2009 Polaris Sportsman 6x6 Problems and Repair Information

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Owners Manual - Page 4

... years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced. WELCOME Thank you for all utility and recreational vehicles manufactured in this owner's manual. For safe and enjoyable operation of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician.
Owners Manual - Page 10

...is included in the purchase price of this vehicle in your owner's manual. If you purchased a used Polaris vehicle will be charged for Polaris. Familiarize yourself ... www.atvsafety.org, or call Polaris at specific intervals. You should review this vehicle to ensure that explain safe operating procedures. When you purchased your new vehicle, your dealer instructed you on the authorized ...
Owners Manual - Page 14

... water and change clothing. Exposure to inspect and verify that the vehicle is stored. • Do not overfill the tank. Operate this...procedures and schedules described in the owner's manual. 11 Do not fill the tank neck. • ...engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed...
Owners Manual - Page 18

...• Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to ADC 4X4 (if equipped) before ascending or descending a hill. Travel straight down hills as... follow proper procedures as described in the owner's manual. See page 57. • Always descend a hill with the transmission in the owner's manual. Crossing Hillsides Driving on level ground) as described...
Owners Manual - Page 19

.... • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch 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. Apply the service brake gradually. • When fully stopped, apply the rear brake as well, and...
Owners Manual - Page 36

...vehicle is moving could cause transmission damage. Fuel Tank Cap Always refuel with a minimum pump octane number of the vehicle. Remove the fuel tank cap to add fuel to a complete stop. Fuel... fuel tank. Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is left unattended. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission ...
Owners Manual - Page 39

... 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 (high, low...
Owners Manual - Page 41

... usually indicates that the vehicle is activated. Fuel Gauge - Mode Indicator 38 Gear Indicator - Service Interval/Diagnostic Mode Indicator 5. It may have shut off to your Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is 1 on either ADC 4X4 or 4X4. 3. This 9 indicator illuminates when the 4X4 switch is applied. The...
Owners Manual - Page 42

The transmission cannot be normal because of changes in reverse when using this feature. Press and hold the mode button (... and elevation. See page 26. Tachometer Mode The engine RPM is also the MODE button. Trip Meter Mode The trip meter records the miles traveled by the vehicle. Hour Meter Mode This mode logs the total hours the engine has been in a 12-hour format. To reset...
Owners Manual - Page 46

See page 45 for informational purposes only. Stop the engine. 3. Please see your Polaris dealer for all codes have been transmitted. 43 The number "61" and the word "END" displays after all major repairs. Turn the key switch to download blink codes (failure codes) from ... off and on three times in the EFI module will display, one at a time, on . Place the transmission in park. 2.
Owners Manual - Page 49

...or the time it takes to operate the vehicle properly can result in a collision, loss of a new engine and drive components will damage close-fitted engine parts and drive components. Break-In Period The...full tanks of this owner's manual. Do not operate at full throttle or high speeds during the first three hours of operation will result in more efficient performance and longer life for a...
Owners Manual - Page 54

... this procedure until the engine starts. Allow the engine to engage the starter. Cold Weather Operation If the vehicle is not engaged. 4. Water in a well-ventilated area. 2. Water accumulation increases as water or excess fuel in gear and the brake is used year-round, check the oil level frequently. Place the transmission in colder weather...
Owners Manual - Page 61

... service brake, release the parking brake lock and slowly allow the vehicle to your right until the vehicle is pointing straight uphill. 5. Dismount on the uphill side of the vehicle, turn around to roll around . 8 ft. (2.4 m) 1. Release the parking brake and proceed slowly, controlling speed with the transmission still in forward and shut off the engine...
Owners Manual - Page 62

... footrest level: • Proceed slowly. Determine water depths and current before restarting the engine. The following areas need special attention: engine oil, transmission oil, demand drive fluid, rear gearcase oil, and all grease fittings. Transport the vehicle to your dealer for service at the first opportunity. 4. If this is not thoroughly inspected after operation in...
Owners Manual - Page 71

.... Item Maintenance Interval (whichever comes first) Hours Calendar Q Steering Remarks Miles (Km) Inspect; Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations more often for vehicles subjected to conduct this maintenance will not void the emissions warranty but may result in serious injury or death. clean often; See...
Owners Manual - Page 73

... Miles (Km) 620 (1000) Perform a break-in oil change 620 (1000) Inspect; Replace every 2 years, more often for leaks 620 (1000) Inspect 620 (1000) Inspect 620 (1000) Inspect; replace lines every two years 620 (1000) Inspect; clean external surfaces 620 (1000) Inspect for vehicles subjected to water, mud, etc. 620 (1000) Inspect; X Perform these services...
Owners Manual - Page 75

... the level on the bottom side of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for ...higher on the upper surface of the vehicle. 1. Never substitute or mix oil brands. Position the vehicle on Top Side Dipstick Safe Add Oil...oil is not used. Follow the manufacturer's recommendations for this engine. See page 124 for the part numbers of the stick consistent...
Owners Manual - Page 90

... transmission in this manual and on the labels on page 122 for recommended tire type, size and pressure. Remove the wheel nuts. 7. Lock the parking brake. WARNING! Remove the wheel. 87 Loosen the wheel nuts slightly. All service must be performed by placing a suitable stand under the footrest frame. 6. Stop the engine. MAINTENANCE Tires WARNING Operating your vehicle...
Owners Manual - Page 115

... Filter / Air Box 1. Allow the engine to disperse through the entire fuel delivery system. Clean the air box. 3. Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended. Fill the fuel tank. 2. Drain the sediment tube. 112 Stabilize the Fuel 1. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Oil and Filter Change...
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...

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