Polaris 6X6 User manual

WARNING
The engine exhaust from this
product contains chemicals
known to cause cancer, birth de-
fects or other reproductive harm.

Indicates a potential hazard that could result in serious
injury or death.
WARNING

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We’ve created a web site, just for YOU!!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner

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WELCOME
Thank you for choosing Polaris, and welcome to our world-wide
family of Polaris enthusiasts. Polaris proudly produces an exciting line
of recreational products, including snowmobiles, all-terrain vehicles,
personal watercraft, utility vehicles, and Victory motorcycles.
We believe Polaris sets the standard of excellence for all recreational
vehicles manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
Polaris vehicle the finest machine we’ve ever produced.
Follow the instructions and recommendations in this Owner’s Manual
for safe and enjoyable operation of your vehicle. Your Owner’s Manual
contains instructions for minor maintenance. Major repairs are covered
in the Polaris Service Manual and should be performed by a Factory
Certified MSD (Master Service Dealer) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
complete satisfaction. Return to your dealership for all of your service
needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and
Accessories) which are available on our online store
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris
Industries Inc.
Copyright 2001
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

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ATTENTION!
This is an ADULT VEHICLE ONLY; not a toy. Operation is
prohibited for anyone under 16 years of age. READ AND
UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE
OPERATION.
KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!
Read this manual thoroughly referring to the various areas which are
being discussed on your machine. Operating this vehicle carries with it
responsibilities for your personal safety, the safety of others, and the
protection of our environment.
SAFETY TRAINING
When you purchased this vehicle your dealer offered a hands-on safety
training course covering all aspects of vehicle safety. In addition, you
were provided with certain printed material which instructs you on safe
operating procedures.
You should review this information on a regular basis. In the event
you purchased a used Polaris vehicle from a party other than a Polaris
dealer, you can obtain this safety training at no charge from any
authorized Polaris dealer.
Failure to follow the warnings contained in this manual can result in
SEVERE INJURY OR DEATH.
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.

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TABLE OF CONTENTS
Vehicle Identification Numbers 6..............
Safety 7 - 20.................................
Understanding Warnings 7.........................
Key Safety Issues 8...............................
Decals and Locations 13...........................
Operator Safety 21................................
Controls and Features 37 - 49.................
Controls 37.......................................
Features 47......................................
Operation 50 - 56.............................
Pre Ride 50......................................
Vehicle Break-In Period 51.........................
Starting the Engine 52.............................
Carrying Loads 54................................
Noise Emission Control System 57............
Riding 58 - 72................................
Pre Ride Inspection 58............................
Riding Safely 59..................................

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TABLE OF CONTENTS
Maintenance and Lubrication 73 - 117..........
Tools 73.........................................
Periodic Maintenance Schedule 74..................
Lubrication Recommendations 77...................
Maintenance Record 85...........................
Cooling System 86................................
Filter Systems 88.................................
Adjustments 90...................................
Spark Plugs 103..................................
Spark Arrestor 104................................
Recoil Housing 106................................
PVT 107.........................................
Battery 108.......................................
Lights 111........................................
Cleaning and Storage 115..........................
Specifications 118 - 119.......................
Wiring Diagram 120..........................
Trouble Shooting 121 - 123....................
Warranty 124 - 125...........................

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VEHICLE IDENTIFICATION NUMBERS
Important: Record these numbers from your vehicle in the spaces
provided.
1. Frame VIN
2. Engine Serial Number (Right front side of engine crankcase)
The vehicle frame and engine serial numbers are important for model
identification when registering your vehicle, obtaining insurance or
whenever replacement parts are required. In the event your vehicle
were stolen these numbers are essential to the recovery and
identification of your vehicle.
Dealer Imprint
2
1
Remove the spare key and store in a safe place. Your key can be
duplicated only by obtaining a key blank from Polaris and having it
cut by mating it with your existing key.

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SAFETY
Understanding Warnings
The following two pages identify signal words and symbols that appear
in this manual. 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.
Indicates a potential hazard that could result in serious injury or
death.
Indicates a potential hazard that may result in minor personal
injury or damage to the machine.
WARNING
CAUTION
NOTE
“NOTE:” will alert you to important information or instructions.
Indicates a situation that may result in damage to the machine.
CAUTION