Polaris Sportsman 9922233 User 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.
Pantone 426 C
for Maintenance and Safety
Sportsman
Big Boss 6X6

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

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

Pantone 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 [phone]
Part No. 9922233 Rev 03
Printed in USA
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER:
SOperate on public roads. A collision can occur with another
vehicle.
SCarry passengers. Passengers affect balance and steering and
increase risk of losing control.
SUSE ALCOHOL or DRUGS before or while operating this
vehicle.
SOperate at speeds too fast for your skills or the conditions.
SOperate this vehicle on HILLS steeper than 25 degrees. To
prevent flipover on hilly terrain, use throttle and brakes
gradually.
ALWAYS:
SUse an approved HELMET AND PROTECTIVE GEAR.
SAvoid paved surfaces. Pavement may seriously affect
handling and control.
SUse proper RIDING TECHNIQUES to avoid vehicle
overturns on hills and rough terrain and in turns.
SUse 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.

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, THE WAY OUT, SPORTSMAN and BIG BOSS are registered trademarks
of Polaris Industries Inc.
Copyright 2009 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.
2010 SPORTSMAN BIG BOSS 6X6 800 EFI Owner’s Manual
P/N 9922233

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Emission Control Systems . . . . . . . . . . . . . . . 66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 118
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 122
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 124
Declaration of Conformity . . . . . . . . . . . . . . . 125
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5
INTRODUCTION
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. This Polaris vehicle 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating this vehicle. Keep this manual with the
vehicle.
• Never operate this vehicle without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
WARNING

6
INTRODUCTION
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

7
SAFETY
Safety Training
ATV safety training is a top priority for Polaris. Polaris strongly
encourages you and any family members who will be riding the ATV to
take a training course.
If you purchased a new Polaris ATV in the United States, your dealer
provided instruction to you about the authorized ATV RiderCoursesm
that is available to you and your eligible family members. This training
is included in the purchase price of your ATV. 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 in the United States, you can enroll
in the ATV RiderCoursesm for a fee. Call ATV Enrollment Express at
[phone] or visit www.atvsafety.org.
If you purchased a Polaris ATV outside the United States, please contact
your dealer or local law enforcement agencies for information about
safety training.
This Polaris vehicle is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of this vehicle 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 vehi-
cle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800-
638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.

8
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding this vehicle. Wear pro-
tective clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31

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 goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris vehi-
cle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris vehicle 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.
The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.

10
SAFETY
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain.
Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.
Never permit a guest to operate the vehicle unless
the guest has read this manual and all product
labels and has completed a certified safety training
course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.
Even though a child may be within the
recommended age group for operating some
Polaris vehicles, he/she may not have the skills,
abilities, or judgment needed to operate this
vehicle safely and could be susceptible to accident
or injury.
WARNING

11
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling 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-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in
safe operating condition before operating
increases the risk of an accident.
Always inspect the vehicle before each use to
make sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.

12
SAFETY
Safety Warnings
Protective Apparel
Riding on this vehicle without wearing an
approved helmet and protective eyewear
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 or face shield).
Using Alcohol or Drugs
Operating the vehicle after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.
Never consume alcohol or drugs before
or while operating this vehicle.
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the
vehicle, which may result in an accident or
overturn.
Never carry a passenger on this vehicle.

13
SAFETY
Safety Warnings
Operating on Pavement
Operating this vehicle on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the vehicle and could result in
loss of control and accident or overturn.
Avoid operating the vehicle on pavement.
The tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this vehicle on public streets,
roads or highways could result in a collision
with another vehicle.
Never operate the vehicle on any public
street, road or highway, including dirt and
gravel roads. In many states it's unlawful to
operate this type of vehicle on public
streets, roads and highways.
Operating at Excessive
Speeds
Operating the vehicle at excessive speeds
increases the operator's risk of losing
control.
Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.

14
SAFETY
Safety Warnings
Physical Control of the Vehicle
Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control 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.
Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or overturn.
Always follow proper procedures for turning
as described in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 55. Always
move the 4X4 switch to ADC 4X4 (if
equipped) before ascending or descending a hill.

15
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or overturn.
• Always follow proper procedures for travel-
ing down hills as described in the owner's
manual. NOTE: A special technique is
required when braking while traveling down-
hill. See page 57.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral. Always move the
4X4 switch to ADC 4X4 (if equipped) before
ascending or descending a hill. See page 36.
• Always check the terrain carefully before descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill when possible.
Crossing Hillsides
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or overturn. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow proper procedures as
described in the owner's manual. See page 56.
Never attempt to turn the vehicle around on any hill until you've mastered the
turning technique (on level ground) as described in the owner's manual. See
page 58.

16
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing 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 is lost:
• Keep body weight uphill.
• Apply the service brakes.
• Lock the parking brake when fully stopped.
• Dismount on 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 58.
If the vehicle begins rolling downhill:
• Keep body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the service brake
gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on 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 58.