the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main[...]

90 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience othe r electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com- partment on the top of the access door . 1. Open the front box cov[...]

91 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility . Upper Headlight Lamp Replacement When servicing a ha logen lamp[...]

92 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in park. 2. Measure the distance from the floo r to the cen[...]

93 MAINTENANCE Light s Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw located at the rea r of the he adlamp. 2. T ilt the headlamp upward or downward. 3. T ighten the screw . Phillips Screw[...]

94 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedome ter harnesses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a s[...]

95 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headla mp. 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harness clock- wise to secure th[...]

96 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the specifi cations section beginning on page 122 for the recom- mended spark plug type and gap for your v ehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S p[...]

97 MAINTENANCE Spar k P l u g s S p ark Plug Inspection Normal S p ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator [...]

98 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, major en gine damage can resu lt if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impo ssible to take your vehicle to a dealer before starting it, fo llow the steps outlined below . 1. Move the vehicle to d ry l[...]

99 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combusti ble materials from the a rea. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Ne[...]

100 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure ma y occur at a high speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of bala[...]

101 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed d[...]

102 MAINTENANCE P VT System When T o Use Low Range and High Range P VT Drying There may be some instances w hen wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall th[...]

103 MAINTENANCE Battery Improperly connecting or discon necting battery cables can result in an explosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisono us. It contains s[...]

104 MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery o ut of the vehicl e. Be careful not to tip a conven- tio[...]

105 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery charging instructio ns on page 107 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in[...]

106 MAINTENANCE Battery Batter y S torage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha r ge as needed to mainta in a full charge. Polaris re[...]

107 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 104. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to [...]

108 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. S t ate of Charge V oltage Action Charge Ti me (Using constant current charger @ st andard amps specifi ed on top o f battery) 100% 12.8-13.0 vol t s None, check at 3 mos. from date of manufacture None required [...]

109 MAINTENANCE Cleaning and S torage W ash ing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, inclu[...]

110 MAINTENANCE Cleaning and S torage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or co[...]

111 MAINTENANCE Cleaning and S torage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C l[...]

112 MAINTENANCE Cleaning and S torage Sto r a g e Tips NOTICE: S t arting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary repa irs and then clean the vehicle as recomme nded. See page 109. S t a[...]

113 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommende d in the Periodic Maintenance Char t beginni ng on page 67. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Middl e gearcase • T ra nsmission • Bra[...]

114 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cables a nd lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 67. Battery Maintenance Remove the battery and recharge it as o utlined on page 107. S tore the battery in a cool, dry place. S torage Area/Covers[...]

115 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in park. 3. Lock the parking br ake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or ro pe. Do not attach tie stra[...]

116 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear S prings The rear shock absorber springs are adjusted by rotating the adjusters either clockwise or counter-clockwise to increase or decrease spring tension. Always adjust all re ar sp rings to equal settings. Accessory springs are available through your Polaris de ale[...]

117 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and [...]

118 TROUBLESHOOTING Drive Belt W ear/Burn Possible Cause Solution Driving onto a picku p or tall trailer in high rang e Use low range during loading. Starting out going up a steep in cline Use low range or turn around using the K-turn (see page 58). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or us e low range more frequen[...]

119 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solution Out of fuel Refuel, [...]

120 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range S et gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plug[...]

121 TROUBLESHOOTING Engine S top s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Inspec t, clean and/or replace spark[...]

122 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN BIG BOSS 6X6 800 EFI Maximum W eigh t Capacity 1 1 15 lbs. ( 507 kg) (includes operator , cargo, accessories) Fuel Capacity 4.1 gal. (15.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts. (3.4 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Rear Gearcase Oil Capacity 5 o[...]

123 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN BIG BOSS 6X6 800 EFI T ransmissi on Automat ic PVT with E-Z Shift H/L/N/ R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5 .1 1:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 T ires/Pressure, Front 25x8-12 / 7 psi (48.3 k[...]

124 POLARIS PRODUCTS Part Number Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Perfo rmance Synthet ic 2W-50 4-C ycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2 W -50 4-Cycl e Oil (gal.) Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603 Premium A[...]

125 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

126 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris Light Utilit y V ehicle against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain (if equipped) for failure due to defects. This warr[...]

127 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris l imited warranty exc ludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This wa rranty also does not c over any ve[...]

128 W ARRANTY LIMIT A TIONS OF WARR ANTIES AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfect ions caused by external stress, heat, col d or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensat io[...]

129 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXP RESS W ARRANTIES NOT ST A TED IN THIS W A RRANTY . Some states do not allow limi- tations on h[...]

130 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. Dea[...]

131 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was [...]

132 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited warrant y is in additi on to the Polaris sta ndard limited warran ty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified veh icle is designed, built and equipped so it conforms with applica- ble U.S. Environ[...]

133 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SET FOR TH IN TH IS LIMITED W ARRANTY AR E THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O[...]

134 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

135 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

136 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

137 INDEX 0-9 4X4 (AWD) Switch . . . . . . . . . . 26, 34 A Accessories . . . . . . . . . . . . . . . . . . . 114 Active Descent Control Fluid . . . 80-81 Active Desc ent Control Syste m . . . . 36 ADC System . . . . . . . . . . . . . . . . . . . 36 Air Filt er . . . . . . . . . . . . . . . . . . . . . . 89 All Wheel Drive (A WD) System 34-35 AWD S[...]

138 INDEX F Fluid ADC . . . . . . . . . . . . . . . . . . . 80-81 Brake . . . . . . . . . . . . . . . . . . . . 31 Demand Drive . . . . . . . . . . . 76-77 Fluid Change ADC . . . . . . . . . . . . . . . . . . . . . 81 Demand Dri ve . . . . . . . . . . . . . 77 Footwell Removal . . . . . . . . . . . . . . 86 Front Gearcase (Demand Drive) . 76-77 Fue[...]

139 INDEX P Parking Brak e . . . . . . . . . . . . . . . . . . 32 Parking on an Incline . . . . . . . . . . . . 65 Periodic Maintenance Chart . . . . 67-70 Polaris Pro duct List . . . . . . . . . . . . . 124 Polishing the Vehicle . . . . . . . . . . . 110 Pre-Ride Checklist . . . . . . . . . . . . . . 48 PVT Break-In . . . . . . . . . . . . . . . .[...]