Polaris Sportsman 9920775 User 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.
2007
Sportsman 6X6
Owner's Manual
for Maintenance and Safety
2007
Sportsman 6X6
Owner's Manual
for Maintenance and Safety

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

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.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER utility vehicles
• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence 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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2006 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 discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. 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.
2007 Sportsman 6X6 Owner’s Manual
P/N 9920775

3
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Emission Control Systems . . . . . . . . . . . . . . . 69
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 120
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 124
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 126
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 137
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

4

5
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 informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
Vehicle Identification Numbers
Record your vehicle's identification 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 your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
VIN
Engine Serial Number
####
Key Number

6
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully. If any of
the decals depicted in this manual differ from the decals on your ATV,
always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
General Warning
WARNING
Improper vehicle use can result in SEVERE
INJURY or DEATH
NEVER:
• Operate on public roads. A collision can
occur with another vehicle.
• Carry passengers. Passengers affect bal-
ance and steering and increase risk of los-
ing control.
• USE ALCOHOL or DRUGS before or while
operating this vehicle.
• Operate at speeds too fast for your skills or
the conditions.
• Operate this vehicle on HILLS steeper than 15 degrees. To prevent flipover
on hilly terrain, use throttle and brakes gradually.
ALWAYS:
• Use an approved HELMET AND PROTECTIVE GEAR.
• Avoid paved surfaces. Pavement may seriously affect handling and control.
• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and
rough terrain and in turns.
• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of
control, never activate override button with open throttle.
REVERSE operation can be dangerous, even at low speeds. Steering becomes
difficult. To prevent flipover, avoid sharp turns.
PARKING BRAKE may relax when used for more than 5 minutes. When parking
on grades, leave shift in forward.
LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS
DEALER FOR A REPLACEMENT.
+

7
SAFETY
Safety Decals and Locations
Tire Pressure/Load Warning
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) CENTER 5 (34.5) REAR 5
(34.5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING
MACHINE, DRIVER AND CARGO IS 1965 LBS. (893 kg).
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered, carried as low as possible in bed,
and firmly secured to the rack. For stability on rough or hilly terrain, reduce
speed and cargo. Do not block headlight. Be careful if load extends over the
side of the rack or box.
Read Owner's Manual for more detailed loading information.
Front Rack/Box Warning
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch. Max.
combined Front Rack and container Load 75 lbs. (34 kg)
Reverse Override Warning
WARNING
Pushing reverse override button may cause sudden increases in power and
traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in AWD. See Owner's Manual.
+
+
Tire Pressure/Load
Warning
Front Rack
Warning
+
Reverse Override
Warning