Owners Manual
Page 22
.... Operate this vehicle. • Cargo should be properly distributed and securely attached. • Reduce speed when carrying cargo or pulling a trailer. Use caution and drive at reduced speeds in conditions of control or an accident. • Never exceed the stated load capacity for braking. • Always follow proper operating procedures as fog, rain and darkness. Clean headlights frequently and replace burned out...
.... Operate this vehicle. • Cargo should be properly distributed and securely attached. • Reduce speed when carrying cargo or pulling a trailer. Use caution and drive at reduced speeds in conditions of control or an accident. • Never exceed the stated load capacity for braking. • Always follow proper operating procedures as fog, rain and darkness. Clean headlights frequently and replace burned out...
Owners Manual
Page 25
... on your protection. General Warning WARNING Improper vehicle use throttle and brakes gradually. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. 7175784 22 To prevent flipover on the vehicle carefully. PARKING BRAKE may seriously affect handling and control. • Use proper RIDING TECHNIQUES to purchase a replacement. LOCATE AND READ OWNER'S MANUAL. A collision can occur with open throttle. To prevent flipover, avoid sharp turns. If any of the...
... on your protection. General Warning WARNING Improper vehicle use throttle and brakes gradually. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. 7175784 22 To prevent flipover on the vehicle carefully. PARKING BRAKE may seriously affect handling and control. • Use proper RIDING TECHNIQUES to purchase a replacement. LOCATE AND READ OWNER'S MANUAL. A collision can occur with open throttle. To prevent flipover, avoid sharp turns. If any of the...
Owners Manual
Page 36
.... FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is idling, move the lever to the desired gear. Refuel on the right side of 87=(R+ M/2) octane. Use either leaded or unleaded gasoline with the engine speed above idle or while the vehicle is left unattended. Belt Life To extend belt life, use E-85 fuel. When the engine is located on a level surface. Gear Selector NOTICE: Shifting gears with a minimum pump...
.... FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is idling, move the lever to the desired gear. Refuel on the right side of 87=(R+ M/2) octane. Use either leaded or unleaded gasoline with the engine speed above idle or while the vehicle is left unattended. Belt Life To extend belt life, use E-85 fuel. When the engine is located on a level surface. Gear Selector NOTICE: Shifting gears with a minimum pump...
Owners Manual
Page 39
... neutral or park 36 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
... neutral or park 36 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
Owners Manual
Page 41
... Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is applied. Mode Indicator 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank. Service Interval/Diagnostic Mode Indicator 5. The segments of the fuel gauge show the level of fuel in the instrument cluster. Refuel immediately. 8. The word HOT displays if the engine overheats. If the instrument cluster fails to illuminate, a battery...
... Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is applied. Mode Indicator 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the fuel tank. Service Interval/Diagnostic Mode Indicator 5. The segments of the fuel gauge show the level of fuel in the instrument cluster. Refuel immediately. 8. The word HOT displays if the engine overheats. If the instrument cluster fails to illuminate, a battery...
Owners Manual
Page 48
...-Battery ADC: Open Load/Short-to-Ground ADC: Shorted Load/Short-to-Battery Starter Enable: Open Load/Short-to-Ground Starter Enable: Shorted Load/Short-to-Battery Gear Sensor Signal 4X4: Open Load/Short-to-Ground 4X4: Shorted Load/Short-to-Battery Rear Differential Enable: Open Load/Short-to-Ground (if equipped) Rear Differential Enable: Shorted Load/Short-to -Ground Injector Circuit Malfunction - FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code...
...-Battery ADC: Open Load/Short-to-Ground ADC: Shorted Load/Short-to-Battery Starter Enable: Open Load/Short-to-Ground Starter Enable: Shorted Load/Short-to-Battery Gear Sensor Signal 4X4: Open Load/Short-to-Ground 4X4: Shorted Load/Short-to-Battery Rear Differential Enable: Open Load/Short-to-Ground (if equipped) Rear Differential Enable: Shorted Load/Short-to -Ground Injector Circuit Malfunction - FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code...
Owners Manual
Page 50
... Break-in (Clutches/Belt) A proper break-in 1. OPERATION Break-In Period Engine and Drivetrain Break-in of the clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling. 4. Always exercise extreme caution whenever handling gasoline. 2. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at first. Pull...
... Break-in (Clutches/Belt) A proper break-in 1. OPERATION Break-In Period Engine and Drivetrain Break-in of the clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling. 4. Always exercise extreme caution whenever handling gasoline. 2. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Change both the oil and the filter at first. Pull...
Owners Manual
Page 65
... Towing Capacities Towed Load (level ground) Towed Load (up to the vehicle, include the weight of the vehicle. OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can result in serious injury or death. Always follow these items must not exceed the maximum weight capacity. • Reduce speed and allow a greater distance for your vehicle. • Use extreme caution when applying brakes...
... Towing Capacities Towed Load (level ground) Towed Load (up to the vehicle, include the weight of the vehicle. OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can result in serious injury or death. Always follow these items must not exceed the maximum weight capacity. • Reduce speed and allow a greater distance for your vehicle. • Use extreme caution when applying brakes...
Owners Manual
Page 72
... 6M 6M 6M 6M 6M X Engine oil change yearly Inspect level; replace as needed Inspect; pressure test system yearly 69 replace as needed Inspect periodically Perform a break-in ) Battery X Front gearcase (demand drive) oil X Middle gearcase oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Engine breather E filter (if equipped) X General lubrication Shift linkage Q Steering X Front suspension X Rear suspension E ETC Switch Q Throttle Cable/ E Throttle Body Intake Duct X Front hub bearings (if equipped) Drive belt Cooling system (if applicable) 620 (1000...
... 6M 6M 6M 6M 6M X Engine oil change yearly Inspect level; replace as needed Inspect; pressure test system yearly 69 replace as needed Inspect periodically Perform a break-in ) Battery X Front gearcase (demand drive) oil X Middle gearcase oil (if equipped) X Rear gearcase oil (if equipped) X Transmission oil X Engine breather E filter (if equipped) X General lubrication Shift linkage Q Steering X Front suspension X Rear suspension E ETC Switch Q Throttle Cable/ E Throttle Body Intake Duct X Front hub bearings (if equipped) Drive belt Cooling system (if applicable) 620 (1000...
Owners Manual
Page 73
... X Radiator (if applicable) X Cooling hoses (if applicable) X Engine mounts Exhaust muffler/ pipe E Q Spark plug 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M X Wiring Q Clutches (drive and driven) Q Shift selector lubricant Q Brake fluid Q ADC fluid (ADC models) X Fuel filter Q E Spark arrestor Q Toe adjustment X Auxiliary brake Q Headlight aim 100 H 200 H 200 H 200 H 200 H 12 M 24 M 24 M 24 M 24 M 300 H 36 M - replace worn parts 1240 (2000) Inspect; adjust 620 (1000) Check for leaks...
... X Radiator (if applicable) X Cooling hoses (if applicable) X Engine mounts Exhaust muffler/ pipe E Q Spark plug 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M X Wiring Q Clutches (drive and driven) Q Shift selector lubricant Q Brake fluid Q ADC fluid (ADC models) X Fuel filter Q E Spark arrestor Q Toe adjustment X Auxiliary brake Q Headlight aim 100 H 200 H 200 H 200 H 200 H 12 M 24 M 24 M 24 M 24 M 300 H 36 M - replace worn parts 1240 (2000) Inspect; adjust 620 (1000) Check for leaks...
Owners Manual
Page 91
... with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Lock the parking brake. 3. Loose nuts could cause a tire to specification. 90 ft. lbs. (122 Nm) Cast Aluminum Steel 27 ft. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. lbs. (37...
... with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Lock the parking brake. 3. Loose nuts could cause a tire to specification. 90 ft. lbs. (122 Nm) Cast Aluminum Steel 27 ft. lbs. (37 Nm) Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. lbs. (37...
Owners Manual
Page 94
... the connector, not on the wiring. 6. Oil from the speedometer. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Lift the pod cover and disconnect the speedometer harnesses from your skin leaves a residue, causing a hot spot that will shorten the life of the pod. 3. Be sure to cool before servicing. 5. Apply dielectric grease to...
... the connector, not on the wiring. 6. Oil from the speedometer. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Lift the pod cover and disconnect the speedometer harnesses from your skin leaves a residue, causing a hot spot that will shorten the life of the pod. 3. Be sure to cool before servicing. 5. Apply dielectric grease to...
Owners Manual
Page 95
... to the center of the headlight beam should be adjusted slightly upward or downward. Include rider weight on the right side of the headlight pod. MAINTENANCE Lights High Beam Adjustment The headlight beam can be two inches (5 cm) below the mark on the wall. The adjustment knob is located on the seat when measuring. 5. Place the transmission in park. 25...
... to the center of the headlight beam should be adjusted slightly upward or downward. Include rider weight on the right side of the headlight pod. MAINTENANCE Lights High Beam Adjustment The headlight beam can be two inches (5 cm) below the mark on the wall. The adjustment knob is located on the seat when measuring. 5. Place the transmission in park. 25...
Owners Manual
Page 97
... adjusting knob up to remove the o-rings from the speedometer. 4. Lift the pod slightly while depressing the tabs at the rear of the pod. 9. Adjust the headlight aim by 5 1/8" turning the adjusting knob. (13 cm) 94 Remove the two screws on the lower front corners of the adjustment knob stop is 5 1/8" (13 cm). 10. MAINTENANCE Lights Headlight Housing Replacement 1.
... adjusting knob up to remove the o-rings from the speedometer. 4. Lift the pod slightly while depressing the tabs at the rear of the pod. 9. Adjust the headlight aim by 5 1/8" turning the adjusting knob. (13 cm) 94 Remove the two screws on the lower front corners of the adjustment knob stop is 5 1/8" (13 cm). 10. MAINTENANCE Lights Headlight Housing Replacement 1.
Owners Manual
Page 98
... cover and gasket and set aside for proper operation. 5. Remove the lamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the headlight harness clockwise to the socket and install the new lamp. 4. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Harness Taillight/Brakelight Lamp Replacement 1. Test the light for reassembly. 2. Apply dielectric grease to secure the headlamp. MAINTENANCE Lights Lower Headlamp Replacement...
... cover and gasket and set aside for proper operation. 5. Remove the lamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the headlight harness clockwise to the socket and install the new lamp. 4. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Harness Taillight/Brakelight Lamp Replacement 1. Test the light for reassembly. 2. Apply dielectric grease to secure the headlamp. MAINTENANCE Lights Lower Headlamp Replacement...
Owners Manual
Page 113
Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components • Radiator • Switches and controls • Transmission seals • Fuel system components • Cab and body panels • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your Polaris vehicle. Grease all zerk fittings immediately after washing. Follow the instructions on your Polaris dealer...
Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components • Radiator • Switches and controls • Transmission seals • Fuel system components • Cab and body panels • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your Polaris vehicle. Grease all zerk fittings immediately after washing. Follow the instructions on your Polaris dealer...
Owners Manual
Page 116
... 1/4" hose and a small plastic squeeze bottle filled with a protective film of gasoline. 113 Reinstall the spark plugs. Apply dielectric grease to specification. 4. Run the engine for several times. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be forced in the Periodic Maintenance Chart beginning on the can. Stop the engine. 2. Oil will be completely drained of fresh oil. 6. Change fluids...
... 1/4" hose and a small plastic squeeze bottle filled with a protective film of gasoline. 113 Reinstall the spark plugs. Apply dielectric grease to specification. 4. Run the engine for several times. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be forced in the Periodic Maintenance Chart beginning on the can. Stop the engine. 2. Oil will be completely drained of fresh oil. 6. Change fluids...
Owners Manual
Page 121
... during loading. Inspect clutch seals for fouled plugs or foreign material in mud or snow Shift the transmission to low range and carefully use /plowing Use low range only. Wrong or missing belt Install the recommended belt. Drive at a higher speed or use fast, aggressive throttle application to Always warm up the belt by operating below freezing). WARNING! Poor engine performance Check for or...
... during loading. Inspect clutch seals for fouled plugs or foreign material in mud or snow Shift the transmission to low range and carefully use /plowing Use low range only. Wrong or missing belt Install the recommended belt. Drive at a higher speed or use fast, aggressive throttle application to Always warm up the belt by operating below freezing). WARNING! Poor engine performance Check for or...
Owners Manual
Page 125
SPECIFICATIONS Sportsman Big Boss 6X6 800 EFI Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Rear Gearcase Oil Capacity Mid Gearcase Oil Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Cargo Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Ignition Timing ...
SPECIFICATIONS Sportsman Big Boss 6X6 800 EFI Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Rear Gearcase Oil Capacity Mid Gearcase Oil Capacity Transmission Oil Capacity Front Rack/Storage Box Capacity Cargo Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Ignition Timing ...
Owners Manual
Page 131
...'s authorized location as your vehicle to continue your warranty coverage. WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to perform the warranty repair. You should take your vehicle. How to government officials...
...'s authorized location as your vehicle to continue your warranty coverage. WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to perform the warranty repair. You should take your vehicle. How to government officials...