Polaris 6X6 Guide

A card containing important ATV safety information should be attached
to the owner’s manual on the next page. If you cannot locate this card,
or if it has been removed, please call 1-800-342-3764 for assistance.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!

2
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 Sportsman 6X6 Owner’s Manual P/N 9920163

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TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS 4..............
SAFETY 5..........................................
FEATURES AND CONTROLS 32......................
OPERATION 49.....................................
EMISSION CONTROL SYSTEMS 68...................
MAINTENANCE AND LUBRICATION 69...............
SPECIFICATIONS 114...............................
POLARIS PRODUCTS 116...........................
TROUBLESHOOTING 117............................
WARRANTY 121....................................
MAINTENANCE LOG 130............................
INDEX 132..........................................

4
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
Key Number (3):
2
131XX
3

5
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.

6
SAFETY
Operator Safety
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You
were also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of the ATV in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.

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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

8
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever operate the Sportsman 6x6 without proper instruction. Take a
training course. Beginners should receive training from a certified
instructor. Contact an authorized Polaris dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
SNever allow anyone under 16 years of age to operate this vehicle.
SNever permit a guest to operate the vehicle unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
SAlways avoid operating this vehicle on paved surfaces, including
sidewalks, driveways, parking lots, and streets.
SNever operate this vehicle on a public street, road or highway, in-
cluding a dirt or gravel road.
SNever operate this vehicle without wearing an approved helmet that
fits properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
SNever consume alcohol or drugs before or while operating this ve-
hicle.
SNever operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
SNever attempt wheelies, jumps or other stunts.
SAlways inspect your vehicle before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.

9
SAFETY
Operator Safety
SAlways keep both hands on the handlebars and both feet on the foot-
rests of the vehicle during operation.
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
SNever operate on excessively rough, slippery, or loose terrain.
SAlways follow recommended turning procedures as described in this
manual. Practice turning at low speeds before attempting to turn at
faster speeds. Do not turn at excessive speeds.
SAlways have the vehicle inspected by an authorized Polaris dealer if
it’s been involved in an accident.
SNever operate on hills too steep for the vehicle or for your abilities.
Practice on smaller hills before attempting larger hills.
SAlways follow proper procedures for climbing hills. Check the ter-
rain carefully before ascending a hill. Never climb hills with exces-
sively slippery or loose surfaces. Shift your weight forward. Never
open the throttle suddenly or make sudden gear changes. Never go
over the top of a hill at high speed.
SAlways follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos-
sible.
SAlways follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the vehicle. Never attempt to turn the
vehicle around on any hill until you’ve mastered (on level ground)
the turning technique outlined in this manual. Avoid crossing the
side of a steep hill when possible.

10
SAFETY
Operator Safety
SAlways use proper procedures if the vehicle stalls or rolls backwards
while climbing a hill. To avoid stalling, maintain a steady speed
when climbing a hill. Always dismount on the uphill side, or to ei-
ther side if the vehicle is pointed straight uphill. Turn the vehicle
around and remount following the procedure described in this manu-
al.
SAlways check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
SAlways be alert to the potential for skidding or sliding. On slippery
surfaces (like ice), travel slowly and use extra caution to reduce the
chance of skidding or sliding out of control.
SAvoid operating the vehicle through deep or fast-flowing water. If
it’s unavoidable, travel slowly, balance your weight carefully, avoid
sudden movements, and maintain a slow and steady forward motion.
Do not make sudden turns or stops, and do not make sudden throttle
changes.
SWet brakes may have reduced stopping ability. Test your brakes af-
ter leaving water. If necessary, apply them lightly several times to
allow friction to dry out the pads.
SAlways check for obstacles or people behind the vehicle before oper-
ating in reverse. When it’s safe to proceed in reverse, move slowly
and avoid turning at sharp angles.
SAlways use the size and type of tires specified for your vehicle, and
always maintain proper tire pressure.
SNever modify this vehicle through improper installation or use of
accessories.
SNever exceed the stated load capacity for your vehicle. Cargo must
be properly distributed and securely attached. Reduce speed and
follow the instructions in this manual for hauling cargo or towing.
Allow a greater distance for braking.
SAlways remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-
sumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.

11
SAFETY
Operator Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. 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, or make any other modifications to the
vehicle for these purposes. Any modifications to the original
equipment of the vehicle create a substantial safety hazard and increase
the risk of bodily injury.
The warranty on your Polaris Sportsman 6x6 is terminated if any
equipment has been added to the vehicle, or if any modifications have
been made to the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the vehicle properly in different
situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.
For more information about the training course, contact an
authorized Polaris dealer or call Polaris at 1-800-342-3764.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
Severe injury and/or death could occur if a person under the age
of 16 operates the Sportsman 6x6.
Even though a child may be within the recommended age group
for operating some vehicles, he/she may not have the skills,
abilities, or judgment needed to operate the Sportsman 6x6 safely
and could be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate a Polaris Sportsman
6x6.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on a Sportsman 6x6.
WHAT CAN HAPPEN
Carrying a passenger greatly reduces the operator’s ability to
balance and control the vehicle, which could cause an accident
and injury to the operator and/or passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
WARNING
POTENTIAL HAZARD
Operating a Sportsman 6x6 on paved surfaces, including
sidewalks, paths, parking lots, and driveways.
WHAT CAN HAPPEN
Sportsman 6x6 tires are designed for off-road use. Operating on
paved surfaces may seriously affect the handling and control of
the vehicle and could result in loss of control, accident, and/or
injury.
HOW TO AVOID THE HAZARD
Avoid operating the Sportsman 6x6 on pavement. If it’s
unavoidable, travel slowly and avoid sudden turns or stops.
WARNING
Safe operation of this rider active vehicle requires good
judgement and physical skills. Persons with cognitive or physical
disabilities who operate this vehicle have an increased risk of
overturns and loss of control, which could result in serious injury
or death.

14
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
WHAT CAN HAPPEN
The vehicle could collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the Sportsman 6x6 on any public street, road or
highway, including dirt and gravel roads.
WARNING
POTENTIAL HAZARD
Operating this vehicle without wearing an approved helmet, eye
protection and protective clothing.
WHAT CAN HAPPEN
Operating a Sportsman 6x6 without an approved helmet
increases the risk of a severe head injury or death in the event of
an accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.

15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling or rolling backwards while climbing a hill.
WHAT CAN HAPPEN
Stalling or rolling while climbing a hill could result in vehicle
overturn.
HOW TO AVOID THE HAZARD
Maintain steady speed when climbing a hill.
Ifyouloseallforwardspeed:
Keep your body weight toward the front of the vehicle (uphill).
Apply the brakes. After the vehicle has completely stopped, lock
the parking brake.
If you begin rolling backwards:
Keep your body weight toward the front of the vehicle (uphill).
Do not apply engine power.
Do not apply the rear brakes.
Gradually apply the service brake. When fully stopped, apply the
auxiliary brake as well, and then lock the parking brake.
Dismount on the uphill side, or to either side if the vehicle is
pointed straight uphill.
Turn the vehicle around and remount, following the procedure
described in the owner’s manual. See page 62. In the event of
an accident, have an authorized Polaris dealer inspect the entire
vehicle for possible damage, including (but not limited to) brakes,
throttle and steering.

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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the Sportsman 6x6 at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing
control of the vehicle, which can result in an accident.
HOW TO AVOID THE HAZARD
Always operate the vehicle at a speed that’s proper for the
terrain, visibility and operating conditions, and your experience.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
The Sportsman 6x6 could collide with an obstacle or person,
resulting in severe injury.
HOW TO AVOID THE HAZARD
Before shifting into reverse gear, always check for obstacles or
people behind the vehicle. When it’s safe to proceed, back
slowly.
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating.
Failure to properly maintain the vehicle.
WHAT CAN HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your vehicle before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.

17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the footrests
during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce ability to control the
vehicle or could cause loss of balance and ejection from the
vehicle.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the
footrests of the vehicle during operation.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the vehicle could
overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating the vehicle on
unfamiliar terrain.
WHAT CAN HAPPEN
Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.