Polaris Light Utility Hauler 6x6, Owner'S Manual

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Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 3: ...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 Tech...

Page 4: ...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 Pola...

Page 5: ...ND 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 ...

Page 6: ...arts 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 Ve...

Page 7: ...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 A note will alert you to important information or instructions A caution indicates a sit...

Page 8: ... 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 ...

Page 9: ... gloves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating this ve hicle S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other stunts S Always inspect your vehicle before each use to make sure it s in safe operating c...

Page 10: ...ppery 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 S Always use proper procedures if the vehicle stalls or rolls backwards while climbing a hill To avoid stalling maintain a steady spe...

Page 11: ...e 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...

Page 12: ...d 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...

Page 13: ...YS 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 speed...

Page 14: ...ever 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 ...

Page 15: ...OUND 850 LBS 368 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 35 LBS 16 KG 7078261 ATTENTION S Operation of this vehicle without the filter element will severely damage the engine S Clean air filter often more frequent cleaning required in dusty condi tions S Operation of this vehicle without en gine breather filter s can cause en gine damage Consult owner s manual for details S Specific carburetor...

Page 16: ...nt 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 knuck...

Page 17: ...e 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 recom...

Page 18: ... 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 Operati...

Page 19: ...ng 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 th...

Page 20: ...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...

Page 21: ...D 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 LUH 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 ...

Page 22: ...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 ...

Page 23: ...AZARD 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...

Page 24: ... rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the vehicle on such terrain Always use extra caution on rough slippery or loose terrain WARNING ...

Page 25: ...nual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn and cause serious injury or death HOW TO AVOID THE HAZARD Never operate on hills too steep for the vehicle or for your abilities Never operate the LUH 6x6 on hills steeper than 15_ Practice on sm...

Page 26: ...ills as described in the owner s manual Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The vehicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the...

Page 27: ... HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual Always check the terrain carefully before descending a hill Shift your weight backward 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 WARNING ...

Page 28: ...n the LUH 6x6 around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 57 Use extra caution when turning on any hill Avoid crossing the side of a steep hill If it s unavoidable always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill si...

Page 29: ...RD Overloading the vehicle or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when hauling cargo or pulling a trailer Allow a greater di...

Page 30: ...el 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 Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Attempting wheelies jumps and other stunt...

Page 31: ...er tire pressure POTENTIAL HAZARD Operating the vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the vehicle may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the LUH 6x6 through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polari...

Page 32: ...operator as well as the force created by a moving vehicle Exercise extreme caution POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating the vehicle c...

Page 33: ...AND CONTROLS IDENTIFICATION 1 Service Brake Lever 2 Middle Axle Auxiliary Brake 3 Throttle Lever 4 Bed Dump Latch Release 5 Gearbox Shift Lever 6 Floorboards 7 Backrest 8 Cargo Bed 9 Front Rack 1 2 3 4 4 5 6 7 8 9 ...

Page 34: ...Switch The engine will not start or run when the switch is in the off position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights To stop the engine slide the stop switch either right or left to th...

Page 35: ...ator blue 4 Transmission Reverse Indicator yellow 5 Transmission Neutral Indicator green 6 All Wheel Drive Indicator red 7 Engine High Temp Warning Indicator red The high temp indicator will light only if the engine overheats 6 1 4 3 5 7 2 Operating the vehicle on streets or roads especially in darkness could result in an accident and serious injury or death Your LUH 6x6 is not equipped with highw...

Page 36: ... the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms WARNING Do not start or operate a vehicle with sticking or improperly operating throttle controls Doing so could cause an accident and lead to severe injury or death Always contact your dealer for service repairs i...

Page 37: ...er travel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before operating Contact your dealer for proper diagnosis and repairs Auxiliary Brakes The auxiliary brake lever 2 is located on the right handlebar This lever controls the auxiliary brake for the r...

Page 38: ...r NOTE When checking the fluid level the vehicle should be on level ground with the handlebars turned so the top of the reservoir is level If the fluid level is low add DOT 3 brake fluid see page 106 2 1 After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture...

Page 39: ...y relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the vehicle if leav ing it parked on a hill Another option is to park the vehicle in a sidehill position S Never depend on the parking brake alone for more than five minutes if the vehicle is parked on a hill Always block the wheels to pre vent rolling Operatin...

Page 40: ...R M 2 octane The fuel tank supply valve 2 is located on the left side of the vehicle and has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after exhausting the main supply After refueling switch the ...

Page 41: ...ll the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Gaso line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time S Turn the fuel valve off whenever the vehicle is stored or parked The engine ...

Page 42: ...cked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Belt Life To extend belt life refrain from continuous operation of the vehicle at the point of engagement the point at which the vehicle begins to move Continuous operation in this manner increases belt wear F ...

Page 43: ...al 3 Grasp the recoil starter tightly and pull slightly until the starter mechanism engages 4 Pull the rope abruptly to start the engine 1 Extending the starter rope too far will cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fu...

Page 44: ... the front wheels will automatically disengage NOTE The override switch 2 allows activation of AWD in reverse if the AWD switch is on A red AWD light on the switch indicates when the vehicle is in AWD There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving th...

Page 45: ...ted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE If the hubs remain engaged after following this procedure return the vehicle to your dealer for service To continue using AWD while operating in reverse activate both the override switch and the Demand 6 Drive AWD switch See page 32 Operating with only one front hub engaged co...

Page 46: ...lowly at first Select an open area that will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 45 6 Pull only light loads during the break in period 7 Break in the oil and the filter Change both at 20 hours or 200 miles CAUTION ...

Page 47: ...uts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain check condition and slack refer to drive chain adjustment procedure 9 Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 12 Riding gear wear ...

Page 48: ...Activate the starter for a maximum of five seconds releasing the switch when the vehicle starts If the engine does not start release the starter and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts 7 If the engine slows or stops position the choke knob half way in to allow proper engine warm up 8 Vary the engine RPM slightly with th...

Page 49: ...n the fuel tank valve to on 4 Sit on the vehicle 5 If the engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary 6 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 7 Release the throttle lever immediately after the engine starts If the engine does not start and a...

Page 50: ...er towing is 15 Do not tow any trailer on a grade steeper than 15 Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability S Never exceed the stated load capacity for this vehicle S Do not obstruct the headlight when loading the front rack S Cargo should be properly distributed and carried as low and for ward in th...

Page 51: ...bed release lever forward 5 Lift the front of the cargo bed and dump the cargo If the weight distribution on the bed is located toward the rear of the bed when the release lever is pulled forward the bed may dump on its own which could cause serious injury Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo bed Never carry passen...

Page 52: ...Unintentional bed tilting will result if weight is placed in the rear of the bed and the latch is not secured Maximum Front Rack 90 lbs 41 kg Maximum Cargo Bed LUH 6x6 800 lbs 363 kg WARNING Operating with the cargo bed in the raised position can cause serious injury and damage to the vehicle The cargo bed could close unexpectedly and injure the driver The rear tires will also catch the rear of th...

Page 53: ...warm up shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening PVT shifting is automatic 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 54: ...e inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same learning technique should be used for turning in reverse WARNING Turning at sharp angles in rever...

Page 55: ...ransferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe inju...

Page 56: ...rward Never brake during a skid 3 Drive with Demand 6 Drive All Wheel Drive engaged to assist in controlling the vehicle in slippery areas Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Activate the AWD switch only when the rear wheels have traction CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tir...

Page 57: ...le 3 Slow down 4 Apply the brakes slightly to aid in slowing Hard use of the braking system while descending a hill could result in a front end overturn causing serious injury or death Always operate the brakes slightly when descending a hill Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 58: ...le opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 15_ Maximum WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15_ maximum Use extreme caution when operating on hills and follo...

Page 59: ...ease the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the service brake until the ve...

Page 60: ...avoid water that exceeds the recommended maximum depth go 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 IMPORTANT After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See pages 65 67 The following areas need speci...

Page 61: ... backing 6 Never activate the override button while the throttle is open Loss of control may result NOTE This vehicle is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed Opening the throttle more than required may cause f...

Page 62: ...ult in serious injury or death Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Avoid backing on inclines Avoid turning at sharp angles in reverse ...

Page 63: ...d the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain WARNING ...

Page 64: ... Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Place the transmission in gear 2 Set the parking brake 3 Always block the rear wheels on the downhill side See illustration 4 Shut off fuel supply ...

Page 65: ...ESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance USFS App...

Page 66: ...S Spark plug wrench and handle S Torx wrench rack removal Accessories Polaris has a wide variety of accessories for your vehicle Contact your Polaris dealer for a complete list 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 Be sure any accessories added to the vehicle have been appr...

Page 67: ...r dusty areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical ...

Page 68: ...y Daily Inspect drain deposits whenever visible Air filter pre cleaner Daily Daily Inspect and clean Coolant level Daily Daily Replace engine coolant every two years Air Filter main element Weekly Weekly Inspect replace if necessary J Brake pads 10 hrs 100 miles Monthly Inspect for wear periodically Breather filter 20 hrs Monthly Inspect replace annually and as needed Battery 20 hrs Monthly Inspec...

Page 69: ...n fasteners J Valve clearance 100 hrs 12 months Inspect adjust J Fuel system 100 hrs 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor replace lines ev ery two years J Fuel filter 100 hrs 12 months Replace annually Radiator 100 hrs 12 months Inspect clean external surface Cooling system hoses 100 hrs 12 months Inspect Engine mounts 100 hrs 12 months Inspect Spark ar...

Page 70: ...vel See page 36 As required change every two years or 200 hours Drive Chains O Ring chain lube or SAE 80 90 Lubricate as often as re quired before each ride in wet conditions As required Gear Selector Oil 1 10 W Non detergent Oil Maintain oil level at the center of the shift rail Do not overfill Change every 2 years or 200 hours Transmission Oil 2 Polaris Premium Synthetic gearcase lube Fill to bo...

Page 71: ...0 hrs Front A Arm Pivot Shaft 3 LGrease Locate zerk on pivot shaft and grease with grease gun Every 3 months or at 50 hrs Steering Post Bushings 4 LGrease Locate fitting on steering post and grease with grease gun Every 3 months or at 50 hrs More often under severe use such as wet or dusty conditions L Grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special F Use Polaris ...

Page 72: ...earings 4 Grease Locate fitting on eccentric and grease with grease gun Every 3 months or 50 hrs Center Swing Arm Housing 5 Grease Locate fitting on swing arm hous ing and grease with grease gun Every 3 months or 50 hrs Rear Strut 6 Grease Locate fitting on rear strut and grease with grease gun Every 3 months or 50 hrs More often under severe use such as wet or dusty conditions L Grease conforming...

Page 73: ...oil if needed Oil should be kept at the bottom of the fill plug thread NOTE Use Polaris Premium Synthetic Gearcase Lubricant in the transmission see page 106 3 Replace the fill plug Transmission Oil Change 1 Remove the propshaft shield from the right side of the vehicle 2 Remove the fill plug 3 Remove the transmission drain plug 2 located on the bottom left hand side and drain the oil Catch and di...

Page 74: ... View the oil level and add oil if needed Oil should be kept at the bottom of the fill plug thread NOTE Use GL5 80 90 Weight Gear Lube see page 106 3 Replace the fill plug Gearcase Oil Changing Procedure 1 Remove the fill plug 2 Remove gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug and tighten securely 14 ft lbs 1 93 kg m 4 Add GL 8...

Page 75: ...y if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation Oil System The oil tank is located on the left side of the vehicle To check the oil 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine Remove the dipstick and wipe it dry with a clean cloth 4 Screw the dipstick completely in th...

Page 76: ...om of the oil tank and the bottom of the engine 2 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain...

Page 77: ... plug and crankcase should be clean and free of burrs nicks or scratches 11 After draining reinstall the drain plug 12 Remove the dipstick 2 and add two quarts 1 9 l of Polaris Premium 4 synthetic oil see page 106 Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 13 Place the gear selector in neutral and set the parking brake 14 Start the engine and let it idl...

Page 78: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs ...

Page 79: ...pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part NOTE To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mi...

Page 80: ...llow the manufacturer s mixing recommendations for the freeze protection required in your area Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coo...

Page 81: ...e clamp and remove the filter 4 Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water rinse and allow to dry thoroughly 5 Reinstall the pre filter over the main filter Replace the main filter if necessary 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp or filter damage may occur CAUTION Operating the vehicle withou...

Page 82: ...NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if necessary 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter and clamps with the arrow pointing toward the engine NOTE The breather filter is intended to be u...

Page 83: ...rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE ...

Page 84: ...en gaps in the block 4 Torque the handlebar adjuster block bolts to 10 12 ft lbs Optional Suspension Springs Although the Polaris LUH 6x6 suspension has the capability of providing the best ride possible the following accessory springs are available to better suit individual riding preferences NOTE Optional springs may be a different color than standard springs Springs may be painted to a desired ...

Page 85: ...ge 36 Under normal functioning the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid see page 106 2 Check the brake system for fluid ...

Page 86: ...cessive wear Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever Flip the throttle lever several times to confirm adjustment 3 Tighten the locknut and slide the boots over the cable adjuster unti...

Page 87: ...h through the sprocket hub and into the eccentric axle housing 5 Roll the vehicle ahead or back to adjust chain slack to the proper dimension 6 Tighten the caliper mount bolts to 10 12 ft lbs 1 4 1 7 kg m 7 Tighten the eccentric locking bolts to 45 ft lbs 6 2 kg m 8 Confirm correct tension by rolling the vehicle forward checking chain tension in several places around the chain 9 Reinstall the chai...

Page 88: ...RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Start the engine and allow it to warm up for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 in or out until the desired idle RPM is reached Turning the screw in clockwise will r...

Page 89: ...ystem can be made to allow efficient operation These changes include 1 Carburetor re jetting to compensate for atmospheric pressure and oxygen loss 2 Transmission convertor modification to adjust for engine horsepower loss We recommend that you see your Polaris dealer for altitude adjustments Polaris dealers have the proper training and tools required to perform these modifications NOTE Pilot scre...

Page 90: ... hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until the tabs lock Bend the rear of the side panel and insert the two t...

Page 91: ...tion arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them Make sure the tapered side of the rear wheel nut fits into the taper on the wheel 1 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the following torque Torque center and rear wheel nuts to 50 ft lbs 6 9 kg m Torque front wheel nuts to 20 ft lbs 2 1 kg m Improper wheel insta...

Page 92: ...hich could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire alway...

Page 93: ...city 800 lbs 363 kg Front Rack Load Capacity 75 lbs 34 kg Gross Vehicle Weight 1970 lbs 894 kg including vehicle driver and cargo Vehicle weighs 895 lbs 406 kg The following items should be checked for tightness occasionally or if they ve been loosened for service Axle and Wheel Nut Torque Specifications Item Specification Front Spindle Nut s 100 in lbs Front Wheel Nuts 20 ft lbs Center and Rear A...

Page 94: ... caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments Spark Plug R...

Page 95: ...e still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 7 Repeat steps 3 through 6 until no more particles are expelled when the engine is revved 8 Stop the engine and allow the arrestor to cool Reinstall the arrestor...

Page 96: ...G Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at...

Page 97: ...n If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery 2 1 Battery electrolyte is poisonous It contains sulfuric acid Serious b...

Page 98: ...e the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle Becareful not to tip it sideways and spill electrolyte 1 Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the ...

Page 99: ...he black negative cable 5 Reinstall the battery cover and attach the hold down strap 6 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed...

Page 100: ...emove the boot and locking collar from the back of the lamp housing 7 Grasp the base of the lamp and lift it out 8 Reverse the previous steps to replace the lamp and reassemble the pod Make sure the tab on the lamp locates properly in the housing WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the hea...

Page 101: ...m a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Adjust...

Page 102: ... the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Remove the o ring 1 from the headlight pivot pins 6 Pull the headlight housing up to release from the locking tabs 7 Lift the adjusting knob up to remove from the locking tabs 8 Carefully pull the assembly up and out of pod 9 Reverse the steps ...

Page 103: ...sembly 2 Remove the lamp 1 and replace it with the recommended lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Follow steps 1 3 of Headlight Housing Replacement on page 100 2 Unplug the light from the harness 3 Using a screwdriver turn the light 1 4 turn counterclockwise 1 4 Install new light and use a screwdriver to ...

Page 104: ...t and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots If a high pressure car wash system is used not recommended use extreme care to avoid water damage to the drive chain wheel bearings transmission seals body panels brakes and warning labels Grease all zerk fittings immediately after washing with a high pressure system Allow the vehicle to run long e...

Page 105: ...ion pivot points the lower steering post and the rear axle fittings 6 Drain the recoil housing 7 Block the vehicle so all tires are suspended off the ground 8 Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ventilation of the vehicle Transporting the Vehicle Follow these procedures before transporting the vehicle with another unit 1 Turn off the...

Page 106: ...e Fixed Disc Hydraulic Floating Caliper Auxiliary Brake Fixed Disc Hydraulic Floating Caliper Fuel Capacity 4 25 U S Gal Engine Oil Capacity 2 U S Qts Headlight 12V 60W Taillight 12V 5W Exhaust USFS Approved Front Rack Standard Hitch Standard Tool Kit Standard Gross Vehicle Weight 1970 lbs including vehicle driver cargo Load Capacity 75 lbs 34 kg Front Rack 800 lbs Cargo Bed Tongue Weight 150 lbs ...

Page 107: ...g BKR5E NGK Alternator 250W Comp Ratio 10 2 Full Stroke Timing 30 3500 Carburetion 1 BST34 CV Type Main Jet 142 5 Pilot Jet 40 Jet Needle 4HB41 3 Needle Jet Q 4 829 Pilot Screw 3 Pilot Air Jet 160 Valve Seat 1 5 Fuel Octane R M 2 87 Non oxygenated or 89 Oxygenated Polaris Industries Inc reserves the right to make changes in design and specifications and or to make additions or improvements to its ...

Page 108: ...d 12 oz 2870465 Oil Pump for Gearcase Oil 2871654 Premium Drive Hub Fluid 8 oz 2872277 Premium Drive Hub Fluid 2 5 gal 2871653 Angle Drive Fluid 8 oz Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit ...

Page 109: ...107 WIRING DIAGRAM ...

Page 110: ...efully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Carefully use fast brief aggressive throttle ap plication to engage clutch WARNING Exces sive throttle may cause loss of control and ve hicle overturn Belt slippage from water or snow ingestion into the PVT sy...

Page 111: ...f No Fuel Water in Fuel Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Contact Your Dealer Clogged Fuel Valve ENGINE STOPS OR LOSES POWER No Fuel Contact Your Dealer Contact Your Dealer Overuse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Turn Fuel Valve to Res Water in Fuel Air Filter Clogged Reverse Speed Limiter Malfunction Electronic Throttle Control Malfun...

Page 112: ...ion Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without pro...

Page 113: ...CLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy...

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Page 115: ...mmendations 68 75 Main Switch 32 33 MAINTENANCE AND LUBRICATION 64 103 Maintenance Record 76 Making Turns 52 Master Cylinders 36 NOISE CONTROL SYSTEM 63 Oil Change 74 75 Oil Filter Change 74 75 Oil System 38 39 73 Operating Safety 49 OPERATION 44 62 Operator Safety 5 30 Override Switch 32 POLARIS RECOMMENDED PRODUCTS 106 Parking On An Incline 62 Periodic Maintenance Schedule 65 67 Pre Ride Inspect...

Page 116: ...GS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 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 NEVER Operate on public roads A collision can occur with another vehicle Carry passengers Passengers a...