Polaris PTV 6x6 SERIES 10 User manual

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

1

2
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.
Copyright 2002
Polaris Industries Inc.
All Rights ReservedPrinted in the U.S.A.

3
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.
Polaris Recreational and Utility Vehicles
SSnowmobiles
SAll-terrain vehicles (ATVs)
SPersonal watercraft
SVictory motorcycles
SRANGER utility vehicles
Polaris Professional Series Workmobilest
SUtility Task Vehiclest(UTVs)
SPersonal Task Vehiclest(PTVs)
SAll-Surface Loaders (ASLs)
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 Workmobiles are registered
trademarks of Polaris Industries Inc.

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:
Key Number:

5
TABLE OF CONTENTS
WELCOME 3........................................
VEHICLE IDENTIFICATION NUMBERS 4...............
TABLE OF CONTENTS 5.............................
SAFETY 6..........................................
FEATURES 34.......................................
CONTROLS 37......................................
OPERATION 46.....................................
NOISE EMISSION CONTROL SYSTEM 65.............
MAINTENANCE AND LUBRICATION 66................
SPECIFICATIONS 106................................
POLARIS RECOMMENDED PRODUCTS 108...........
TROUBLESHOOTING 109............................
WARRANTY 113.....................................
INDEX 115..........................................
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.

6
SAFETY
Operator Safety
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.
The PTV 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.
Safety Training
When you purchased your new PTV 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 PTV 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 PTV 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 PTV 6x6.

7
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

8
SAFETY
Operator Safety
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever operate the PTV 6x6 without proper instruction. Take a train-
ing 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.
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.

9
SAFETY
Operator Safety
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.
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.

10
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.

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 PTV 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 PTV 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.
WARNING
Make sure your PTV 6x6 is in excellent operating condition at all
times. We strongly recommend that the operator check all safety
components before each ride.
Your Polaris PTV 6x6 is designed to provide safe operation when
used as directed. Failure of critical machine components may
result from operation with any modifications, especially those that
increase speed or power. The PTV 6x6 may become
aerodynamically unstable at speeds higher than those for which it
is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
Do not make any modifications to your PTV 6x6.

12
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 PTV 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 PTV 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 PTV 6x6.
WARNING
WARNING

13
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 a PTV 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 a PTV 6x6 on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN HAPPEN
PTV 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 PTV 6x6 on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.
WARNING
WARNING
WARNING

14
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 PTV 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 a PTV 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

15
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 59. 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

16
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating the PTV 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.
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
The PTV 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
WARNING

17
SAFETY
Operator Safety
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.
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
WARNING

18
SAFETY
Operator Safety
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.
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
WARNING