Polaris Light Utility Hauler 6x6 User manual

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. Visit our Web site at
www.polarisindustries.com.
Polaris Professional Series (PPS) Workmobilest
Available through Polaris Professional Series dealers.
SUtility Task Vehiclet(UTV)
SLight Utility Hauler (LUH)
SAll-Surface Loader (ASL)
SAT V P r o
Polaris Recreational Vehicles
Available through Polaris dealers.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SPersonal watercraft
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 vehicle 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 Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Polaris Professional Series are
registered trademarks of Polaris Industries Inc.
Copyright 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

2
READ YOUR OWNER’S MANUAL
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.
Safety Training
When you purchased your new LUH 6x6, 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 LUH 6x6 from a party other than a
Polaris dealer, you can request this free safety training from any
authorized Polaris dealer.
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris LUH 6x6 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 LUH 6x6.

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TABLE OF CONTENTS
WELCOME 1........................................
READ YOUR OWNER’S MANUAL 2...................
TABLE OF CONTENTS 3.............................
VEHICLE IDENTIFICATION NUMBERS 4...............
SAFETY 5..........................................
FEATURES AND CONTROLS IDENTIFICATION 31......
CONTROLS 32......................................
FEATURES 42.......................................
OPERATION 44.....................................
NOISE EMISSION CONTROL SYSTEM 63.............
MAINTENANCE AND LUBRICATION 64................
SPECIFICATIONS 104................................
POLARIS RECOMMENDED PRODUCTS 106...........
WIRING DIAGRAM 107...............................
TROUBLESHOOTING 108............................
WARRANTY 110.....................................
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.

4
VEHICLE IDENTIFICATION NUMBERS
The frame vehicle identification number (VIN) (1) and engine serial
number (2) are important for model identification when registering
your vehicle, when obtaining insurance, and when ordering
replacement parts. If your vehicle is stolen, these numbers are essential
to its recovery and identification.
NOTE: Record your vehicle’s ID numbers 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 an existing key.
NOTE: If both keys are lost, see your dealer for ignition switch
replacement.
2
1
Frame VIN:
Engine Serial Number:
Vehicle Model Number:
Dealer Imprint:

5
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.
The safety alert warning indicates a potential hazard that may result
in serious injury or death.
The safety alert caution indicates a potential hazard that may result
in minor personal injury or damage to the vehicle.
CAUTION
NOTE:
Anote will alert you to important information or instructions.
Acaution indicates a situation that may result in damage to the
vehicle.
CAUTION
WARNING

6
SAFETY
Operator Safety
The LUH 6x6 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 vehicle are thoroughly inspected at specific
intervals.
All information in this manual is based on the latest product data and
specifications available at the time of printing. Polaris Industries Inc.
reserves the right to make product changes and improvements that may
affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written
permission of Polaris Industries Inc.

7
SAFETY
Operator Safety
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever operate the LUH 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.
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.
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.

8
SAFETY
Operator Safety
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.
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.

9
SAFETY
Operator Safety
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.
FOR MORE INFORMATION ABOUT SAFETY, call the Consum-
er Product Safety Commission at 1-800-638-2772, or call Po-
laris at 1-800-342-3764.
Additional Important Information
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 LUH 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 LUH 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.
We also advise you to strictly follow the recommended maintenance
program outlined in this manual. This preventive maintenance
program is designed to ensure that all critical components on the
vehicle are thoroughly inspected by your dealer at various mileage
intervals.
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.

10
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. If any decal
becomes illegible or comes off, contact your Polaris dealer for a
replacement. Any safety decal needing replacement will be provided
by Polaris at no charge. The part number is printed on the decal.
1
2
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
Maximum Front Rack Load 75 lbs.
IMPROPER TIRE PRESSURE OR OVERLOADING can cause
loss of control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI): FRONT 5 CENTER 5 REAR 5
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight
INCLUDING MACHINE, DRIVER AND CARGO IS 1970 LBS.)
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 bed.
Read Owner’s Manual for more detailed loading information.
WARNING
WARNING
2
1

11
SAFETY
Safety Decals and Locations
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER:
DOperate on public roads. A collision can occur with another vehicle.
DCarry passengers. Passengers affect balance and steering and in-
crease risk of losing control.
DUSE ALCOHOL or DRUGS before or while operating this vehicle.
DOperate at speeds too fast for your skills or the conditions.
DOperate this vehicle on HILLS steeper than 15 degrees ∠15°.
DTo prevent flipover on hilly terrain, use throttle and brakes gradually.
ALWAYS:
DUse an approved HELMET AND PROTECTIVE GEAR.
DAvoid paved surfaces. Pavement may seriously affect handling and
control.
DUse proper RIDING TECHNIQUES to avoid vehicle overturns on
hills and rough terrain and in turns.
DUse OVERRIDE for reverse speed limiter with caution. To prevent
loss of control, never activate override button with open throttle.
DREVERSE operation can be dangerous, even at low speeds. Steer-
ing 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.
3
WARNING
3

12
SAFETY
Safety Decals and Locations
ETC
This vehicle is equipped with a
Polaris Electronic Throttle Control
(ETC) to reduce the risk of a stuck or
“frozen” throttle. Please refer to your
owner’s manual for details.
4
5
Operating this vehicle if you are under the
age of 16 increases your chance of severe
injury or death.
NEVER operate this vehicle if you are under
age 16.
7078254
Remove flammable containers from bed before refueling. Maximum Bed Load 800 lbs.
DPassengers can be thrown off.
This can cause serious injury
or death.
DNever carry passengers.
ALL WHEEL
DRIVE
SWITCH
Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your owner’s
manual.
7079780
7079604
AWD Models
WARNING
Pushing reverse
override button
may cause
sudden in-
creases in pow-
er and traction if
too much
throttle is ap-
plied. Loss of
control or for-
ward flipover
may result, es-
pecially in
AWD. See Own-
er’s Manual.
6
78
4
5
6
7
8
This vehicle is equipped with a
back-up alarm.
ALARM MUST SOUND! when
operating this vehicle in reverse.
Failure to maintain a clear view
in the direction of travel could
result in serious injury or death.
The Operator is responsible for
the safe operation of this vehicle.
7170572
WARNING
9
9

13
SAFETY
Safety Decals and Locations
Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
Do not modify engine or clutch. Doing so can cause
part failure, possible imbalance, and excessive
engine RPM which can result in serious injury or
death.
NO STEP 7078689
WARNING
(On Hitch)
TRAILER MAX WEIGHT:
1225 LBS. (557 KG) ON LEVEL GROUND
850 LBS. (368 KG) UP TO 15 GRADE
HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16 KG)
7078261
ATTENTION
SOperation of this vehicle without the
filter element will severely damage
the engine.
SClean air filter often, more frequent
cleaning required in dusty condi-
tions.
SOperation of this vehicle without en-
gine breather filter(s) can cause en-
gine damage. Consult owner’s
manual for details.
SSpecific carburetor jetting and adjust-
ments are required depending on tem-
perature and altitude. See your owner’s
manual.
Factory setting:
40_to 80_F. at 0-3000 feet
(5_to 27_C. at 0-900 meters).
7079902

14
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. LUH 6x6 riding
requires special protective clothing for comfort and to reduce the
chance of injury.
1. Helmet
Your helmet is the most important
piece of protective gear for safe
riding. A helmet can prevent a
severe head injury.
Select an approved helmet that
meets or exceeds your state’s
safety standards and bears either
the Department of Transportation
(DOT) label, the American
National Standards Institute label
(ANSI z90.1), or the Snell
Memorial Foundation label.
2. Eye Protection
Do not depend on sunglasses for
proper eye protection. A pair of
goggles or a helmet face shield
offer the best protection for your
eyes. They should be kept clean
and be of shatterproof design
(bearing the markings z2.1 or
VESC 8).
3. Gloves
Gloves with knuckle pads are the best for comfort and protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
1
2
3
4
5

15
SAFETY
Operator Safety
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.
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 LUH 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 LUH 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 LUH 6x6.
WARNING
WARNING

16
SAFETY
Operator Safety
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.
POTENTIAL HAZARD
Carrying a passenger on an LUH 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.
POTENTIAL HAZARD
Operating an LUH 6x6 on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN HAPPEN
LUH 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 LUH 6x6 on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.
WARNING
WARNING
WARNING

17
SAFETY
Operator Safety
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 LUH 6x6 on any public street, road or
highway, including dirt and gravel roads.
POTENTIAL HAZARD
Operating this vehicle without wearing an approved helmet,
eye protection and protective clothing.
WHAT CAN HAPPEN
Operating an LUH 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.
WARNING
WARNING

18
SAFETY
Operator Safety
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 57. 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.
WARNING